null  null
Part No. 92801SL, Rev. I
Service Manual
Groundsmaster 300 Series
®
Groundsmaster 328-D
Preface
Use this book along with the Toro Operator’s Manual and Parts Catalog for the specific model and serial
number of the machine, and the Kubota 05 Series Workshop Manual.
This publication will provide the service technician with
information for troubleshooting, testing, and repair of
major systems and components on the Groundsmaster
345, 322-D and 325-D (Model 30788 and 30795).
REFER TO THE TRACTION UNIT AND CUTTING
UNIT OPERATOR’S MANUALS FOR OPERATION,
MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. Space is provided in Chapter 2 of this book to
insert the Operator’s Manuals and Parts Catalogs for
your machine. Replacement Operator’s Manuals are
available by sending complete Model and Serial Num­
ber of traction unit and cutting unit to:
The Toro Company
8111 Lyndale Avenue South
Minneapolis, MN 55420
The Toro Company reserves the right to change product
specifications or this publication without notice.
This safety symbol means DANGER, WARNING, or CAUTION, PERSONAL SAFETY INSTRUCTION. 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 important instructions which must be followed to prevent damage to systems or components on the
machine.
© The Toro Company - 1992, 1996, 1998, 2001, 2003, 2004, 2005, 2007
Table Of Contents
Chapter 1 - Safety
Chapter 6 - Electrical System
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . 6 - 2
Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 3
Troubleshooting (Groundsmaster 345) . . . . . . . . . . . . 6 - 6
Troubleshooting (Groundsmaster 322-D/325-D) . . . . . 6 - 12
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 18
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 30
Chapter 2 - Product Records and Manuals
Product Records. . . . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions . . . . . . . . . . . . . . . .
Torque Specifications . . . . . . . . . . . . . . . . . . . . . .
Maintenance Interval Charts. . . . . . . . . . . . . . . . .
Equipment Operational and
Service Historical Report Record
2-1
2-2
2-3
2-4
Chapter 3 - Ford VSG-411 Gasoline Engine
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
General Information . . . . . . . . . . . . . . . . . . . . . . . 3 - 2
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6
FORD VSG-411/413 ENGINE SERVICE MANUAL
Chapter 4 - Mitsubishi K3D Diesel Engine
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2
Specificationis. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 11
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 15
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 18
Preparation for Engine Repair . . . . . . . . . . . . . . 4 - 25
External Engine Component Repair . . . . . . . . . . 4 - 26
Fuel System Repairs . . . . . . . . . . . . . . . . . . . . . 4 - 34
Removing and Installing the Engine . . . . . . . . . . 4 - 46
Cylinder Head Overhaul . . . . . . . . . . . . . . . . . . . 4 - 47
Cylinder Block Overhaul . . . . . . . . . . . . . . . . . . . 4 - 53
Chapter 6A - Electrical System (S/N 21000000 & Up)
Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1
Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 2
Electrical System Quick ChecksT. . . . . . . . . . . . . 6 - 3
Component Identification and Testing. . . . . . . . . . 6 - 4
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . 6 - 12
Chapter 7 - Differential Axle
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 2
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3
Chapter 8 - Steering and Brakes
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 1
Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 4
Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 5
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 7
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 9
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 11
Chapter 9 - Transmission Coupler and PTO
General Information . . . . . . . . . . . . . . . . . . . . . . . 4 - 2
Specificationis. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 5 - Hydraulic System
Chapter 10 - 4WD Rear Axle
Chapter 4A - Kubota Diesel Engine
9-2
9-3
9-4
9-7
(GM322-D or GM325-D with Inasaka axle)
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2
General Information . . . . . . . . . . . . . . . . . . . . . . . 5 - 3
Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . 5 - 6
Hydraulic Flow Diagrams . . . . . . . . . . . . . . . . . . . 5 - 7
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 10
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 12
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 18
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 22
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 26
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information . . . . . . . . . . . . . . . . . . . . . .
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 - 2
10 - 3
10 - 4
10 - 5
Chapter 10.1 - 4WD Rear Axle
(GM325-D or GM328-D with Dae Dong axle)
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 2
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 3
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 4
Groundsmaster ® 300 Series
Chapter 11 - 72″ Cutting Units
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information. . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 - 2
11 - 3
11 - 4
11 - 5
11 - 8
Chapter 12 - Triflex® 88″ Cutting Unit
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 2
General Information. . . . . . . . . . . . . . . . . . . . . . 12 - 3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 4
Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 5
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 13
Chapter 13 - Guardian® 72″ Recycler® Cutting Unit
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 - 2
13 - 3
13 - 4
13 - 7
Groundsmaster ® 300 Series
Chapter 1
Safety
While Doing Maintenance, Troubleshooting,
Testing, Adjustments or Repairs . . . . . . . . . . . . . 3
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . 1
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . 1
While Operating. . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Instructions
The Groundsmaster 300 Series was tested and certified
by TORO for compliance with the B71.4 1984 specifications of the American National Standards Institute. Although hazard control and accident prevention partially
are dependent upon the design and configuration of the
machine, these factors are also dependent upon the
awareness, concern, and proper training of the personnel involved in the operation, transport, maintenance,
and storage of the machine.
CAUTION
Improper operation, maintenance, troubleshooting, testing, adjustments or repairs
of the machine can result in injury or death.
To reduce the potential for injury or death,
comply with the following safety instructions.
Before Operating
1. Read and understand the Operator’s Manual before
starting and operating the machine. Become familiar
with all controls and know how to stop quickly. A replacement manual is available by sending complete Model
and Serial Numbers to:
6. Do not wear loose fitting clothing because it could get
caught in moving parts. Always wear long pants and
substantial shoes. Wearing safety glasses, safety
shoes, and a helmet is advisable and required by some
local ordinances and insurance regulations.
7. Be sure interlock switches are adjusted correctly so
engine cannot be started unless traction pedal is released to neutral position and PTO lever is in OFF
position.
The Toro Company
8111 Lyndale Avenue South
Minneapolis, Minnesota 55420
2. Never allow children to operate the machine. Do not
allow adults to operate the machine without proper
instruction. Only trained operators, skilled in slope operation and who have read the Operator’s Manual
should operate this machine.
3. Never operate machine when under the influence of
drugs or alcohol.
8. Grass deflectors must be installed in lowest position
on side discharge cutting units and properly attached to
Triflex ® cutting unit wings.
9. Fill fuel tank with the proper fuel before starting the
engine. Avoid spilling any fuel. Since fuel is very flammable, handle it carefully.
4. Remove all debris or other objects that might be
picked up and thrown by cutter blades or fast moving
components from other attached implements. Keep all
bystanders away from the operating area.
A. Use an approved fuel container.
B. Do not fill fuel tank when engine is hot or running.
C. Do not smoke while handling fuel.
5. Keep all shields and safety devices in place. If a
shield, safety device, or decal is defective or damaged,
repair or replace it before operating the machine. Also,
tighten any loose nuts, bolts, and screws to make sure
machine is in safe operating condition.
Groundsmaster® 300 Series
Page 1 - 1
D. Fill fuel tank outdoors and up to about one inch
(25 mm) from the top of the tank, not the filler neck.
E. Wipe up any spilled fuel.
Safety Instructions
10. Sit on the seat when starting the engine and operating the machine.
11. On machines equipped with roll-over protection
(ROPS), always use seat belt and ROPS together.
Make sure seat pivot retaining pin is installed.
12. Before starting the engine:
If movement is evident, the neutral return mechanism is adjusted incorrectly. Shut engine off and
adjust until machine does not move when traction
pedal is released.
13. Do not run the engine in a confined area without
adequate ventilation. Exhaust fumes are hazardous and
could possibly be deadly.
14. Maximum seating capacity is one person. Therefore,
never carry passengers.
A. Engage parking brake,
B. Make sure traction pedal is in neutral and PTO is
in OFF (disengage) position.
15. Check carefully for overhead clearances before
driving under any objects.
C. After engine is started, release parking brake and
keep foot off traction pedal. Machine must not move.
While Operating
16. Using the machine demands the operator’s complete attention. To prevent loss of control:
A. Operate only in daylight or when there is good
artificial light.
B. Drive slowly.
C. Avoid sudden stops and starts.
21. The grass deflector(s) must always be installed and
in lowest position on the cutting unit. This product is
designed to drive objects into the ground where they
lose energy quickly in grassy areas. However, don’t take
an injury risk!! When a person or pet appears 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.
D. Look behind machine before backing up.
22. Never raise the cutting unit or other attached implement while the blades or other parts are rotating.
E. Watch for holes or other hidden hazards.
F. Do not drive close to a sand trap, ditch, creek, or
hazard.
G. Reduce speed when making sharp turns and
when turning on a hillside
H. The cutting deck must be lowered when going
down slopes for steering control.
17. To maintain machine control, 35 lb. of weight must
be mounted on rear of traction unit before using the
Triflex 88" cutting unit. More weight may be required in
some steeper slope conditions.
18. Operator must be skilled and trained in how to drive
on hillsides. Failure to use caution on slopes or hills may
cause loss of control and vehicle to tip or roll possibly
resulting in personal injury or death.
19. Traverse slopes carefully. Do not start or stop suddenly when traversing slopes or when traveling uphill or
downhill.
23. If cutting blades or other implement components
strike a solid object or the machine vibrates abnormally,
disengage PTO, move throttle to SLOW, set parking
brake, and shut engine off. Remove key from switch to
prevent possibility of accidental starting. Check cutting
unit or other implement and traction unit for damage and
defective parts. Repair any damage before restarting
the engine and operating the implement or cutting unit.
Assure cutting unit blades are in good condition and
blade bolts are torqued to proper specifications (See
Cutting Unit Operator’s Manual).
24. To stop machine, remove foot from traction pedal
and use brakes. Gradually reversing the traction pedal
can provide additional braking.
25. Do not touch engine, muffler, or radiator while engine
is running or soon after it has stopped. These areas
could be hot enough to cause a burn.
26. Lower the cutting unit or other attached implement
to the ground and remove key from switch whenever
machine is left unattended.
20. If engine stalls or machine loses headway and
cannot make it to the top of a slope, do not turn machine
around. Always back slowly straight down the slope.
Safety Instructions
Page 1 - 2
Groundsmaster® 300 Series
27. Before getting off the seat:
B. Set the parking brake and disengage the PTO.
A. Move traction pedal to neutral position and remove foot from pedal.
C. Shut the engine off and remove key from ignition
switch. Wait for all movement to stop before getting
off the seat.
While Doing Maintenance, Troubleshooting, Testing, Adjustments or Repairs
28. Remove key from ignition switch to prevent accidental starting of the engine when servicing, adjusting, or
storing the machine.
29. Make sure you understand a service procedure
before working on the machine. Unauthorized modifications to the machine may impair the function, safety and
life of the machine. If major repairs are ever needed or
assistance is desired, contact an Authorized TORO
Distributor.
30. To reduce potential fire hazard, keep the engine free
of excessive grease, grass, leaves, and accumulations
of dirt. Clean protective screen on front of engine frequently. When cleaning parts, do not use flammable
solvents, such as diesel fuel, kerosene or gasoline.
34. If machine is equipped with roll-over protection
(ROPS), periodically inspect the roll bar and roll bar
mounting. Repair as necessary. Do not weld, cut, drill,
or modify roll bar in any manner.
35. Make sure all hydraulic line connectors are tight, and
all hydraulic hoses and lines are in good condition
before applying pressure to the system.
36. Keep body and hands away from pin hole leaks or
nozzles that eject hydraulic fluid under high pressure.
Use paper or cardboard, not hands, to search for leaks.
Hydraulic fluid escaping under pressure can have sufficient force to penetrate skin and do serious damage. If
fluid is ejected into the skin, it must be surgically removed within a few hours by a doctor familiar with this
form of injury or gangrene may result.
31. THE ASBESTOS BRAKE LININGS CONTAIN ASBESTOS FIBERS. BREATHING ASBESTOS DUST MAY BE HAZARDOUS TO YOUR HEALTH AND MAY CAUSE SERIOUS
RESPIRATORY OR OTHER BODILY HARM. For your pro-
tection:
A. AVOID CREATING DUST.
B. Do not remove brake drum without proper
equipment.
C. Do not work on brake linings without proper
protective equipment.
D. Do not replace brake linings without proper protective equipment.
E. Do not attempt to sand, grind, chisel, file, hammer,
or alter brake linings in any manner without proper
protective equipment.
F. Follow O.S.H.A standards for proper protective
devices to be used when working with asbestos
materials.
32. If the cutting unit discharge area ever plugs, disengage PTO and shut engine off before removing the
obstruction.
33. Make sure machine is in safe operating condition by
keeping nuts, bolts, and screws tight. Check all cutting
unit blade mounting bolts frequently to assure they are
torqued to proper specifications (See Cutting Unit Operator’s Manual).
Groundsmaster® 300 Series
37. Before disconnecting or performing any work on the
hydraulic system, all pressure in system must be relieved by stopping engine and lowering implement to the
ground.
38. If the engine must be running to perform maintenance or an adjustment, keep clear of PTO shaft, cutting
unit blades, and other moving parts.
39. Do not over-speed the engine by changing the
governor settings. To ensure safety and accuracy, have
an Authorized TORO Distributor check maximum engine speed with a tachometer.
40. Engine must be shut off before checking oil or
adding oil to the crankcase.
41. Disconnect the cables from the battery before servicing the machine. If battery voltage is required for
troubleshooting or test procedures, temporarily connect
the battery.
42. Do not charge a frozen battery because it can
explode and cause injury. Let the battery warm to 60° F
(15.5° C) before connecting to a charger. Charge the
battery in a well-ventilated place so that gases produced
while charging can dissipate. Since the gasses are
explosive, keep open flame and electrical spark away
from the battery; do not smoke. Nausea may result if the
gases are inhaled. Unplug the charger from the electrical outlet before connecting or disconnecting the
charger leads from the battery posts.
Page 1 - 3
Safety Instructions
43. Wear safety glasses, goggles or a face shield to
prevent possible eye injury when using compressed air
for cleaning or drying components.
44. Failure to follow proper procedures when mounting
a tire on a wheel or rim can produce an explosion which
may result in serious injury. Do not attempt to mount a
tire unless you have the proper equipment and experience to perform the job. Have it done by your Toro
Distributor or a qualified tire service.
use jack stands to safely support the machine when it
is raised by a jack or hoist.
46. At the time of manufacture, the machine conformed
to safety standards in effect for riding mowers. To ensure
optimum performance and continued safety certification
of the machine, use genuine TORO replacement parts
and accessories. Replacement parts and accessories
made by other manufacturers may result in non conformance with the safety standards, and the warranty may
be voided.
45. When changing attachments or performing other
service, use the correct blocks, hoists and jacks. Always
Safety Instructions
Page 1 - 4
Groundsmaster® 300 Series
Chapter 2
Product Records and Manuals
Table of Contents
1
2
2
2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . 3
Capscrew Markings and Torque Values - U.S. . . 3
Capscrew Markings and Torque Values - Metric . 3
EQUIPMENT OPERATION
AND SERVICE HISTORY REPORT FORM
Record information about your Groundsmaster 345,
322-D or 325-D on the Equipment Operation and Service History Report Form. Use this information when
referring to your machine.
Insert Operator’s Manuals and Parts Manuals for your
Groundsmaster 345, 322-D or 325-D at the end of this
section.
PRODUCT RECORD FORM . . . . . . . . . . . . . . . . . .
EQUIVALENTS AND CONVERSIONS . . . . . . . . . .
Decimal and Millimeter Equivalents . . . . . . . . . .
U.S. to Metric Conversions . . . . . . . . . . . . . . . . .
Product Records
Groundsmaster® 300 Series
Page 2 - 1 Rev. A
Product Records
Equivalents and Conversions
Decimal and Millimeter Equivalents
___________________________________________________________________________________________________
Fractions
Decimals
mm
Fractions
Decimals
mm
___________________________________________________________________________________________________
1/64 0.015625
1/32 –––––
0.03125
3/64 0.046875
1/16 ––––––––––––
0.0625
5/64 0.078125
3/32 –––––
0.9375
7/64 0.109275
1/8 –––––––––––––
0.1250
9/64 0.140625
5/32 –––––
0.15625
11/64 0.171875
3/16 ––––––––––––
0.1875
13/64 0.203125
7/32 –––––
0.21875
15/64 0.234375
1/4 –––––––––––––
0.2500
17/64 0.265625
9/32 –––––
0.28125
19/64 0.296875
5/16 ––––––––––––
0.3125
21/64 0.328125
11/32 ––––
0.34375
23/64 0.359375
3/8 –––––––––––––
0.3750
25/64 0.390625
13/32 ––––
0.40625
27/64 0.421875
7/16 ––––––––––––
0.4375
29/64 0.453125
15/32 ––––
0.46875
31/64 0.484375
1/2 –––––––––––––
0.5000
1 mm = 0.03937 in.
— 0.397
— 0.794
— 1.191
— 1.588
— 1.984
— 2.381
— 2.778
— 3.175
— 3.572
— 3.969
— 4.366
— 4.762
— 5.159
— 5.556
— 5.953
— 6.350
— 6.747
— 7.144
— 7.541
— 7.938
— 8.334
— 8.731
— 9.128
— 9.525
— 9.922
— 10.319
— 10.716
— 11.112
— 11.509
— 11.906
— 12.303
— 12.700
33/64 0.515625
17/32 –––– 0.53125
35/64 0.546875
9/16 –––––––––––– 0.5625
37/64 0.578125
19/32 –––– 0.59375
39/64 0.609375
5/8 ––––––––––––– 0.6250
41/64 0.640625
21/32 –––– 0.65625
43/64 0.671875
11/16 ––––––––––– 0.6875
45/64 0.703125
23/32 –––– 0.71875
47/64 0.734375
3/4 ––––––––––––– 0.7500
49/64 0.765625
25/32 –––– 0.78125
51/64 0.796875
13/16 ––––––––––– 0.8125
53/64 0.828125
27/32 –––– 0.84375
55/64 0.859375
7/8 ––––––––––––– 0.8750
57/64 0.890625
29/32 –––– 0.90625
59/64 0.921875
15/16 ––––––––––– 0.9375
61/64 0.953125
31/32 –––– 0.96875
63/64 0.984375
1 –––––––––––––– 1.000
0.001 in. = 0.0254 mm
— 13.097
— 13.494
— 13.891
— 14.288
— 14.684
— 15.081
— 15.478
— 15.875
— 16.272
— 16.669
— 17.066
— 17.462
— 17.859
— 18.256
— 18.653
— 19.050
— 19.447
— 19.844
— 20.241
— 20.638
— 21.034
— 21.431
— 21.828
— 22.225
— 22.622
— 23.019
— 23.416
— 23.812
— 24.209
— 24.606
— 25.003
— 25.400
___________________________________________________________________________________________________
U.S to Metric Conversions
___________________________________________________________________________________________________
To Convert
Into
Multiply By
___________________________________________________________________________________________________
Linear
Measurement
Miles
Yards
Feet
Feet
Inches
Inches
Inches
Kilometers
Meters
Meters
Centimeters
Meters
Centimeters
Millimeters
1.609
0.9144
0.3048
30.48
0.0254
2.54
25.4
___________________________________________________________________________________________________
Area
Square Miles
Square Feet
Square Inches
Acre
Square Kilometers
Square Meters
Square Centimeters
Hectare
2.59
0.0929
6.452
0.4047
___________________________________________________________________________________________________
Volume
Cubic Yards
Cubic Feet
Cubic Inches
Cubic Meters
Cubic Meters
Cubic Centimeters
0.7646
0.02832
16.39
___________________________________________________________________________________________________
Weight
Tons (Short)
Pounds
Ounces (Avdp.)
Metric Tons
Kilograms
Grams
0.9078
0.4536
28.3495
___________________________________________________________________________________________________
Pressure
Pounds/Sq. In.
Kilopascal
6.895
___________________________________________________________________________________________________
Work
Foot-pounds
Foot-pounds
Inch-pounds
Newton-Meters
Kilogram-Meters
Kilogram-Centimeters
1.356
0.1383
1.152144
___________________________________________________________________________________________________
Liquid Volume
Quarts
Gallons
Liters
Liters
0.9463
3.785
___________________________________________________________________________________________________
Liquid Flow
Gallons/Minute
Liters/Minute
3.785
___________________________________________________________________________________________________
Temperature
Fahrenheit
Celsius
1. Subract 32o
2. Multiply by 5/9
___________________________________________________________________________________________________
Equivalents and Conversions
Page 2 - 2
Groundsmaster® 300 Series
Torque Specifications
Use these torque values when specific torque values
are not given. DO NOT use these values in place of
specified values. Torque values listed are for lubricated
threads. Plated threads are considered to be lubricated.
Capscrew Markings and Torque Values - U.S. Customary
SAE Grade Number
5
8
________________________________________________________________________________________________________________________________________________________
Capscrew Head Markings
________________________________________________________________________________________________________________________________________________________
Capscrew Torque - Grade 5
Cast Iron
Aluminum
ft-lb
Nm
ft-lb
Nm
Capscrew Body Size
ft-lb
Capscrew Torque - Grade 8
Cast Iron
Aluminum
Nm
ft-lb
Nm
________________________________________________________________________________________________________________________________________________________
1/4-20
-28
7
9
9
12
6
7
8
9
11
13
15
18
9
10
12
14
________________________________________________________________________________________________________________________________________________________
5/16-18
-24
15
17
20
23
12
14
16
19
22
24
30
33
18
19
24
25
________________________________________________________________________________________________________________________________________________________
3/8-16
-24
30
30
40
40
20
25
25
35
40
45
55
60
30
35
40
45
________________________________________________________________________________________________________________________________________________________
7/16-14
-20
45
50
60
65
35
40
45
55
65
70
90
95
50
55
65
75
________________________________________________________________________________________________________________________________________________________
1/2-13
-20
70
75
95
100
55
60
75
80
95
110
130
150
75
90
100
120
________________________________________________________________________________________________________________________________________________________
9/16-12
-18
100
110
135
150
80
85
110
115
140
155
190
210
110
125
150
170
________________________________________________________________________________________________________________________________________________________
5/8-11
-18
135
155
180
210
110
120
150
160
190
215
255
290
150
170
205
230
________________________________________________________________________________________________________________________________________________________
3/4-10
-16
240
270
325
365
190
210
255
285
340
380
460
515
270
300
365
410
________________________________________________________________________________________________________________________________________________________
7/8-9
-14
360
390
490
530
280
310
380
420
550
610
745
825
440
490
600
660
________________________________________________________________________________________________________________________________________________________
1-8
-14
530
590
720
800
420
480
570
650
820
890
1100
1200
660
710
890
960
Capscrew Markings and Torque Values – Metric
Commercial Steel Class
8.8
10.9
12.9
________________________________________________________________________________________________________________________________________________________
Capscrew Head Markings
________________________________________________________________________________________________________________________________________________________
Thread
Diameter
mm
Capscrew Torque - Class 8.8
Cast Iron
Aluminum
ft-lb
Nm
ft-lb
Nm
Capscrew Torque - Class 10.9
Cast Iron
Aluminum
ft-lb
Nm
ft-lb
Nm
Capscrew Torque - Class 12.9
Cast Iron
Aluminum
ft-lb
Nm
ft-lb
Nm
________________________________________________________________________________________________________________________________________________________
6
5
9
4
7
9
14
7
11
9
14
7
11
________________________________________________________________________________________________________________________________________________________
7
9
14
7
11
14
18
11
14
18
23
14
18
________________________________________________________________________________________________________________________________________________________
8
18
25
14
18
23
32
18
25
27
36
21
28
________________________________________________________________________________________________________________________________________________________
10
30
40
25
30
45
60
35
45
50
70
40
55
________________________________________________________________________________________________________________________________________________________
12
55
70
40
55
75
105
60
80
95
125
75
100
________________________________________________________________________________________________________________________________________________________
14
85
115
65
90
120
160
95
125
145
195
110
150
________________________________________________________________________________________________________________________________________________________
16
130
180
100
140
175
240
135
190
210
290
165
220
________________________________________________________________________________________________________________________________________________________
18
170
230
Groundsmaster® 300 Series
135
180
240
320
Page 2 - 3
185
250
290
400
230
310
Torque Specifications
Torque Specifications
Page 2 - 4 Rev. A
Groundsmaster® 300 Series
EQUIPMENT OPERATION AND SERVICE HISTORY REPORT
for
GROUNDSMASTER® 345
Unit Model and Serial Number:
__________-__________
Deck Model and Serial Number: __________-__________
Engine Numbers:
____________________
Transmission Numbers:
____________________
Drive Axle(s) Numbers:
____________________
Date Purchased:
____________________ Warranty Expires__________
Purchased From:
____________________
____________________
____________________
Contacts:
Parts
____________________ Phone __________________
Service
____________________ Phone __________________
Sales
____________________ Phone __________________
See your TORO Distributor/Dealer for other Publications, Manuals, and Videos from The TORO Company.
GROUNDSMASTER® 345 Maintenance Schedule
Minimum Recommended Maintenance Intervals:
Maintenance Procedure
Check Battery Fluid Level
Check Battery Cable Connections
Maintenance Interval & Service
Every
50hrs
Every
100hrs
Every
200hrs
Every
400hrs
Lubricate All Grease Fittings
Lubricate Brake Cables
Check Cutting Unit Gear Box Oil Level
Clean Under Cutting Unit Belt Covers
Check Cutting Unit Drive Belt Adjustment
Check PTO Belt Adjustment
Inspect Air Filter, Dust Cup, and Baffle
A Level
Service
‡ Change Engine Oil and Filter
† Check Fan and Alternator Belt Tension
Inspect Cooling System Hoses
B Level
Service
† Replace Transmission Oil Filter
Service Air Filter
Check Governor Oil Level
Decarbon Spark Arrestor Muffler
Check Rear Wheel Toe-In and Steering Linkage
C Level
Service
† Torque Wheel Lug Nuts
Replace Fuel Filter
Change Transmission Oil
Change Cutting Unit Gear Box Oil
Replace Spark Plugs
Pack Rear Wheel Bearings
D Level
Service
Torque Head, Adjust Valves, Check Engine RPM
† Initial break in at 10 hours
‡ Initial break in at 50 hours
Replace Moving Hoses
Replace Safety Switches
Coolant System - Flush/Replace Fluid
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)
GROUNDSMASTER® 345 Daily Maintenance Check List
Unit Designation:__________
Daily Maintenance:(duplicate this page for routine use)
TORO ID#:_______-_______
Daily Maintenance Check For Week Of
_____________
Maintenance Check Item
MON
TUES
WED
THURS
FRI
SAT
SUN
_____HRS _____HRS _____HRS _____HRS _____HRS _____HRS _____HRS
Safety Interlock Operation
Grass Deflector in Down Position
Brake Operation
Fuel Level
Engine Oil Level
Cooling System Fluid Level
Dust Cup and Baffle (Air Filter)
Radiator & Screen for Debris
Unusual Engine Noises
Unusual Operating Noises
Transmission Oil Level
Hydraulic Hoses for Damage
Fluid Leaks
Tire Pressure
Instrument Operation
Condition of Blades
Lubricate All Grease Fittings1
Touch-up damaged paint
1
= Immediately after every washing, regardless of the intervals specified.
Notation for areas of concern:
Item
Date
Inspection performed by:________________
Information
1
2
3
4
5
6
7
(See Operator's and Service Manual for specifications and procedures)
A B C D
A and B Service required
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
Check Cutting Unit Gear Box Oil Level
Clean Under Cutting Unit Belt Covers
Check Cutting Unit Drive Belt Adjustment
Check PTO Belt Adjustment
Inspect Air Filter, Dust Cup, and Baffle
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
Replace Spark Plugs
Pack Rear Wheel Bearings
Torque Head, Adjust Valves,
A, B, and C Service required
___________________________________
___________________________________
(See Operator's and Service Manual for specifications and procedures)
Form No. 95-844-SL
________________________________
Coolant System - Flush/Replace Fluid
Change Cutting Unit Gear Box Oil
Engine RPM
Replace Safety Switches
Change Transmission Oil
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
Replace Moving Hoses
________________________________
Additional Servicing Items
________________________________
Decarbon Spark Arrestor Muffler
Check Governor Oil Level
Replace Fuel Filter
Annual Service
Torque Wheel Lug Nuts
A-Service required
Lubricate Brake Cables
D - Service (every 400 hours)
Check Rear Wheel Toe-In and Steering
Inspect Cooling System Hoses
Lubricate All Grease Fittings
Service Air Filter
Check Fan and Alternator Belt Tension
Check Battery Cable Connections
Replace Transmission Oil Filter
C - Service (every 200 hours)
Change Engine Oil and Filter
B - Service (every 100 hours)
Remarks:
Date:______________
Check Battery Fluid Level
Other
Service to perform (circle):
____________-____________
TORO I.D. #:
A -Service (every 50 hours)
Technician:
Hours:
Unit Designation:
(duplicate this page for routine use)
GROUNDSMASTER® 345 Supervisor Maintenance Work Order
EQUIPMENT OPERATION AND SERVICE HISTORY REPORT
for
GROUNDSMASTER® 322-D and 325-D
Unit Model and Serial Number:
__________-__________
Deck Model and Serial Number: __________-__________
Engine Numbers:
____________________
Transmission Numbers:
____________________
Drive Axle(s) Numbers:
____________________
Date Purchased:
____________________ Warranty Expires__________
Purchased From:
____________________
____________________
____________________
Contacts:
Parts
____________________ Phone __________________
Service
____________________ Phone __________________
Sales
____________________ Phone __________________
See your TORO Distributor/Dealer for other Publications, Manuals, and Videos from The TORO Company.
GROUNDSMASTER® 322-D and 325-D Maintenance Schedule
Minimum Recommended Maintenance Intervals:
Maintenance Procedure
Check Battery Fluid and Cable Connections
Lubricate Grease Fittings
Maintenance Interval & Service
Every
50hrs
Every
100hrs
Every
200hrs
Every
400hrs
Lubricate Brake Cables
Check Cutting Unit Gear Box Oil Level
Clean Under Cutting Unit Belt Covers
Check Cutting Unit Drive Belt Adjustment
Change Engine Oil
Check PTO Belt Tension
Inspect Air Filter, Dust Cup and Baffle
A Level
Service
‡ Replace Engine Oil Filter
† Check Fan and Alternator Belt Tension
B Level
Service
Inspect Cooling System Hoses
† Replace Transmission Oil Filter
Service Air Filter
Decarbon Spark Arrestor Muffler
C Level
Service
Check Rear Wheel Toe-In and Steering Linkage
† Torque Wheel Lug Nuts
Replace Diesel/Water Separator Filter
Replace Electric Fuel Pump Filter
Check Fuel Lines and Connections
Change Cutting Unit Gear Box Oil
Pack rear wheel bearings (2WD)
Change Rear Axle Lubricant (4WD)
D Level
Service
Change Transmission Oil
‡ Torque Head, Adjust Valves, and Check RPM
† Initial break in at 10 hours
‡ Initial break in at 50 hours
Replace Moving Hoses
Replace Safety Switches
Coolant System - Flush/Replace Fluid
Annual Recommendations:
Items listed are recommended every
1500 hours or 2 years whichever occurs
first.
Fuel Tank - Drain/Flush
(See Operator's and Service Manual for specifications and procedures)
GROUNDSMASTER® 322-D and 325-D Daily Maintenance Check List
Unit Designation:__________
Daily Maintenance:(duplicate this page for routine use)
TORO ID#:_______-_______
Daily Maintenance Check For Week Of
_____________
Maintenance Check Item
MON
TUES
WED
THURS
FRI
SAT
SUN
_____HRS _____HRS _____HRS _____HRS _____HRS _____HRS _____HRS
Safety Interlock Operation
Grass Deflector in Down Position
Brake Operation
Fuel Level
Engine Oil Level
Cooling System Fluid Level
Drain Water/Fuel Separator
Dust Cup and Baffle (Air Filter)
Radiator & Screen for Debris
Unusual Engine Noises1
Unusual Operating Noises
Transmission Oil Level
Hydraulic Hoses for Damage
Fluid Leaks
Tire Pressure
Instrument Operation
Condition of Blades
Lubricate All Grease Fittings2
Touch-up damaged paint
1
2
= Check diesel glow plug and injector nozzles, if hard starting, excess smoke, or rough running is noted.
= Immediately after every washing, regardless of the intervals specified.
Notation for areas of concern:
Item
Date
Inspection performed by:________________
Information
1
2
3
4
5
6
7
(See Operator's and Service Manual for specifications and procedures)
A B C D
A and B Service required
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
Clean Under Cutting Unit Belt Covers
Check Cutting Unit Drive Belt Adjustment
Change Engine Oil
Check PTO Belt Tension
Inspect Air Filter, Dust Cup and Baffle
Fuel Tank - Drain/Flush
________________________________
________________________________
________________________________
________________________________
________________________________
Change Cutting Unit Gear Box Oil
Pack rear wheel bearings (2WD)
Change Rear Axle Lubricant (4WD)
Change Transmission Oil
Torque Head, Adjust Valves, & Check RPM
A, B, and C Service required
Form No. 95-855-SL
________________________________
Coolant System - Flush/Replace Fluid
Check Fuel Lines and Connections
(See Operator's and Service Manual for specifications and procedures)
________________________________
Replace Safety Switches
Replace Electric Fuel Pump Filter
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
Replace Moving Hoses
________________________________
Additional Servicing Items
________________________________
Decarbon Spark Arrestor Muffler
Service Air Filter
Replace Diesel/Water Separator Filter
Annual Service
Torque Wheel Lug Nuts
A-Service required
Check Cutting Unit Gear Box Oil Level
D - Service (every 400 hours)
Check Rear Wheel Toe-In and Steering
Inspect Cooling System Hoses
Lubricate Brake Cables
Replace Transmission Oil Filter
Check Fan and Alternator Belt Tension
Lubricate Grease Fittings
Change Transmission Oil
C - Service (every 200 hours)
Replace Engine Oil Filter
B - Service (every 100 hours)
Remarks:
Date:______________
Check Battery Fluid and Cable Connections
Other
Service to perform (circle):
____________-____________
TORO I.D. #:
A - Service (every 50 hours)
Technician:
Hours:
Unit Designation:
(duplicate this page for routine use)
GROUNDSMASTER® 322-D and 325-D Supervisor Maintenance Work Order
Chapter 3
(For Groundsmaster 345 only)
Ford VSG-411 Engine
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . .
Spark Plug Inspection and Replacement . . . . . .
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Belt Adjustment. . . . . . . . . . . . . . . . . .
Coolant Fan Belt Adjustment. . . . . . . . . . . . . . . .
Governor Adjustment. . . . . . . . . . . . . . . . . . . . . .
1
2
2
3
3
3
4
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Pulley Installation . . . . . . . . . . . . . . .
Engine Removal and Installation . . . . . . . . . . . . .
Engine Repair Information. . . . . . . . . . . . . . . . . .
FORD VSG-411/413 ENGINE SERVICE MANUAL
6
6
7
8
Specifications
Item
Specification
Make / Designation
Ford Model VSG-411
Firing order
Ignition timing
1-2-4-3
Distributorless Ignition System (DIS)
Timing controlled by Universal Electronic Spark Control (UESC)
Spark plug
Motorcraft AGSF22C or AGRF22 or equivalent
Spark plug gap
0.040 in. (1.0 mm)
Crankcase oil capacity
3.5 U.S. qt. (3.25 liter) including filter
Oil service classification
API SG, SG/CC, SG/CD
Oil viscosity
Fuel
Ambient temperature
–10° to +60°F
+10° to +90°F
Above +32°F
Above +50°F
(single viscosity oil)
SAE 10
SAE 20
SAE 30
SAE 40
Ambient temperature
Below +60°F
–10° to +90°F
Above –10°F
Above +10°F
(multi-viscosity oil)
SAE 5W-30
SAE 10W-30
SAE 10W-40 or 10W50
SAE 20W40 or 20W50
Unleaded gasoline 87 octane or higher
Coolant
50 / 50 ethylene glocol anti-freeze and water
Cooling system capacity
6 U.S. qt. (5.7 liter)
Carburetor idle speed setting (throttle arm against stop)
1350 ± 50 RPM
Governor idle speed setting
1500 ± 50 RPM
Governor high speed setting
3200 ± 100 RPM
Groundsmaster® 300 Series
Page 3 - 1 Rev. C
Specifications
General Information
Spark Plug Inspection and Replacement
Since air gap between center and side electrodes increases gradually during normal engine operation,
check condition of electrodes at 100 hour intervals.
The correct spark plugs to use in the engine are Motorcraft AGSF22C or AGRF22 or equivalent. Set air gap at
0.040 in. (1.0 mm).
1. Clean area around spark plugs so dirt does not fall
into cylinder when plugs are removed.
2. Pull wire off spark plugs and remove plugs from
cylinder head.
3. Check condition of center and side electrodes to
determine operating temperature of engine.
A. Light brown insulator tip indicates correct spark
plug and heat range.
B. Black or oily insulator tip indicates an excessively
rich fuel mixture, possibly caused by a dirty air
cleaner element or a carburetor that is set too rich.
C. Light gray or blistered-white insulator indicates
overheating caused by a lean carburetor setting or
incorrect spark plug (heat range too high).
IMPORTANT: A cracked, fouled or dirty spark plug
must be replaced. Do not sandblast, scrape or clean
electrodes by using a wire brush because grit may
release from the plug and enter combustion chamber resulting in engine damage.
4. After setting air gap at 0.040 in. (1.0 mm), install spark
plug in cylinder head. Tighten the plug to 11 - 15 ft-lb.
Push wire onto spark plug.
General Information
Page 3 - 2
Groundsmaster® 300 Series
Adjustments
Alternator Belt Adjustment (Fig. 1)
A new alternator belt is to be tensioned to 65 lbs. A used
belt is to be re-tensioned to 40 lbs.
1. To adjustable tension, loosen bolt securing brace to
engine, bolt securing alternator to brace and alternator
mounting bolts.
2. Insert pry bar between alternator and engine and pry
out on alternator.
3. Hold alternator in position after proper tension is
achieved and tighten alternator and brace bolts to secure adjustment.
Figure 1
1. Alternator
2. Brace
Coolant Fan Belt Adjustment (Fig. 2)
A new fan belt is to be tensioned to 45 lbs. A used belt
is to be re-tensioned to 28 lbs.
1. To adjust belt tension, loosen upper and lower nuts
securing idler arm to front engine mount.
2. Pull out on idler arm until desired belt tension is
achieved.
3. Tighten mounting nuts to secure adjustment.
Figure 2
1. Edler arm
2. Engine mount
Groundsmaster® 300 Series
Page 3 - 3
Adjustments
Governor Adjustment (Fig. 3, 4)
1. With engine shut off, move throttle control to FAST
position and open hood. Check between throttle arm
and stop on carburetor base to make sure there is a
1/32 in. (0.8 mm) gap. If gap is not correct, adjust throttle
rod by turning ball joint ends until gap is 1/32 in.
(0.8 mm). If gap is correct, to to step 2.
WARNING
Engine must be running so final adjustment
of governor can be performed. To guard
against possible personal injury, engage
parking brake and keep hands, feet, face, and
other parts of body away from fan and other
moving parts.
2. Start engine and move throttle to SLOW position.
Allow engine to warm up to normal operating temperature.
Figure 3
1. 1/32" (0.8 mm)
4. Stop
2. Throttle rod
5. Throttle arm
3. Carbruetor idle speed screw
3. Rotate throttle arm closed until it contacts stop.
4. Check idle speed and adjust carburetor idle speed
screw if necessary to attain 1350 ± 50 rpm.
Adjustments
Page 3 - 4
Groundsmaster® 300 Series
5. Release throttle arm, loosen jam nut on governor low
idle stop screw and adjust it to get 1500 ± 100 rpm.
Tighten jam nut.
6. Slowly move throttle to FAST position until engine
speed reaches 3200 ± 100 rpm. Shut off engine. Adjust
high idle stop screw until it contacts speed control lever.
IMPORTANT: Do not over-speed the engine because
the transmission could be damaged.
7. Move throttle rapidly from SLOW to FAST. The engine
should not surge. If engine surges, go to step 8.
8. Check V-belts from engine to governor pulley and
make sure they are tight. If belts are loose, engine will
surge. If belts are tensioned properly, loosen jam nut
that retains anti-surge screw. Rotate screw clockwise
1/8 turn at a time until surging stops. Should governor
continue to surge, check the following:
A. Carburetor too rich or too lean.
B. Binding in throttle linkage.
C. Governor worn internally.
Figure 4
1. High idle stop screw
2. Speed control lever
3. Jam nut
4. Anti-surge screw
5. Oil check plug
6. Low idle stop screw
7. Oil fill plug
IMPORTANT: Never rotate anti-surge screw in too
far so that speed of engine increases.
9. Bump throttle lever with your hand so engine speeds
up momentarily. If governor is working properly, engine
speed should return to normal within one or two surges
of governor. More than two surges of governor usually
indicates that the anti-surge screw must be turned in
slightly more than it is. When adjustment is correct, lock
jam nut against governor body.
10. Check low and high idle speed to be sure there is
no change from initial setting. If high idle speed has
increased, anti-surge screw has been turned into governor too far and it must be backed out. Then, repeat
the entire adjustment procedure.
NOTE: If the throttle control on instrument panel will not
stay in FAST position during operation, remove panel
cover and tighten nut and capscrew at base of throttle
lever assembly.
Groundsmaster® 300 Series
Page 3 - 5
Adjustments
Repairs
Crankshaft Pulley Installation
1. Insert three of four locking rings into crankshaft pulley.
NOTE: Outside locking rings have tapered I.D. and flat
O.D. Inside locking rings have flat I.D. and tapered O.D.
A. Install first outside ring seated against small internal shoulder of pulley, flat edge of ring touching small
pulley shoulder.
B. Install second inside ring, mating taper to taper
with first ring.
C. Install third outside ring with flat edge against
previous inside ring.
D. Align ring end gaps with key slot in pulley.
2. Align pulley key slot with crankshaft key. Install pulley
approximately 1/4" onto crankshaft.
3. Insert fourth locking ring, taper to taper, with third ring.
Figure 5
1. Woodruff key
2. Pulley
3. Locking rings
4. Special washer
5. Metric bolt
4. Insert bolt through special washer. Shoulder on
washer contacts shoulder of fourth locking ring.
5. Draw pulley onto crankshaft by tightening crankshaft
bolt. Resistance will be felt as crankshaft passes
through locking rings.
6. Tighten crankshaft bolt to a torque of 40-44 ft-lb.
Check pulley alignment between crankshaft and water
pump.
Repairs
Page 3 - 6
Groundsmaster® 300 Series
Engine Removal and Installation
Removing the Engine
14. Remove fuel line from inlet side of fuel pump.
1. Put machine on a level surface, stop engine, remove
key from ignition switch and engage parking brake.
NOTE: Be prepared to insert a plug into fuel line to
prevent fuel spill.
2. Remove intake hose from air cleaner and carburetor.
15. Remove capscrews securing fan shroud to radiator
so fan shroud can be move during engine removal for
cooling fan clearance.
3. Remove transmission drive coupling (see Chapter 10
- Transmission Coupler and PTO).
4. Remove PTO belt (see Chapter 10 - Transmission
Coupler and PTO).
16. Attach a short section of chain between the two lifting
shakles on the engine. Attach block and tackle or hoist
chain to this short section of chain, approximately midway between the two shakles.
5. Disconnect battery cables from battery terminals.
6. Disconnect and tag all wires connected to engine and
engine accessories.
7. Put a drain pan under radiator, loosen radiator cap,
loosen radiator petcock and allow radiator to drain completely.
8. Move drain pan under lower radiator hose. Disconnect hose from radiator and allow coolant to drain into
pan. Remove lower and upper radiator hoses.
17. Remove four bolts securing rear engine mount to
frame.
18. Remove slack from lifting chain and carefully remove two capscrews which pass through the two rubber
front engine mounts.
19. Lift and guide engine from engine compartment. Be
careful not to damage the radiator cooling fan or other
components during removal.
Installing the Engine
9. Move drain pan under rear of engine and remove
cylinder block plug (located above starter) to drain coolant from cylinder block. Install cylinder block plug.
1. Do steps 2 - 19 of “Removing the Engine” in reverse
order.
10. Remove cable tie securing control cables and
vacuum sensor hose near caburetor.
2. Fill cooling system with new coolant. Install a new oil
filter and fill engine with correct oil.
11. Disconnect vacuum sensor hose from fuel trap on
carbruetor.
3. Inspect for oil and coolant leaks.
12. Disconnect choke control cable from carburetor.
4. Check engine idle speed and maximum governed
speed settings.
13. Disconnect throttle control cable from governor.
Groundsmaster® 300 Series
Page 3 - 7
Repairs
Engine Repair Information
Ford VSG-411 Component Changes
Ford VSG-411 engines with a date code of 2D21 or later
have five (5) main bearings, which is the same design
used on the VSG-413 engine. VSG-411 engines produced before this date have four (4) main bearings (see
Page 1-01, under IDENTIFICATION in the Ford
VSG-411/413 Engine Service Manual for an explanation of Ford corporate date system).
Listed below is a summary of changes from the four (4)
main bearing design to the five (5) main bearing design
of the VSG-411 engine:
Cylinder block – New, five main bearing design.
Crankshaft – Same as VSG-413.
Crankshaft lower main bearing – No change.
Crankshaft upper main bearing – No change.
Cr anksha ft r ear oil sea l re ta iner – Same
as VSG-413.
Crankshaft rear bearing oil seal gasket – Same
as VSG-413
Repairs
Page 3 - 8
Groundsmaster® 300 Series
Chapter 4
(For Groundsmaster 322-D/325-D only)
Mitsubishi K3D Diesel Engine
Table of Contents
For Groundsmaster 328-D, use the Toro Operator's Manual and Parts Catalog
along with the Kubota 05 Series Workshop Manual (Toro Part No. 01090SL).
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . 7
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Governor System . . . . . . . . . . . . . . . . . . . . . . . . 8
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . 9
Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . 10
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine Speed Adjustments . . . . . . . . . . . . . . . . 14
Throttle Linkage Adjustment . . . . . . . . . . . . . . . 15
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . 15
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Glow Plug Test . . . . . . . . . . . . . . . . . . . . . . . . . 18
Compression Test . . . . . . . . . . . . . . . . . . . . . . . 19
Nozzle Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Injection Pump Test . . . . . . . . . . . . . . . . . . . . . . 22
Injection Timing Test . . . . . . . . . . . . . . . . . . . . . 23
Fuel Pump Test . . . . . . . . . . . . . . . . . . . . . . . . . 24
Thermostat Test. . . . . . . . . . . . . . . . . . . . . . . . . 24
PREPARATION FOR ENGINE REPAIR. . . . . . . . . 25
Cylinder and Cylinder Block Overhaul . . . . . . . 25
EXTERNAL ENGINE COMPONENT REPAIR . . . . 26
Crankcase Breather System . . . . . . . . . . . . . . . 26
Alternator Belt Service . . . . . . . . . . . . . . . . . . . 27
Fan Belt Service . . . . . . . . . . . . . . . . . . . . . . . . 27
Fan, Fan Pulley and Fan Shaft Service . . . . . . 28
Glow Plug Replacement . . . . . . . . . . . . . . . . . . 29
Oil Pressure Switch Replacement. . . . . . . . . . . 29
Oil Pump Servicing . . . . . . . . . . . . . . . . . . . . . . 30
Groundsmaster® 300 Series
Stop Solenoid Replacement . . . . . . . . . . . . . . .
Water Pump Servicing . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM REPAIRS . . . . . . . . . . . . . . . . . . .
Bleeding the Fuel System . . . . . . . . . . . . . . . . .
Bleeding Air From the Injectors . . . . . . . . . . . . .
Fuel Pump Service . . . . . . . . . . . . . . . . . . . . . .
Governor Mechanism Operation . . . . . . . . . . . .
Governor Inspection . . . . . . . . . . . . . . . . . . . . .
Injection Pump Servicing . . . . . . . . . . . . . . . . . .
Nozzle Servicing . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING AND INSTALLING THE ENGINE . . . .
Removing the Engine . . . . . . . . . . . . . . . . . . . .
Installing the Engine . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD OVERHAUL . . . . . . . . . . . . . . .
Cylinder Head Removal. . . . . . . . . . . . . . . . . . .
Cylinder Head Servicing . . . . . . . . . . . . . . . . . .
Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Springs. . . . . . . . . . . . . . . . . . . . . . . . . . .
Rocker Arm and Rocker Shaft Service . . . . . . .
Cylinder Head Reassembly and Installation . . .
CYLINDER BLOCK OVERHAUL . . . . . . . . . . . . . .
Cylinder Block Disassembly . . . . . . . . . . . . . . .
Camshaft and Bearing. . . . . . . . . . . . . . . . . . . .
Fuel Injection Pump Camshaft . . . . . . . . . . . . .
Crankshaft Bearings . . . . . . . . . . . . . . . . . . . . .
Timing Gears . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Rod and Connecting Rod Bearings
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oversized Pistons, Cylinder Bore and Rings. . .
Piston and Pin Replacement . . . . . . . . . . . . . . .
Engine Reassembly. . . . . . . . . . . . . . . . . . . . . .
Page 4 - 1 Rev. C
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33
34
34
35
35
37
37
38
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46
46
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47
47
48
49
49
50
51
51
52
53
53
55
55
56
56
57
57
58
59
59
Table of Contents
Introduction
This chapter gives information about specifications,
maintenance, troubleshooting, testing and repair of the
diesel engine used in the Groundsmaster® 322-D and
325-D mower.
Most repairs and adjustments require tools which are
commonly available in many service shops. Special
tools are described in the Special Tools section. The use
of some specialized test equipment is explained, however, the cost of the test equipment and the specialized
nature of some repairs may dictate that the work be
done at a qualified diesel engine repair facility.
The engine used in the Groundsmaster® 322-D/325-D
mower is manufactured by Mitsubishi Heavy Industries
Limited. Service and repair parts for Mitsubishi engines
are supplied through TORO Distributors. Repair parts
may be ordered by TORO Part Number. If no parts list
is available be sure to provide your dealer or distributor
with the TORO Model Number and Serial Number.
Figure 1
The engine model number is embossed on the pump
mounting side of the crankcase. The serial number is
stamped on the injection pump mounting surface of the
crankcase (Fig. 1).
Introduction
Page 4 - 2
Groundsmaster® 300 Series
Specifications
The illustrations (Figs. 2a and 2b) give information about
the general construction of the engine.
Refer to the specifications listed in this section when
performing tests on the engine or examining parts for
wear. Some specifications are included in the service
procedures later in this chapter.
Figure 2a
Figure 2b
1. Cooling fan
2. Water oulet fitting
3. Intake valve
4. Exhaust valve
5. Water pump pulley
6. Water pump
7. Piston
8. Connecting rod
9. Fan belt
10. Crank pulley
11. Crankshaft
12. Gear case
13. Oil pan
14. Oil screen
15. Oil filler cap
16. Rocker cover
17. Rocker arm
18. Rocker shaft
Groundsmaster® 300 Series
19. Cylinder head
20. Cylinder block
21. Push rod
22. Tappet
23. Camshaft
24. Rear oil seal
24. case
25. Flywheel
1. Air breather pipe
2. Glow plug
3. Intake manifold
4. Nozzle holder
5. Cylinder head
6. Injection pump
7. Pump camshaft
Page 4 - 3
8. Cylinder block
9. Oil screen
10. Oil pan
11. Oil filler cap
12. Rocker cover
13. Rocker arm
14. Exhaust manifold
15. Piston
16. Connecting rod
17. Push rod
18. Tappet
19. Camshaft
20. Crankshaft
Specifications
General
________________________________________________________________________________________________________________________________________________________
Item
Specification
________________________________________________________________________________________________________________________________________________________
Make/Designation
Mitsubishi K3D-61TG, overhead valve,
vertical in-line, 4 cycle diesel
________________________________________________________________________________________________________________________________________________________
Rotation
Counterclockwise at flywheel side
________________________________________________________________________________________________________________________________________________________
Combustion Chamber
Swirl chamber type
________________________________________________________________________________________________________________________________________________________
Number of Cylinders
3
________________________________________________________________________________________________________________________________________________________
Bore x Stroke
73 x 78 mm (2.9 x 3.1 in.)
________________________________________________________________________________________________________________________________________________________
0.979 liter (59.7 in.3)
Total Displacement
________________________________________________________________________________________________________________________________________________________
Compression Ratio
23:1
________________________________________________________________________________________________________________________________________________________
Firing Order
1-3-2
________________________________________________________________________________________________________________________________________________________
Dry Weight (approximate)
124 kg (273 lb.)
________________________________________________________________________________________________________________________________________________________
Fuel
Diesel ASTM No. 2-D (ASTM No. 1-D in very cold weather)
________________________________________________________________________________________________________________________________________________________
Fuel Injection Pump
Bosch M type
________________________________________________________________________________________________________________________________________________________
Governor
Centrifugal fly weight type
________________________________________________________________________________________________________________________________________________________
Fuel Injector Nozzle
Throttle type
________________________________________________________________________________________________________________________________________________________
(120 - 130 kg/cm2) 1700 - 1850 psi
Fuel Injection Pressure
________________________________________________________________________________________________________________________________________________________
Lubrication System
Forced lubrication
________________________________________________________________________________________________________________________________________________________
Oil Pump
Gear type
________________________________________________________________________________________________________________________________________________________
Oil Filter
Paper element filter (full flow type)
________________________________________________________________________________________________________________________________________________________
Crankcase Oil Capacity
3.5 liter (3.7 U.S. qt.) including filter
________________________________________________________________________________________________________________________________________________________
Cooling System
Forced circulation, water cooling
________________________________________________________________________________________________________________________________________________________
Water Pump
Centrifugal type
________________________________________________________________________________________________________________________________________________________
Cooling System Capacity
5.7 liter (6 U.S. qt.)
________________________________________________________________________________________________________________________________________________________
Starter
Solenoid shift type
2.0 kW (12 volt)
________________________________________________________________________________________________________________________________________________________
Alternator
AC type 12 volt 35A
________________________________________________________________________________________________________________________________________________________
Glow Plug
Sheathed type
________________________________________________________________________________________________________________________________________________________
Specifications
Page 4 - 4
Groundsmaster® 300 Series
Engine
________________________________________________________________________________________________________________________________________________________
Item
Standard Specification
Repair Limit
Service Limit
________________________________________________________________________________________________________________________________________________________
Governor
Mechanical/Centrifugal
________________________________________________________________________________________________________________________________________________________
Operating Speed (no load)
± 50 rpm
3200 rpm
________________________________________________________________________________________________________________________________________________________
Idle Speed (no load)
± 50 rpm
1500 rpm
________________________________________________________________________________________________________________________________________________________
Compression
32 kg/cm2 (455 psi) at 280 rpm
26 kg/cm2 (370 psi)
22 kg/cm2 (313 psi)
________________________________________________________________________________________________________________________________________________________
Pressure Difference Between Cylinders
2.5 kg/cm2 (36 psi) max.
________________________________________________________________________________________________________________________________________________________
Cylinder Injection Order
1-3-2
________________________________________________________________________________________________________________________________________________________
Injection Timing
23o B.T.D.C. (at smoke set position
± 2o
________________________________________________________________________________________________________________________________________________________
Cylinder Head
Bottom Surface Flatness (distortion)
Valve Guide I.D.
Valve Seat Angle
Valve Seat Width
Valve Seat Sinkage
0.05 mm (0.002 in.) max.
6.6 mm (0.26 in.)
45o
1.3 - 1.8 mm (0.051 - 0.071 in.)
0.1 mm (0.004 in.)
2.5 mm (0.1 .in.)
–1 mm (– 0.039 in.)
________________________________________________________________________________________________________________________________________________________
Valve Clearance (cold)
(both intake and exhaust)
0.25 mm (0.01 in.)
________________________________________________________________________________________________________________________________________________________
Valves
Valve Head Dia. (IN)
Valve Head Dia. (EX)
Overall Length
Valve Stem O.D.
Stem to Guide Clearance (IN)
Stem to Guide Clearance (EX)
Valve Seat Face Angle
Valve Head Thickness (margin width)
Valve Head Sinkage
(from cyl. head bottom face)
27.2 mm (1.079 in.)
25.2 mm (0.992 in.)
114.5 (4.508 in.)
6.6 mm (0.260 in.)
0.10 mm (0.004 in.)
0.15 mm (0.006 in.)
45o
1 mm (0.039 in.)
0.5 mm (0.020 in.)
0.5 mm (0.020 in.)
1.5 mm (0.06 in.)
________________________________________________________________________________________________________________________________________________________
Valve Spring
Free Length
Installed Load/Height
Squareness
43 mm (1.693 in.)
14 ± 0.7kg/36 mm
(30.9 ± 1.5 lb./1.417 in.)
29.75 ± 1.5 kg/28 mm
(65.6 ± 3.3 lb./1.102 in.)
2o
– 1 mm (– 0.039 in.)
–15%
–10%
3o
________________________________________________________________________________________________________________________________________________________
Rocker Arm I.D.
Rocker Arm to Shaft Clearance
18.9 mm (0.744 in.)
–0.2 mm (0.008 in.)
________________________________________________________________________________________________________________________________________________________
Cylinder Block
Camshoft hole I.D.
Front (Bush)
Oil Clearance
Center
Rear
Cylinder Bore
Oversize finish tolerance
Cylindricity of cylinder bore
Warpage of head gasket mating surface
45 mm (1.772 in.)
0.15 mm (0.006 in.)
44 mm (1.732 in.)
34 mm (1.339 in.)
73 mm (2.874 in.)
0 to 0.03 mm (0 to 0.001 in.)
0.01 mm (0.0004 in.) max.
0.05 mm (0.0020 in.) max.
+0.2 mm (0.008 in.)
+ 0.95 mm (0.037 in.)
0.1 mm (0.004 in.)
________________________________________________________________________________________________________________________________________________________
Groundsmaster® 300 Series
Page 4 - 5
Specifications
Engine (cont.)
________________________________________________________________________________________________________________________________________________________
Item
Standard Specification
Repair Limit
Service Limit
________________________________________________________________________________________________________________________________________________________
Piston
Type
Material
Piston Outside Diameter (skirt end)
Piston to Cylinder Wall Clearance
Oversize
Solid
Aluminum alloy
73 mm (2.874 in.)
0.3 mm (0.012 in.)
0.25, 0.50, 0.75 mm
(0.01, 0.02, 0.03 in.)
________________________________________________________________________________________________________________________________________________________
Piston Pin
Type
Outside Diameter
Pin to Piston Clearance
Pin to Connecting Rod Clearance
Semi-floating
19 mm (0.748 in.)
0.08 mm (0.003 in.)
Press-fit load: 1000 + 500 kg
(2200 + 1100 lb.)
________________________________________________________________________________________________________________________________________________________
Piston Rings
Number of Rings
3 Compression
1 Oil
Compression Ring Width
Oil Ring Width
Compression Ring Side Clearance
No. 1
No. 2
Oil Ring Side Clearance
Ring Gap
No. 1: Chrome plated, semi-keystone type
No. 2 and No. 3: Tapered
Chrome plated ring with coil expander
2 mm (0.079 in.)
3 mm (0.118 in.)
0.06 - 0.12 mm (0.0024 - 0.005 in.)
0.05 - 0.09 mm (0.002 - 0.004 in.)
0.03 - 0.07 mm (0.001 - 0.003 in.)
0.15 - 0.40 mm (0.006 - 0.016 in.)
0.3 mm (0.012 in.)
0.2 mm (0.008 in.)
0.2 mm (0.008 in.)
1.5 mm (.060 in.)
________________________________________________________________________________________________________________________________________________________
Connecting Rod
Type
Bend and Twist
Big End Thrust Clearance
Forged I-beam
0.05 mm (0.002 in.) max.
0.1 - 0.35 mm (0.004 - 0.014 in.)
0.15 mm (0.006 in.) max.
0.5 mm (0.02 in.)
________________________________________________________________________________________________________________________________________________________
Connecting Rod Bearings
Oil Clearance
Undersize
0.15 mm (0.006 in.)
0.25, 0.50, 0.75 mm
(0.01, 0.02, 0.03 in.)
________________________________________________________________________________________________________________________________________________________
Crankshaft
Type
Bend
End Play
Journal O.D.
Pin O.D.
Finish Undersize
Journal U.S. 0.25 mm (0.01 in.)
Journal U.S. 0.50 mm (0.02 in.)
Journal U.S. 0.75 mm (0.03 in.)
Pin U.S. 0.25 mm (0.01 in.)
Pin U.S. 0.50 mm (0.02 in.)
Pin U.S. 0.75 mm (0.03 in.)
Fully counterbalanced
Within 0.03 mm (0.001 in.)
0.05 - 0.205 mm (0.002 - 0.008 in.)
52 mm (2.047 in.)
42 mm (1.654 in.)
0.05 mm (0.002 in.)
– 0.15 mm (– 0.006 in.)
– 0.15 mm (– 0.006 in.)
– 0.95 mm (– 0.037 in.)
– 0.95 mm (– 0.037 in.)
51.735 - 51.750 mm
(2.0368 - 2.0374in.)
51.485 - 51.500 mm
(2.0270 - 2.0276 in.)
51.235 - 51.250 mm
(2.0171 - 2.0177 in.)
41.700 to 41.715 mm
(1.6417 - 1.6423 in.)
41.450 - 41.465 mm
(1.6319 - 1.6325 in.)
41.200 - 41.215 mm
(1.6220 - 1.6226 in.)
________________________________________________________________________________________________________________________________________________________
Specifications
Page 4 - 6
Groundsmaster® 300 Series
Engine (cont.)
________________________________________________________________________________________________________________________________________________________
Item
Standard Specification
Repair Limit
Service Limit
________________________________________________________________________________________________________________________________________________________
Main Bearings
Oil Clearance
Undersize
0.10 mm (0.004 in.)
0.25, 0.50, 0.75 mm
(0.01, 0.02, 0.03 in.)
________________________________________________________________________________________________________________________________________________________
Camshaft
Drive System
Journal to Cylinder Block Hole Clearance
Cam Lobe Height
(both intake and exhaust)
Gear
0.15 mm (0.006 in.)
– 1.0 mm (– 0.039 in.)
35.76 mm (1.401 in.)
________________________________________________________________________________________________________________________________________________________
Pump Camshaft
Drive System
Bearing
Front
Rear
Cam Lobe Height
Gear
Ball bearing
Cylinder block hole
44 mm (1.732 in.)
– 1.0 mm (– 0.039 in.)
________________________________________________________________________________________________________________________________________________________
Tappets
Outside Diameter
Tappet to Cylinder Block Hole Clearance
23 mm (0.906 in.)
– 0.15 mm (– 0.006 in.)
________________________________________________________________________________________________________________________________________________________
Push Rod Bend
0.3 mm (0.012 in.) max.
________________________________________________________________________________________________________________________________________________________
Lubrication System
________________________________________________________________________________________________________________________________________________________
Item
Standard Specification
Repair Limit
Service Limit
________________________________________________________________________________________________________________________________________________________
Oil Capacity
3.5 liter (3.7 qt.)
including oil filter
________________________________________________________________________________________________________________________________________________________
API Service Class
CD
________________________________________________________________________________________________________________________________________________________
Viscosity
Above 68oF (20oC)
41oF to 68oF (5o to 20oC)
Below 41oF (5oC)
SAE 30 or 10W-30
SAE 20 or 10W-30
SAE 10W-30
________________________________________________________________________________________________________________________________________________________
Oil Pump
Type
Check Valve Opening Pressure
Outer Rotor to Housing Clearance
Outer Roto to Inner Rotor Clearance
Rotor to Cover Clearance
Gear type
4 kg/cm2 (56.9 psi)
at 1000 rpm
0.15 - 0.20 mm (0.006 - 0.008 in.)
0.05 - 0.12 mm (0.002 - 0.005 in.)
0.03 - 0.07 mm (0.001 - 0.003 in.)
0.3 mm (0.012 in.)
0.25 mm (0.01 in.)
0.2 mm (0.008 in.)
________________________________________________________________________________________________________________________________________________________
Oil Pressure Switch
Indicator Lamp Lighting Pressure
0.5 kg/cm2 (7.1 psi)
________________________________________________________________________________________________________________________________________________________
Groundsmaster® 300 Series
Page 4 - 7
Specifications
Fuel System
________________________________________________________________________________________________________________________________________________________
Item
Standard Specification
Repair Limit
Service Limit
________________________________________________________________________________________________________________________________________________________
Fuel Pump Delivery Rate
225 cc (13.73 in3) or more (15 sec., 12V)
________________________________________________________________________________________________________________________________________________________
Fuel Injection Pump
Model
Injection Timing (B.T.D.C.)
MD-PER3M
23o B.T.D.C. (at smoke set position
± 2o
________________________________________________________________________________________________________________________________________________________
Nozzles
Type
Model
Injection Start Pressure
Throttle type
ND-DN4SD24
120 kg/cm2 (1707 psi)
120 ± 10 kg/cm2
(1707 ± 142 psi)
________________________________________________________________________________________________________________________________________________________
Cooling System
________________________________________________________________________________________________________________________________________________________
Item
Standard Specification
Repair Limit
Service Limit
________________________________________________________________________________________________________________________________________________________
Coolant Capacity
5.7 liter (6 U.S. qt.)
________________________________________________________________________________________________________________________________________________________
Thermostat
Type
Valve Cracking Temperature
Full Opening Valve Temperature
Valve Lift
Wax type
76.5° ± 1.5°C (177° ± 3°F
90o ± 1.5oC (194o ± 3oF)
8 mm (0.314 in.)
________________________________________________________________________________________________________________________________________________________
Specifications
Page 4 - 8
Groundsmaster® 300 Series
Electrical System
________________________________________________________________________________________________________________________________________________________
Item
Standard Specification
Repair Limit
Service Limit
________________________________________________________________________________________________________________________________________________________
Starter
Type
Nominal Output
Direction of Rotation
No-load Characteristics (Cold)
Terminal Voltage/Current
Speed
Height of Brush
Spring Pressure
Commutator O.D.
Depth of Commutator Undercut
Pinion Gap
Thrust Gap
Solenoid shift type
2.0 kW - 12V
Clockwise as viewed from pinion side
11V/130A max. at 20°C (68°F)
3850 rpm min.
11.5 mm (0.45 in.)
3 kg (6.6 lb.)
38.7 mm (1.52 in.)
0.5 -0.8 mm (0.02 - 0.03 in.)
0.5 - 2.0 mm (0.02 - 0.08 in.)
0.5 (0.02 in.) max.
1.7 mm (0.07 in.)
1.8 kg (4 lb.)
– 1.0 mm (– 0.4 in.)
0.2 mm (0.008 in.)
________________________________________________________________________________________________________________________________________________________
Alternator
Nominal Output
Direction of Rotation
No Load Output Characteristics (Cold)
Terminal Voltage/Current
Speed
Load Output Characteristics (Cold)
Terminal Voltage/Current
Speed
12V - 35A
Clockwise as viewed from pulley side
14V/0A at 20°C (68°F)
1300 rpm or less
14V/30A or more at 20°C (68°F)
2500 rpm
________________________________________________________________________________________________________________________________________________________
Regulator (separate type)
Regulated Voltage
14.8 ± 0.3V
________________________________________________________________________________________________________________________________________________________
Glow Plugs
Rated Voltage
Rated Current (when rated voltage
is applied for 30 seconds)
Resistance
10.5V DC
9.7A ± 1.0A
0.16 ohm (at room temperature)
________________________________________________________________________________________________________________________________________________________
Glow Plug Indicator
Rated Current
Voltage Across Terminals (at 29A)
29A
1.7V ± 0.2V
________________________________________________________________________________________________________________________________________________________
Groundsmaster® 300 Series
Page 4 - 9
Specifications
Tightening Torque
The Mitsubishi diesel engine has many bolts and capscrews of special materials and sizes. It is very important that special care be used to replace all bolts and
capscrews in their proper location during assembly of
the engine. The torque specifications in American
Standard and Metric as listed below MUST be followed
in order to have the assembled engine conform to the
original specifications.
________________________________________________________________________________________________________________________________________________________
Item
Description
Tightening Torque
________________________________________________________________________________________________________________________________________________________
Cylinder head bolt
Cylinder head bolt
M12 (qty. 8)
M10 (qty. 3)
11.5 - 12.5 kgm (wet) (83 - 90 ft-lb)
6.5 - 8.0 kgm (wet) (47 - 58 ft-lb)
________________________________________________________________________________________________________________________________________________________
Crankshaft pulley nut
M18
15 - 16 kgm (109 - 116 ft-lb)
________________________________________________________________________________________________________________________________________________________
Main bearing cap bolt
5 - 5.5 kgm (36 - 40 ft-lb)
________________________________________________________________________________________________________________________________________________________
Connecting rod cap nut
3.2 - 3.5 kgm (23 - 25 ft-lb)
________________________________________________________________________________________________________________________________________________________
Flywheel mounting bolts
(8T) flanged bolts
(8T) bolts with washers
13 - 14 kgm (94 - 101 ft-lb)
11.5 - 12.5 kgm (83 - 90 ft-lb)
________________________________________________________________________________________________________________________________________________________
Oil drain plug
5 - 6 kgm (36 - 43 ft-lb)
________________________________________________________________________________________________________________________________________________________
Oil filter
1.1 - 1.3 kgm (8 - 9 ft-lb)
________________________________________________________________________________________________________________________________________________________
Fuel injection pump
Delivery valve holder
4 - 5 kgm (29 - 36 ft-lb)
________________________________________________________________________________________________________________________________________________________
Nozzle holder
Holder mounting bolt
Holder body and retaining nut
1.5 - 2 kgm (11 - 15 ft-lb)
6 - 8 kgm (43 - 58 ft-lb)
________________________________________________________________________________________________________________________________________________________
Glow plug
1.5 - 2 kgm (11 - 15 ft-lb)
________________________________________________________________________________________________________________________________________________________
Specifications
Page 4 - 10
Groundsmaster® 300 Series
Special Tools
Order special tools from T O R O S P E C IA L T O O L S A N D
A P P L IC AT IO N S G U ID E (C o m m e rcial P ro d u c ts). Some
tools may be available from a local supplier.
Filter Cleaner (Fig. 3)
Filter cleaner. Mix with water and use solution to wash
the Donaldson air cleaner element.
Figure 3
Diesel Engine Compression Test Kit (Fig. 5)
Diesel engine compression test kit. 0-1000 PSI Gauge
allows testing of diesel engines to check general operating condition of engine. Includes case, guage with
hose, glow plug hole adapters and instructions.
Figure 5
Piston Pin Tool (Fig. 6)
Piston pin tool is used to remove and install the wrist pin
without distorting the piston. Inludes an adapter for use
with Mitsubishi and most other engines.
Figure 6
Groundsmaster® 300 Series
Page 4 - 11
Special Tools
Nozzle Tester (Fig. 7)
Nozzle tester tests condition and opening pressure of
fuel injector nozzles.
Figure 7
Nozzle Tester Adapter (Fig. 8)
Nozzle tester adapter is required to test the fuel injection
nozzles.
Figure 8
Camshaft Bushing Tool (Fig. 9)
The camshaft bushing removal and installation tool is
used in conjunction with a soft metal hammer to remove
or install the camshaft bushing in the Mitsubishi K3D
engine.
Figure 9
Special Tools
Page 4 - 12
Groundsmaster® 300 Series
Adjustments
Valve Clearance (Fig. 10, 11, 12)
Check the valve clearance after the first 50 hours of
operation and every 400 hours of operation after that.
1. The engine must be cold when the valve clearance is
checked.
2. Remove the air breather hose from the rocker cover.
3. Remove the rocker cover nuts and washers. Remove
the rocker cover.
4. Tighten the cylinder head bolts to the proper torque.
The rocker assembly must be removed before tightening the cylinder head bolts. When tightening the cylinder
head bolts, lower the coolant level in the engine, loosen
the bolts slightly and then re-tighten in the sequence
shown.
Figure 10
M12 bolt torque (wet): 1.5 - 12.5 kgm (83 - 90 ft-lb)
M10 bolt torque (wet): 6.5 - 8.0 kgm (47-58 ft-lb)
Rocker stay bolt torque: 1.5 - 2.2 KgM (11 - 16 ft-lb)
5. Rotate the crankshaft until the TDC mark (located
next to the injection timing mark(s) on the pulley lines
up with the registration mark on the gear case. This will
be TDC on cylinder No. 1.
NOTE: There are two TDC positions (compression and
intake strokes). At compression TDC the rocker arms
will not move when the crankshaft pulley is rotated a
small distance each way. Compression TDC is where
the valves are to be adjusted.
Figure 11
6. Measure the valve clearance by using a thickness
gauge inserted between the valve stem and rocker arm.
The correct valve clearance for both the intake and
exhaust valves is 0.25 mm (0.01 in.).
7. To adjust the valve clearance, loosen the adjusting
lock nut and turn the rocker arm adjusting screw clockwise or counterclockwise until you get the correct clearance. Tighten the locknut securely. Check to make sure
that the clearance was not changed while tightening the
locknut.
8. Perform steps 6 and 7 of this procedure for cylinder
No. 2 and 3 while at their TDC position. Turn the
crankshaft 240o clockwise to get No. 3 cylinder TDC.
Turn the crankshaft an additional 240o clockwise to get
No. 2 cylinder TDC.
Figure 12
9. Install the rocker cover. Install the rocker cover nuts
and washers. Install the air breather hose on the rocker
cover.
Groundsmaster® 300 Series
Page 4 - 13
Adjustments
Engine Speed Adjustments (Fig. 13, 14)
Adjustments to the engine speed settings are not normally necessary unless the throttle linkage, injection
pump, or governor mechanism have been repaired,
rebuilt, replaced or are not operating correctly.
Since there is no ignition system from which to power
an electronic tachometer, a vibration-type tachometer
must be used to set engine speed.
NOTE: This engine is equipped with a special damper
spring (Fig. 14) which is designed to prevent engine
stalling when the throttle decelerated quickly. Adjustment of this spring is required when adjusting the engine
rpm.
High Speed Adjustment
Idle Speed Adjustment
NOTE: Specified engine rpm is with no load on engine.
1. The engine should be at operating temperature. Make
sure the parking brake is engaged.
2. Move the throttle control lever to the idle position
(against the stop plate). Open the hood.
3. Make sure throttle cable is mounted correctly to allow
complete travel of throttle control.
4. Loosen the lock nut on the low speed set bolt (Fig. 13)
and adjust idle speed to 1500 ± rpm by rotating the low
speed set bolt. Tighten the lock nut.
NOTE: Specified rpm is with no load on engine.
The high speed set bolt has been set properly and
sealed at the factory. Never tamper with the seal unless
necessary.
Idle rpm
1500 ± 50 rpm
No load governed rpm
Setting “A” 3120 - 3160 rpm
Setting “B” 3145 - 3200 rpm
1. The engine should be at operating temperature. Make
sure the parking brake is engaged.
2. Open and support the hood.
3. Remove sealing cap from damper spring adjusting
bolt (Fig. 14) and loosen adjusting bolt to remove
damper spring tension. NOTE: If tie rod cover was
removed, make sure governor tie rod has been pushed
to the high speed position before cover is installed.
Figure 13
4. Loosen the lock nut on the high speed set bolt
(Fig. 13) and adjust maximum engine speed to setting
“A” by rotating the high speed set bolt. Tighten lock nut
after adjusting.
5. Tighten damper spring adjusting bolt to adjust maximum engine speed to setting “B”, then tighten locknut
to secure adjusting bolt (apply Loctite 242 or equivalent
to threads of adjusting bolt).
5. Install a wire and lead seal on high speed set bolt.
Figure 14
Adjustments
Page 4 - 14
Groundsmaster® 300 Series
Throttle Linkage Adjustment (Fig. 15)
1. Loosen the capscrew and nut securing the throttle
cable to throttle lever.
2. Push the governor lever all the way back so it is
contacting the high speed set screw.
3. Move the throttle lever to the maximum speed position (all the way forward).
4. Tighten the cap screw and nut securing the throttle
cable to the governor lever.
5. Make sure the throttle cable conduit does not interfere
with the full range of motion of the throttle lever or
governor lever.
Figure 15
1. Governor lever
2. Cap screw and nut
3. Throttle lever
4. Throttle cable
5. Throttle cable conduit
Troubleshooting
Giving Immediate attention to any indication of a problem can prevent major failures, and increase the life of
the engine.
Groundsmaster® 300 Series
Never make more that one adjustment at a time, then
locate the trouble by a process of elimination. Remember the cause is usually SIMPLE, rather than mysterious
and complicated.
Page 4 - 15
Troubleshooting
Troubleshooting
Page 4 - 16
Groundsmaster® 300 Series
Groundsmaster® 300 Series
Page 4 - 17
Troubleshooting
Testing
Glow Plug Test (Fig. 16)
Be careful while handling or testing glow
plugs. Glow plugs become extremely hot. Accidental contact with the heated plug tip could
cause personal injury.
1. Disconnect the wire lead(s) to the glow plug.
2. Remove the glow plug.
3. Inspect the glow plug for signs of a burnt glow plug
end tube.
Figure 16
NOTE: If the metal of the glow plug end is melted, it is
a sign of cylinder overheating. (See Engine Overheats
in the Troubleshooting section of this chapter.)
4. Connect the positive (+) battery terminal to the glow
plug terminal, and the negative (–) battery terminal to
the plug body. If the glow plug glows red-hot, the glow
plug is operating correctly.
5. Replace any glow plugs that do not operate correctly.
Testing
Page 4 - 18
Groundsmaster® 300 Series
Compression Test (Fig. 17)
Normal cylinder compression is 32 kg/cm2 (455 psi) at
280 rpm (normal cranking speed). The engine should
be warm - coolant temperature of 50o C (120o F).
IMPORTANT: DO NOT put oil into the combustion
chamber before performing a compression test.
Damage may result because of “hydraulic” forces
acting upon the piston and connecting rod.
1. Remove the glow plug lead wires and glow plugs from
all three cylinders.
2. Insert the compression gauge adapter into the glow
plug hole. (See the Special Tools section of this
chapter.)
Figure 17
3. Connect the high pressure compression gauge to the
adapter.
4. Hold fuel shut off lever in closed position to prevent
fuel delivery during compression test. This will prevent
wash-down of cylinders and inaccurate readings.
5. Crank the engine with the starter motor until you get
a stable gauge reading.
6. If the pressure is less than 26 kg/cm2 (370 psi) it will
be necessary to find the cause of low compression. (See
Engine Fails to Start - Low Compression in the Troubleshooting section of this chapter.)
7. Repeat the test for the other two cylinders. Difference
between cylinders should be no more than 2.5 kg/cm2
(36 psi).
Groundsmaster® 300 Series
Page 4 - 19
Testing
Nozzle Tests (Fig. 18, 19)
There are several tests to examine the condition of the
injection nozzles. These tests require the use of a
nozzle tester and nozzle tester adapter. (See the Special Tools section of this chapter.)
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:
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 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.
Minimum starting pressure
2
120 kg/cm (1700 psi)
Maximum starting pressure
2
130 kg/cm (1850 psi)
6. Starting pressure can be adjusted by adding or removing shims from the nozzle. (See Nozzle Service in
the Fuel System Repairs section of this chapter.) A
0.1 mm shim will cause a 10 kg/cm2 (140 psi) starting
pressure difference.
7. Repeat the test after installing shim to verify that a
correct starting pressure has been obtained.
Chattering Test
Proper and free operation of the nozzle valve can be
determined by the chattering test.
1. Securely fasten the nozzle to be tested to the adapter.
To prevent possible injury, wear eye protection 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. Operate the pump handle slowly (ten strokes per
minute). As the pump pressure reaches the starting
pressure the nozzle valve will chatter as it opens and
closes rapidly. A nozzle which does not chatter may be
the result of a binding or bent nozzle valve.
Nozzle Leakage Test
A nozzle that leaks fuel from the nozzle orifice must be
replaced.
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.
1. Securely fasten the nozzle to the adapter.
Injection Pressure Test
3. Operate the pump until the pressure is approximately
108 kg/cm2 (1500 psi). Maintain this pressure to the
nozzle.
The diesel engine requires that fuel be sprayed into the
combustion chamber at a precise point in the compression stroke. The point at which this fuel injection occurs
is determined by the injection timing. If the nozzle is
defective, damaged or adjusted incorrectly, starting 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.
Testing
2. Wipe all fuel from 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 fastened in the retaining nut. If the leak continues, replace
the nozzle.
Page 4 - 20
Groundsmaster® 300 Series
6. While pressure is being applied, watch for an accumulation of fuel at the tip of the nozzle (Fig. 18). A small
amount of fuel may be present due to a previous chattering test - this would be normal. If the fuel accumulates
and drips down during the test (about ten seconds) the
nozzle assembly is defective and must be replaced.
Spray Test
For proper combustion, the nozzle must effectively atomize the injected fuel.
1. Operate the pump handle at a rate of 20 - 30 strokes
per minute.
2. Observe the injector nozzle spray. The spray pattern
should be finely atomized in a broad, straight stream
(Fig. 19).
Figure 18
3. If the nozzle fails to spray properly, it must be cleaned,
repaired or replaced. (See Nozzle Service in the Fuel
System Repairs section of this chapter.)
Figure 19
Groundsmaster® 300 Series
Page 4 - 21
Testing
Injection Pump Test
D. Put the throttle control in the FAST position. Turn
the ignition key to the START position to crank the
engine. Observe the nozzle.
Calibration of fuel delivery volumes, pressure and distribution 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.
The injection pump 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 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.
1. Make sure that fuel is being supplied to the injector
pump. (See Fuel Pump Test in this section and Bleeding
Air From the Fuel System in the Fuel System Repairs
section of this section.)
2. Check the operating condition of the injection nozzles
to make sure that the injection pressure is correct. (See
Injection Pressure Test in this section of the book.)
3. Make sure that the injection pump is providing sufficient fuel pressure to operate the nozzle by performing
the following procedures:
A. Loosen the fuel delivery pipe from the number one
nozzle.
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.
B. Remove the nozzle from the cylinder head.
5. Repeat the test for the other cylinders.
C. Connect the fuel delivery pipe to the nozzle assembly so the tip of the nozzle is pointed away from
the engine. Tighten the fitting securely.
Testing
Page 4 - 22
Groundsmaster® 300 Series
Injection Timing Test (Fig. 20, 21)
Injection timing can be adjusted by installing shims
under the pump body. The timing is important because
it determines when the fuel enters the combustion
chamber.
The most accurate method of timing is done with an
electronic diesel timing tester (available from major tool
supply companies).
The following method is an initial setting for starting the
machine.
1. Remove the number one injection pipe from both the
pump and nozzle. (The number 1 cylinder is opposite
from the flywheel end of the engine.)
7. Standard injection timing can be confirmed by the IT
marks on the crankshaft pulley and the stationary
pointer on the crankcase (Fig. 21).
The center mark on the pulley represents 23o BTDC;
standard fuel injection timing. The outside marks represent 25o BTDC and 21o BTDC; the acceptable range of
injection timing.
Shims are available in different sizes from 0.2 to 1.0 mm
thick. Adding or removing a shim, 0.1 mm thick, will
change injection timing by 1o. Increase shim thickness
if injection is too early. Decrease shim thickness if
injection is too late. (See Injection Pump Service in the
Fuel System Repairs section of this chapter.)
2. Set up the injection pump for the test:
A. Remove the delivery valve holder (Fig. 20). Remove the delivery valve assembly and spring.
B. Replace the valve holder and tighten it in place.
3. Put the throttle control in the middle of its range of
travel.
4. Slowly rotate the crankshaft counterclockwise from
the flywheel end (normal rotation) until the IT marks
(injection timing marks) on the crankshaft pulley are
approximately 1/2 in. (21 mm) from alignment with the
stationary pointer on the engine gear case (Fig. 21).
Make sure the number 1 cylinder compression stroke is
approaching by checking the push rods. Both push rods
on the number 1 cylinder should be loose and the valves
closed. If either push rod is tight, rotate the engine
crankshaft one full revolution and inspect the push rods
again.
Figure 20
Removing the delivery valve
5. Turn the ignition switch ON so the electric fuel pump
will supply fuel through the injection pump and out the
number 1 delivery valve holder.
6. Rotate the engine crankshaft SLOWLY in the normal
direction until the flow from the number one injection
pipe just stops. This is the moment of actual injection
timing. (A large screwdriver inserted between the transmission drive hub and rubber coupler will provide control
and leverage to slowly rotate the engine crankshaft.)
Groundsmaster® 300 Series
Page 4 - 23
Figure 21
Testing
Fuel Pump Test (Fig. 22)
1. Turn the ignition switch to the ON position. Test for
pump operation by listening for the pump oscillating
sound, or by feeling for vibration which indicates the
pump is operating.
2. If no pumping action occurs when the ignition switch
is turned on, connect a 12 volt DC battery directly to the
pump (Fig. 22). If the pump now operates, check for an
electrical failure of the pump circuit, eg. fuses, connections, wires, etc.
3. The delivery of the fuel pump may be checked by
disconnecting the fuel lines from the water separator
and fuel filter and routing them to a can of filtered diesel
fuel and a drain pan (Fig. 22). Activate the pump and
measure the amount of fuel pumped in during a 15
second time interval. The standard pump rate is approximately 8 ounces (225 cc) in 15 seconds.
Figure 22
4. If the fuel delivery rate is below the standard value
the pump should be disassembled and checked. (See
Fuel Pump Service in the Fuel System Repairs section
of this chapter.)
Thermostat Test (Fig. 23)
If the engine overheats and a faulty thermostat is suspected, the thermostat should be tested.
1. Remove the thermostat (see Thermostat Removal
and Installation in the External Engine Component Repair section of this chapter).
2. Put the thermostat in a container of water with a
thermometer and heat the water (Fig. 23).
Valve cracking temperature: 76.5o C (177o F).
Full-open temperature: 90o C (194o F)
Valve lift: 8 mm (0.314 in.)
3. If the thermostat fails to open, only partially opens, or
sticks, it should be replaced.
Testing
Page 4 - 24
Figure 23
Groundsmaster® 300 Series
Preparation for Engine Repair
1. Before cleaning and disassembly, carefully check for
problems that cannot be found after the engine has
been cleaned or disassembled (e.g. oil leaks from
cracked components, gaskets or loose fittings, 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.
engine oil to disassembled parts, as necessary to prevent rust.
5. Keep the work area clean; dirt causes engine failures.
6. Be very careful when working on fuel system components. 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: Do not spray water on a hot engine.
Injection pump seizure or other failures could
result.
Engine Compression
3. Do not disassemble or remove parts that do not
require disassembly.
The time interval to overhaul the engine can most
accurately be determined by regular and systematic
cylinder compression measurement. (See Compression Test in the Testing section of this chapter.)
4. Disassemble the engine in proper order, arranging
the parts the disassembled parts neatly. Apply clean
Cylinder and Cylinder Block Overhaul
Before removing any parts, disassembly or overhaul of
the Mitsubishi engine, it is very important to understand
the nature and probable cause of the problem that made
an overhaul necessary.
When the engine trouble is caused by worn cylinders,
rings or valves, one or more of the following symptoms
will occur:
1. Low engine power, and a decrease in compression
pressure.
2. Increased fuel consumption.
list can be a result of excessive fuel injection, improper
injection timing, or nozzle and injection pump wear. Poor
starting may be a result of electrical problems. Noises
may be associated with a mechanical part outside the
engine. Excess fuel or oil consumption may be the result
of leaks. (See the Troubleshooting section of this chapter.)
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 maintenance 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.
3. Increased lubricating oil consumption.
4. Poor engine starting.
5. Loud noises in the engine.
It is important to find the cause of the engine failure
before beginning repair. Symptoms 2 and 3 in the above
Groundsmaster® 300 Series
Page 4 - 25
Preparation for Engine Repair
External Engine Component Repair
In this section, repairs to the external engine components will be outlined. These are repairs which can be
accomplished without removing the engine from the
mower frame. They are:
Crankcase Breather
Fan, Pulley, Bearing and Shaft Repair or Replacement
Oil Pressure Switch Replacement
Oil Pump
Stop Solenoid Replacement
Water Pump Replacement
Crankcase Breather System (Fig. 24)
The crankcase breather system is shown in the illustration. Blow-by fumes are recirculated for recombustion
without being discharged into the atmosphere. The
fumes within the cylinder block flow into the rocker cover
through holes in the valve tappets and the push rod
clearance holes. They are carried through a rubber air
breather pipe from the rocker cover to the inlet pipe, and
then to the combustion chamber. The air breather pipe
(rubber hose) should be replaced if it is damaged or
shows any sign of deterioration.
Failure to periodically inspect this hose, or to replace a
faulty hose, will allow dirt to enter directly into the engine
cylinder, and can cause premature engine wear or
damage.
Figure 24
Crankcase breather system
External Engine Component Repair
Page 4 - 26
Groundsmaster® 300 Series
Alternator Belt Service (Fig. 25)
1. Unlatch and open hood.
2. Check tension by depressing belt midway between
alternator and crankshaft pulleys. Belt should deflect
7/16 in. (11 mm). If deflection is incorrect, proceed to
step 3. If correct, continue operation.
3. Loosen bolt securing brace to engine and bolt securing alternator to brace.
4. Insert pry bar between alternator and engine and pry
out alternator.
5. Hold alternator in position after proper belt tension
setting is achieved and tighten alternator and brace
bolts to secure adjustment.
Figure 25
1. Alternator
2. Engine brace bolt
3. Alternator brace bolt
4. Brace
5. Fan belt guard
Fan Belt Service (Fig. 25, 26)
1. Unlatch and open hood.
2. Remove capscrews (5) securing fan belt guard and
remove guard.
3. Belt should deflect 1/4 in. (6 mm) midway between
pulleys with 5 lbf (22 N) of force applied. If deflection is
incorrect, proceed to step 4. If correct proceed to step 5.
4. Loosen locknut securing idler pulley. Push idler pulley
against belt until proper deflection is achieved and
tighten idler pulley locknut.
5. Install fan belt guard and secure with capscrews.
Close and latch hood.
To replace belt:
Figure 26
1. 1/4 in. (6 mm) deflection
2. Idler pulley locknut
1. Do steps 1 and 2 above.
2. Loosen locknut securing idler pulley, slide pulley
away from belt and remove belt from top and bottom
pulleys.
3. Install new belt and adjust for proper tension. Push
idler pulley against belt until belt deflects 1/4 in. (6 mm)
with 5 lbf (22 N) of force applied midway between top
and bottom pulleys. Tighten idler pulley locknut to secure adjustment.
4. Install fan belt guard and secure with capscrews.
Close and latch hood.
NOTE: Check fan belt tension after first days of operation. Readjust tension, if necessary.
Groundsmaster® 300 Series
Page 4 - 27
External Engine Component Repair
Fan, Fan Pulley and Fan Shaft Service (Fig. 27)
Fan Assembly Removal
Fan Assembly Inspection
1. Park the machine on a level surface, turn engine off,
remove key from switch, and apply the parking brake.
1. Inspect fan for cracks; replace fan if damaged.
2. Remove five capscrews which secure fan belt guard
and remove guard.
3. Loosen locknut securing idler pulley. Slide pulley to
right to remove tension from fan V-belt and slip belt off
of flywheel and fan pulleys.
2. Inspect shaft and tube for signs of wear in bearing
areas; replace if bearings are loose and a press-fit is not
possible.
3. Rotate bearings; replace them if they do not rotate
smoothly, or if there is noticeable play in them.
4. Use a hoist connected to the two engine hangers to
support the rear of the engine.
IMPORTANT: Position lift chain underneath fan
shaft tube to prevent damage to tube.
NOTE: An alternate method is to put a sturdy board
beneath oil pan and use a floor jack to support engine.
5. Remove two cap screws which pass through rubber
engine mounts. If shims are used between rubber
mounts and metal engine mount (bar), be sure to note
their locations and reinstall them correctly.
6. Remove two cap screws which fasten fan mount to
the rear of engine block. These are located just above
edge of flywheel.
7. Remove four cap screws which secure fan mount to
front of cylinder head, cylinder block and muffler
bracket.
8. Remove fan assembly from machine.
9. Remove cotter pins, slotted nuts, woodruff keys and
washers from ends of the fan shaft. Note number and
placement of washers.
10. Remove pulley from end of shaft (it may be neces­
sary to use a puller).
11. Remove cap screws and lock washers which retain
fan to fan hub. Remove fan hub and woodruff key from
shaft.
NOTE: If bearings or mating tube and shaft surfaces are
not worn or damaged do not disassemble.
12. Press shaft and fan-side bearing from tube by
pressing on belt pulley end of shaft. Inner races of
bearings are pressed onto shaft and fit against shoul­
ders on shaft; both bearings are also pressed into tube
ends.
13. Press remaining bearing from tube by applying
pressure to bearing outer race.
External Engine Component Repair
Page 4 - 28 Rev. D
Groundsmaster® 300 Series
Fan Assembly Installation
1. Clean inside of pulley end of tube and outside diameter of pulley end bearing. Apply Loctite #609 (or equivalent) to outside diameter of bearing and press bearing
into pulley end of tube.
4
2
6
7
7
1
3
2
1
4. Position woodruff key in fan shaft and slide pulley
onto shaft. Fit flat washer and shim washer(s) to shaft
and install slotted hex nut. Torque nut from 50 to 70 ft–lb
(68 to 94 N–m).
5. Position woodruff key in fan shaft and slide fan hub
onto shaft. Install fan to fan hub with cap screws and
lock washers. Fit flat washer and shim washer(s) to
shaft and install slotted hex nut. Torque nut from 50 to
70 ft–lb (68 to 94 N–m).
8
5
2. Insert shaft through tube and into installed bearing.
Support inner race of bearing as shaft is being installed
into bearing.
3. Position second bearing (no Loctite on this bearing)
onto fan end of shaft. Press bearing into tube.
3
Figure 1
1.
2.
3.
4.
Slotted hex nut
Cotter pin
Flat washer
Fan shaft
5.
6.
7.
8.
Woodruff key
Fan hub
Bearing
Shim washer
IMPORTANT: If hex nut slot and cotter pin shaft
hole do not align after applying correct torque to
slotted hex nut, remove nut and add shim washers
until alignment is correct. DO NOT loosen nut to
align the slot and hole.
6. Install new cotter pins through slotted nut and fan
shaft to retain both pulley and fan hub.
7. Reinstall fan assembly onto engine by performing removal steps 1 through 8 in reverse order.
Groundsmaster 300 Series
Page 4 – 28.1 Rev. D
External Engine Component Repair
This page is intentionally blank.
External Engine Components Repair
Page 4 – 28.2 Rev. D
Groundsmaster 300 Series
Glow Plug Replacement
If a glow plug has been determined to be defective by
failing the glow plug test, it should be replaced.
3. Remove the defective glow plug from its mounting
hole.
1. Remove the nut and lead wire.
4. Install the replacement glow plug. Torque the glow
plug to 11 - 14.5 ft-lb (1.5 - 2 KgM).
2. Clean the area around the glow plug to prevent dirt
or grit from falling into the glow plug hole and the cylinder
during replacement.
5. Reinstall the lead wires and nuts.
Oil Pressure Switch Replacement (Fig. 28)
The engine is equipped with an oil pressure switch
which activates a lamp and buzzer on the control panel
if the oil pressure drops below safe levels during operation. The switch is located on the oil pump at the rear of
the right-hand side of the cylinder block.
The switch and lamp circuit can be tested with a 12 VDC
battery. With the switch removed the warning
lamp should light and buzzer sound when it is connected
in series with the switch and battery. Removing the
switch from the circuit will test the lamp and buzzer only.
If the switch is defective it should be replaced. Use a
small amount of LOCTITE #567 Thread Sealant (or
equivalent) on the switch threads. Be careful to install
the switch carefully so that the sealant will not block the
oil hole in the switch.
Groundsmaster® 300 Series
Page 4 - 29
Figure 28
External Engine Component Repair
Oil Pump Servicing
The oil pump is a trochoid gear type pump, mounted to
the rear of the fuel injection pump, and driven by the fuel
injection pump camshaft. The pump houses a check
valve which opens to the oil pan when the pump delivery
pressure exceeds 57 psi (393 kPa), thereby preventing
excessive oil pressure.
Disassembly of Oil Pump (Fig. 29)
1. Drain the engine oil.
2. Remove the oil filter. The use of a filter wrench may
be necessary.
Figure 29
3. Remove the four bolts which hold the pump cover in
place and attach the pump to the cylinder block.
4. Remove the pump cover, body and rotors and gasket.
Oil Pump Inspection (Fig. 30, 31, 32)
The oil pump, or its worn components, should be replaced when internal pump clearances exceed those
shown in the table above.
1. Outer Rotor to body clearance should be checked
with a feeler gauge. If clearance exceeds the service
limit, replace the rotor assembly.
Figure 30
2. Outer rotor to Inner Rotor clearance should be
checked with a feeler gauge. If clearance exceeds the
service limit, replace the rotor assembly. Check the
coupling end of the Inner Rotor shaft for cracks or
damage.
3. Rotor to cover clearance should be check with a feeler
gauge by placing the rotor assembly in the pump body
and using the cover as a straight edge.
In case of excessive clearance, replace either the Rotor
Assembly or the Oil Pump Body.
Figure 31
4. Inspect the Pump Body 0-ring for cuts, cracks or other
damage.
5. The Pump Relief Valve can be disassembled by
removing the plug, gasket, spring and plunger. Ensure
that the Relief Plunger travels freely, and that the drain
holes in the Plunger are not blocked.
Figure 32
External Engine Component Repair
Page 4 - 30
Groundsmaster® 300 Series
Oil Pump Reassembly (Fig. 33)
1. Install the Plunger, Spring, Gasket and Plug of the Oil
Relief Valve into the Pump Cover.
2. Verify that the dowel pins are in place, and install the
0-ring in the pump body (if replaced or removed).
3. Place the Rotor Assembly into the Pump Body. Apply
oil to the rotating parts.
NOTE: The Inner and Outer Rotors have a dimple which
faces outward from the Pump Body.
4. Place the Pump Body, along with a new oil Pump
Body Gasket, in position, and rotate the rotor assembly
until the inner rotor shaft couples with the slot in the
injector pump cam shaft.
Figure 33
5. Position the Pump Cover on the dowel pins and
secure the pump into positions with the four bolts,
washers, and lock washers. Torque the bolts to 12 13 ft-lb (1.7 KgM).
Groundsmaster® 300 Series
Page 4 - 31
External Engine Component Repair
Stop Solenoid Replacement (Fig. 34)
The Mitsubishi engine uses an electrical solenoid to
shut off the fuel supply and stop the engine. An emergency stop lever is provided in case the stop solenoid
fails. If a solenoid failure is suspected, it can be checked
by attaching 12 VDC battery leads to the solenoid
terminals. If the solenoid operates when battery contact
is make the stopping failure is elsewhere in the electrical
system (refer to Chapter 6).
1. Turn the engine off (with emergency stop lever if
necessary), and remove the key from the ignition switch.
2. Disconnect the solenoid wires from the main wire
harness.
3. Loosen the nut securing the solenoid to the engine
and unscrew the solenoid. (Use a 36 mm wrench.)
Figure 34
4. Remove the gasket and the nut and install them on
the new solenoid. Thread the nut fully onto the solenoid.
Remove the cap from the old solenoid.
5. Start to thread the solenoid into the cylinder block.
6. Push the plunger on the solenoid fully in and hold it
in this position.
7. Rotate the emergency engine stop lever to the STOP
position (counterclockwise).
8. Continue to hold the solenoid plunger in and thread
the solenoid into the cylinder block until the inner end of
the plunger contacts the control rack of injector pump.
Contact will be indicated when the outside end of the
plunger is pushed away from the solenoid body.
9. When contact is indicated, discontinue threading the
solenoid into the cylinder block. Turn the solenoid slowly
outward until the plunger again contacts the solenoid
body, then rotate the solenoid body one eighth turn
further out.
10. Hold the solenoid body to prevent it from turning and
tighten the nut against the cylinder block to secure the
adjustment. DO NOT over tighten the nut or the solenoid
may become distorted causing it to malfunction.
11. Connect the solenoid wires, install the cover.
External Engine Component Repair
Page 4 - 32
Groundsmaster® 300 Series
Water Pump Servicing
The water pump is a centrifugal impeller type pump
which is mounted on the front upper part of the cylinder
block. The pump bearings and seals are not serviceable.
Water Pump Removal
1. Drain the coolant from the radiator and cylinder block
(drain plug on the left-hand side of the block).
Water Pump Inspection
1. Inspect all hoses for cracks or leaks.
2. Rotate the water pump impeller and shaft. If the
bearings do not rotate smoothly, or are noisy, the water
pump must be replaced; the water pump has no replaceable components.
Water Pump Reassembly
2. Disconnect the water hoses.
Reassemble in reverse order of disassembly. Use a new
water pump gasket to avoid leaks.
3. Remove the V-belt which drives the water pump.
4. Disconnect the water bypass hose.
now move freely when operated by hand. If it does not,
difficulty with the injection pump should be suspected.
5. Remove the six bolts fastening the water pump to the
cylinder block.
Groundsmaster® 300 Series
Page 4 - 33
External Engine Component Repair
Fuel System Service
When cleaning the engine, DO NOT spray water onto a
hot injection pump. This could cause the fuel pump to
seize and be damaged.
When working on the fuel system, ALWAYS make sure
that the equipment and work area is clean. The close
tolerance parts of the fuel system can be easily damaged by dirt.
Wash fuel system parts in clean fresh diesel fuel. If parts
are removed for a period of time, store them in containers of clean diesel fuel to prevent corrosion.
Bleeding the Fuel System (Fig. 35, 36)
1. Stop the engine and engage the parking brake.
Unlatch and raise hood.
2. Loosen the air bleed screw on the fuel filter / water
separator.
3. Turn the ignition key switch to the ON position. The
electric fuel pump will begin to operate and force fuel
out around the screw loosened in step 2. Fuel will fill the
filter bowl and then flow out around the screw. When a
solid stream of fuel flows out around the screw, tighten
the screw and turn the key switch OFF.
4. Open the air bleed screw on the fuel injection pump.
5. Turn the ignition key switch to the ON position. The
electric fuel pump will begin to operate and force fuel
out around the injection pump air vent screw. When a
solid stream of fuel flows out around the screw, tighten
the screw and turn the key switch OFF.
Figure 35
1. Fuel filter/water separator
2. Air bleed screw
NOTE: Normally the engine should start after this procedure. If the engine does not start, air may be trapped
between the injection pump and injectors (See Bleeding
Air From the Injectors in this section of the book.)
Figure 36
1. Fuel injection pump
Fuel System Service
Page 4 - 34
2. Air bleed screw
Groundsmaster® 300 Series
Bleeding Air From the Injectors (Fig. 37)
This procedure should only be used if the fuel system
has been purged of air. (See Bleeding the Fuel System
in this section of the book.)
1. Loosen the pipe connection at the number 1 nozzle
and holder assembly on the cylinder head .
2. Move the throttle control to the FAST position.
3. Turn the ignition key to the START position to crank
the engine and pump fuel to the nozzles. Turn the
ignition key to the OFF position when a steady stream
of fuel flows out of the loose pipe connection.
4. Tighten the pipe connector.
Figure 37
5. Repeat steps 1 - 4 for the No. 2 and No. 3 injector
nozzle and holder.
Fuel Pump Service (Fig. 38)
The only serviceable parts of the fuel pump are the
magnet, filter, and the gaskets on each end of the filter.
1. Disconnect the fuel pump wires from the wiring harness and ground connection.
2. Disconnect the fuel hoses from the pump. Plug the
fuel lines.
3. Remove the two screws which secure the pump to
the frame.
4. Use a 17 mm wrench to remove the cover from the
fuel pump. Remove the gasket, magnet and filter element.
Figure 38
1. Cover
2. Cover gasket
3. Magnet
Groundsmaster® 300 Series
Page 4 - 35
4. Filter
5. Body
Fuel System Service
5. Carefully remove the spring retainer from the end of
the plunger tube. Remove the washer, o-ring, valve,
plunger spring and plunger.
IMPORTANT: Be careful not to bend or deform the
plunger tube while disassembling the fuel pump. If
the plunger tube is bent, the fuel pump plunger will
bind and the pump will need to be replaced.
6. Install the plunger (valve side out), plunger spring,
valve, o-ring, washer and spring retainer. Make sure the
plunger operates freely.
7. Install the filter and cover gaskets, magnet, filter and
cover. Tighten the cover to prevent air leaks.
8. Install the fuel pump to the frame. Connect the fuel
lines and electrical wires.
9. Bleed the fuel system. (See Bleeding the Fuel System
in this section of the book.)
Fuel System Service
Page 4 - 36
Figure 39
1. Spring retainer
2. Washer
3. O-ring
4. Valve
5. Plunger spring
6. Plunger
7. Plunger tube
8. Body
Groundsmaster® 300 Series
Governor Mechanism Operation
Operation of the governor keeps the engine speed
constant as the centrifugal force acting on the governor
weights balances with the tension of the governor
spring.
As the engine speed increases the governor weights will
open, forcing the end of the sliding shaft against the
governor lever. The governor lever then moves against
the governor spring tension and moves the control rack,
through the tie rod, in the direction that decreases the
amount of fuel delivered by the injection pump. A leaf
spring on the tie rod cover is used to prevent stalling
during rapid deceleration by limiting the travel of the tie
rod.
Servicing the governor requires removal of the gear
case on the front of the engine, and there for engine
removal.
Governor Inspection (Engine Not Removed) (Fig. 40)
A governor failure can result in a starting failure loss of
engine speed control, or engine surging (hunting). Before removal and disassembly of the engine the following inspections are recommended:
1. Remove the tie rod cover and operate the speed
control lever. The injection pump control rack should
move as the lever is operated.
2. If the control rack does not move, remove the tie rod
retaining spring and tie rod from the control rack. The
control rack should now move freely when operated by
hand. If it does not, difficulty with the injection pump
should be suspected.
3. With the tie rod removed from the control rack,
operate the speed control lever and watch for tie rod
travel. Failure of the tie rod to move would indicate
difficulty with the governor spring, governor lever or
other internal parts. Refer to “Removing and Replacing
the Engine” for engine removal instructions.
Figure 40
1. Injection pump
2. Stopper spring
3. Tie rod
4. Governor lever
5. Governor weight
Groundsmaster® 300 Series
Page 4 - 37
6. Sliding shaft
7. Gear case
8. Governor shaft
9. Pump gear
10. Pump camshaft
11. Idle gear
12. Needle bearing
13. Needle bearing
14. Governor spring
15. Speed control lever
Fuel System Service
Injection Pump Servicing (Fig. 41)
A built-in three-cylinder injection pump is mounted
on the right-hand side of the cylinder block. It
consists of a pump element (plunger and barrel assembly), a delivery valve, a tappet and a smoke set unit. As
the pump cam rotates, the plunger is moved up and
down through a prescribed stroke, delivering fuel to the
engine cylinders. A key operated stop system is provided.
Fuel Injection Control
The fuel injection rate is controlled by changing the
effective stroke of the plunger within the barrel. The
plunger is rotated by the control pinion which meshes
with the plunger lower collar to directly turn the plunger.
As the engine turns, the injection pump camshaft rotates
to move the control rack by way of the governor weights,
governor sleeve, and lever. The control rack slides to
turn the control pinions. Movement of the control rack to
the right decreases the fuel injection rate and movement
to the left increases the rate.
Figure 41
1. Air vent screw
2. Stopper
3. Control rack
4. Return spring
5. Gasket
6. O-ring
7. Plunger
8. Lower seat
9. Tappet
10. Valve holder
Fuel System Service
Page 4 - 38
11. Spring
12. Delivery valve
13. Valve seat
14. Plunger barrel
15. Adjusting plate
16. Control pinion
17. Upper seat
18. Plunger spring
19. Pump housing
Groundsmaster® 300 Series
Control Rack Smoke Set and Ungleich Device
(Fig. 42, 43, 44)
The injection pump on the is equipped with a mechanism that allows for over injection of fuel during starting,
and thereafter limits the amount of fuel delivered during
operation to reduce excessive exhaust smoke. These
devices, the smoke set plate and Ungleich set plate, are
located on the side of the injection pump and operate
by limiting the travel of the control rack.
The Ungleich device requires that the engine be OFF,
either with the key switch or emergency stop lever, in
order for the control rack to travel completely to the left
(over-injection). Once started, the action of the governor
causes the control rack to move to the right (less fuel)
until the corner of the smoke set plate engages the
shoulder of the Ungleich set plate. The amount of control
rack movement is now restricted by the locations of the
smoke set plate and the Ungleich set plate.
Figure 42
During extreme loading the control rack will overcome
the tension on the smoke set spring and slightly increase the amount of fuel delivered to the cylinders. This
fuel increase is determined by the Ungleich set plate
and is referred to as Ungleich Effect “L” (length).
Figure 43
Figure 44
Groundsmaster® 300 Series
Page 4 - 39
Fuel System Service
Delivery Valve Operation (Fig. 45)
The delivery valve serves two functions. First, the valve
opens to deliver fuel to the delivery pipe when the
pressure generated by the stroke of the plunger within
the barrel is sufficiently high. The pressure must be high
enough to cause the injector nozzle to open. Second,
after injection into the cylinder the Delivery Valve closes,
reducing the pressure within the delivery pipe to nearly
zero while preventing fuel from flowing from the tube.
Figure 45
Inter-Cylinder Injection Control (Fig. 46)
The amount of fuel delivered to each of the three cylinders is adjusted by means of adjusting plates. These
plates function as a cam to position the plunger barrel
within the pump housing.
IMPORTANT: Do not remove the Adjusting Plates
from the pump housing. If removed, re-calibration
by a diesel shop will be necessary.
If it is necessary to remove the plates, carefully scribe
the plate and pump body to allow for exact, correct
reassembly.
Figure 46
Fuel System Service
Page 4 - 40
Groundsmaster® 300 Series
Injection Pump Disassembly (Fig. 47)
The injection pump may be disassembled to replace
worn, damaged or defective components according to
the following procedures:
IMPORTANT: Clean external engine area near injection pump before disassembly. Do not spray water
on a hot injection pump. Do not remove Inter-cylinder adjusting plates unless necessary. If necessary,
scribe plates and housing carefully to ensure exact
repositioning upon reinstallation. Do not mix delivery valves, delivery valve seats, plungers or plunger
barrels from one cylinder to another. Handle these
parts carefully. Place these parts in clean diesel fuel
to prevent rust.
1. Remove the fuel pipes from the injection pump to the
injector nozzles.
2. Remove the fuel return hose by disconnecting the
collar from the pump, or by removing the hose clamp.
3. Remove the tie rod cover. Disconnect the Tie Rod
retaining spring and Tie Rod from the Control Rack.
4. Remove the four injection pump mounting bolts.
Figure 47
5. Remove the injection pump from the cylinder block.
Make note of the number and thickness of the adjusting
shims under the pump. The shims determine the injection timing.
6. Straighten the locking tabs on the plate which retains
the Tappet Guide Pin). Rotate the pin 180", push in on
the Tappet slightly and remove the Guide Pin and Tappet.
7. Remove the Lower Seat, Plunger Spring, Upper Seat,
Control Pinion and Plunger.
1. E-ring
2. Ungleich set spring
3. Ungleich set plate
4. Pump housing
5. E-ring
6. Return spring
7. Smoke set plate
8. Air breather screw
9. Washer
10. Hollow screw
11. Pump element ass’y
12. Delivery valve ass’y
13. Gasket
14. Delivery valve spring
15. O-ring
16. Delivery valve holder
17. Bolt/washer
18. Adjusting plate
19. Tappet guide pin
20. Plate
21. Control rack
22. Plunger control sleeve
23. Upper spring seat
24. Pump plunger spring
25. Lower spring seat
26. Shim plate
27. Tappet
8. Remove the Delivery Valve Holder, Gasket, 0-ring,
Valve Spring and Delivery Valve. Push the barrel assembly out from below.
9. Remove the components of the other two injector
pumps using the same procedure.
10. To remove the Control Rod, remove the E-rings,
Ungleich set spring, and Ungleich set plate. Slide the
rack from the pump body.
11. To remove the smoke set plate, remove the cotter
pin, washer and return spring.
Groundsmaster® 300 Series
Page 4 - 41
Fuel System Service
Injection Pump Inspection (Fig. 48)
1. Inspect the contact surfaces of the delivery valve
seat. Replace the Delivery Valve Assembly if defective.
2. Inspect the plunger and barrel for wear, damage or
rust. Check to see that the plunger slides smoothly in
the barrel. Replace the Pump Element Sub-Assembly if
defective.
3. Inspect the Control Rack and Pinions for worn or
damaged teeth. Replace worn or damaged components.
4. Inspect the Tappet outside diameters, rollers and
shafts for wear or damage. Replace damaged or worn
components.
Figure 48
Injection Pump Reassembly (Fig. 49, 50)
NOTE: Wash each part thoroughly in clean diesel fuel
as it is reassembled.
1. Install the Control Rack, Smoke Set and Ungleich
plates, retainer springs and fasteners.
2. If the adjusting plate assemblies have been removed,
reinstall them, paying careful attention to install them
according to the marks scribed on the pump housing
and plates.
3. Install the Plunger Barrel into the bore in the top of
the Pump Housing. Make sure that the groove in the
barrel aligns with the pin in the side of the bore.
4. Install the delivery valve and seat, gasket, spring,
0-ring and Valve Holder and hand tighten the assembly.
Be careful not to damage the 0-ring when installing it
onto the valve holder.
Figure 49
Alignment of pinions and control rack
5. Install the control pinion by positioning it so that the
deeply cut tooth is aligned with the grooves in the
Control Rack.
Fuel System Service
Page 4 - 42
Groundsmaster® 300 Series
6. Install the upper spring seat and spring.
7. Assemble the lower spring seat to the plunger. Insert
the plunger into the barrel with the side of the plunger
collar marked “L” towards the control rack.
NOTE: the collar and pinion are designed to prevent
incorrect installation.
8. Insert the tappet carefully to avoid dropping the shim.
Align the tappet guide hole with the hole for the tappet
guide pin. Install the guide pin locking plate and guide
pin. Rotate the guide pin to lock its edge under the lip
on the pump housing and lock the pin by bending the
plate tab.
9. Torque the Delivery Valve Holder to 28.9 - 36.2 ft-lb
(4 - 5 KgM). Ensure that the control rack slides smoothly,
with little resistance. Sliding force should be 1.75 oz. (50
g) or less. If the rack binds, it is assembled incorrectly
or parts are dirty, and it must be reassembled or
cleaned.
10. Repeat the procedure for the other remaining cylinders.
11. Install the injection pump to the cylinder block. Make
certain that the same number and size shims that were
under the pump when removed are replaced correctly.
12. Connect the Tie Rod and Tie Rod Retaining Spring
to the Control Rack.
13. Push the control rack to the high speed position (left)
and reinstall the tie rod cover using a new cover gasket.
14. Reassemble the fuel return line and delivery pipes.
15. Bleed the air from the fuel system. Refer to “Bleeding
Air From Fuel System,”.
Groundsmaster® 300 Series
Page 4 - 43
Figure 50
1. E-ring
2. Ungleich set spring
3. Ungleich set plate
4. Pump housing
5. E-ring
6. Return spring
7. Smoke set plate
8. Air breather screw
9. Washer
10. Hollow screw
11. Pump element ass’y
12. Delivery valve ass’y
13. Gasket
14. Delivery valve spring
15. O-ring
16. Delivery valve holder
17. Bolt/washer
18. Adjusting plate
19. Tappet guide pin
20. Plate
21. Control rack
22. Plunger control sleeve
23. Upper spring seat
24. Pump plunger spring
25. Lower spring seat
26. Shim plate
27. Tappet
Fuel System Service
Injection Pump Pressure and Delivery Rate
Injection pump pressure and the delivery rate of the
pump, as well as inter-cylinder delivery rates must be
determined by the use of specialized equipment. If
difficulties with the injection pump are suspected the
help of a competent diesel engine service shop should
be sought.
Injection Pump Timing and Adjustment
Adjusting the shim thicknesses as explained on, “Injection Timing Test,” will adjust the injection timing.
NOTE: If timing requires adjustment, and the engine has
not been worked on, or the shim thickness changed, the
injection pump components and camshaft should be
inspected for wear or damage.
Fuel System Service
Page 4 - 44
Groundsmaster® 300 Series
Nozzle Servicing (Fig. 51)
The fuel from the injection pump flows through the
injection pipes to the nozzle. During the injection stroke
of the pump, pressurized fuel builds up in the nozzle.
When the pressure becomes sufficiently high, the nozzle valve opens and a spray of fuel is injected into the
combustion chamber where it is ignited due to the heat
produced by the cylinder compression. If the nozzle
does not function properly, starting failure, low power
output, or engine knocking can occur.
IMPORTANT: When servicing the injection nozzles
make certain that the engine and fuel delivery pipes
are clean in order to prevent dirt from entering the
cylinder or nozzle. Do not mix components of one
nozzle with another.
2. Remove carbon or lacquer deposits from the nozzle
by cleaning in clean diesel fuel. Stubborn deposits may
be removed with brass wired brush.
IMPORTANT: Do not use a steel brush, steel wool,
etc. or the nozzle hole or pin tip may become damaged and need to be replaced.
3. Clean the flange, body, shim, spring, pin and distance
piece in clean diesel fuel. Replace any worn or damaged
parts.
Reassembly and Test
1. Install the nozzle assembly, distance piece and pressure pin into the retaining nut.
Nozzle Testing
2. Install the shim, pressure spring and flange in the
body. Assemble the body to the retaining nut. Torque the
body and nut to 43 - 58 ft-lb (6 - 8 KgM).
Refer to “Nozzle Tests” for complete instructions.
Nozzle Removal and Disassembly
1. Remove the fuel overflow line from the
3. Test the reassembled nozzle for proper operation.
Refer to “Nozzle Tests.”
nipple on the nozzle body.
Installation
2. Disconnect the fuel injection pipe from the nozzle
body.
1. Install a new nozzle holder gasket onto the nozzle.
3. Remove the two bolts which pass through the nozzle
flange and remove the nozzle assembly from the cylinder head. Remove the copper nozzle holder gasket.
2. Position the nozzle assembly on the head and install
the bolts through the flange. Alternate tightening the
bolts to ensure even pressure on both sides of the
flange. Torque the bolts to 11 - 15 ft-lb (1.5 - 2 KgM).
NOTE: Further disassembly of the nozzle is not required
for testing purposes.
4. Secure the retaining nut in a vise which is equipped
with aluminum or brass jawplates and loosen the nozzle
body with a wrench.
5. Remove the nozzle body, shim, pressure spring,
flange, pressure pin and distance piece.
6. Remove the nozzle from the retaining nut. If it is
difficult to remove, tap it lightly with a rubber or wooden
mallet. Be careful not to hit or damage the protruding tip
of the nozzle needle valve.
Inspection and Cleaning
1. Clean the inside and outside of the retaining nut in
clean diesel fuel to remove carbon or fuel deposits.
Inspect the lower seating surface for rust or damage.
The sealing area may be restored with emery cloth.
Groundsmaster® 300 Series
Page 4 - 45
Figure 51
Fuel System Service
Removing and Installing the Engine
Removing the Engine
1. Put machine on a level surface, stop engine, remove
key from ignition switch and engage parking brake.
NOTE: Be prepared to insert a plug into fuel line to
prevent fuel spill.
2. Remove intake hose from air cleaner and carburetor.
12. Remove main fuel return hose at injector nozzle
connection.
3. Remove transmission drive coupling (see Chapter 10
- Transmission Coupler and PTO).
4. Remove PTO belt (see Chapter 10 - Transmission
Coupler and PTO).
5. Disconnect battery cables from battery terminals.
6. Disconnect and tag all wires connected to engine and
engine accessories.
7. Put a drain pan under radiator, loosen radiator cap,
loosen radiator petcock and allow radiator to drain completely.
8. Move drain pan under lower radiator hose. Disconnect hose from radiator and allow coolant to drain into
pan. Remove lower and upper radiator hoses.
9. Move drain pan under rear of engine and remove
cylinder block plug (located above starter) to drain coolant from cylinder block. Install cylinder block plug.
10. Disconnect throttle control cable from throttle
bracket.
11. Remove fuel line from outlet side of fuel filter/water
separator.
13. Remove capscrews attaching fan belt guard and
remove fan belt guard.
14. Remove capscrews securing fan shroud to radiator
so fan shroud can be move during engine removal for
cooling fan clearance.
15. Attach a short section of chain between the two lifting
shakles on the engine. Attach block and tackle or hoist
chain to this short section of chain, approximately midway between the two shakles.
NOTE: Do not attach hoist chain or chains directly to
shackles on engine as this may cause damage to fan
shaft tube or muffler when the engine weight is supported by chains.
16. Remove four bolts securing rear engine mount to
frame.
17. Remove slack from lifting chain and carefully remove two capscrews which pass through the two rubber
front engine mounts.
18. Lift and guide engine from engine compartment. Be
careful not to damage the radiator cooling fan or other
components during removal.
Installing the Engine
1. Do steps 2 - 18 of “Removing the Engine” in reverse
order.
2. Fill cooling system with new coolant. Install a new oil
filter and fill engine with correct oil.
Removing and Installing the Engine
3. Inspect for oil and coolant leaks.
4. Check engine idle speed and maximum governed
speed settings.
Page 4 - 46
Groundsmaster® 300 Series
Cylinder Head Overhaul
This section explains disassembly, inspection, repair,
and reassembly of the cylinder head and its components as outlined below:
Cylinder Head Removal
Cylinder Head Servicing
Valve Guides
Valves
Valve Seats
Valve Springs
Rocker Arms, Bearings, Shaft
Cylinder Head Reassembly and Installation
IMPORTANT: When overhauling the cylinder head
and cylinder block it is important that many of the
components be reinstalled in the exact location
from where they were removed. These items are
noted in the text. It is useful to construct a rack
where these components can be stored, in order,
until reassembly.
Cylinder Head Removal (Engine Removed) (Fig. 52, 53)
1. Remove the fan shaft bracket, muffler, and rear motor
mount.
2. Disconnect the water bypass hose from the cylinder
head.
3. Remove the injection pipes (injection pump) to nozzles.
4. Remove the rocker cover and breather tube.
5. Loosen the two bolts and the cap screw which retain
the rocker shaft assembly, and remove the rocker shaft.
6. Remove the push rods. Place each push rod into a
marked holder so that it can be replaced in the original
position.
Figure 52
7. Loosen and remove the cylinder head bolts in the
sequence shown. Lift the cylinder head from the cylinder
block. It may be necessary to tap the cylinder head with
a wooden mallet to break the seal of the head gasket.
Place the cylinder head on a flat, clean surface.
9. Remove the thermostat housing and the thermostat.
10. Remove the glow plug lead wires and glow plugs.
11. Remove the nozzle holder bolts and nozzles.
12. Remove the used cylinder head gasket. Use a
scraper to remove all traces of gasket material. Pay
particular attention not to damage or scratch the cylinder
head or cylinder block surface.
Groundsmaster® 300 Series
Page 4 - 47
Figure 53
Cylinder Head Overhaul
Cylinder Head Servicing (Fig. 54)
1. Use a spring compressor to compress the valve
springs. Remove the retainer locks (keepers), retainers,
and valve springs. Place each part in a holder or rack
so that they can be replaced in their original position.
2. Remove the valves and place them in position in the
rack. Examine each valve for indications of burning,
pitting, heavy carbon deposits or wear. The condition of
the valves can give important clues to other components
which may require service (example: improper valve
clearance, worn valve guides, damaged seals, etc.).
Remove the valve seals.
3. Remove all of the carbon deposits from the combustion chamber using a scraper and wire brush.
4. Clean the cylinder head thoroughly with solvent or
degreasing solution and dry. Inspect it carefully for
cracks.
Figure 54
Checking cylinder head distortion
5. Remove all carbon deposits from the valve guide
bores with a valve guide cleaner. Use a valve guide
bristle brush to remove loosened carbon deposits in the
valve guide. Push a solvent soaked cloth through the
valve guides to remove all foreign materials.
6. Use compressed air to ensure that the oil passage
way through the head is not clogged.
Wear eye protection during use of compressed air. Limit air pressure to 40 psi
(280 kPa).
7. Check the flatness of the cylinder head lower surface
using a straight edge and feeler gauge. Be sure to check
the surface variation crosswise, lengthwise, and diagonally. If a surface flatness variation greater than 0.002
inch (0.05 mm) exists, the cylinder head or cylinder
block must be replaced or resurfaced.
8. Use a micrometer and a small hole gauge to check
the valve guide to valve stem clearance. The valve and
valve guide should be replaced if the clearance exceeds
the following limits:
Intake Valve . . . . . . . . . . . . . . . . 0.0039 inch (0.10 mm)
Exhaust Valve . . . . . . . . . . . . . . . 0.0059 inch (0.15 mm)
Cylinder Head Overhaul
Page 4 - 48
Groundsmaster® 300 Series
Valve Guides (Fig. 55)
If the valve guide clearance, after cleaning, exceeds the
specifications in step 6 above, they must be replaced.
1. Remove the existing valve guide by pressing it upward using a valve guide removing mandrel with a pilot
section.
2. To install the new guide press it in from the top of the
cylinder head using the valve guide mandrel. Valve
guides should be installed so that their installed height
is as shown.
NOTE: Placing the valve guide in a refrigerator or
freezer for several minutes before installation will aid in
assembly.
3. After installing the valve guide, again check the guide
to stem clearance. If the clearance is smaller than the
standard size it will be necessary to ream the valve
guide bore to obtain the proper clearance.
Figure 55
Installing valve guide
Valves (Fig. 56)
1. Carefully clean each valve with a wire wheel to
remove all carbon deposits.
2. Check the valve face and the valve stem for excessive
wear, damage, cracks or deformation. If any of these
conditions exist the valve must be replaced. It is possible to reface the valve as long as the margin or valve lip
thickness is not less than the surface limit.
3. Check the tip of the valve stem for wear or pitting. If
pitted or worn the valve stem tip may be resurfaced by
placing the valve stem in a V-block and dressing the tip
against a grinding wheel.
Figure 56
Dimensions of valve
Groundsmaster® 300 Series
Page 4 - 49
Cylinder Head Overhaul
Valve Seats (Fig. 57, 58)
1. Check the valve seat for damage and signs of incorrect contact.
2. If the valve seat is defective, the seat can be re-cut
to the dimensions shown.
3. After cutting new valve seats, lap the valve to the seat
using the lapping compound. After lapping, thoroughly
clean the valve seat and valve areas to remove any
traces of lapping compound. To verify that the valve face
is making proper contact to the valve seat, lightly coat
the valve seat area with Prussion blue, install the valve,
rotate the valve 1/4 turn while holding it down and then
bring it back to the original position. Remove the valve
and examine the valve seat. The valve seat should show
an even wear pattern from contact with the valve. Examine the valve. The dye should be evenly distributed
around the valve and in the center of the valve face.
Figure 57
Dimension of valve seat
Figure 58
Correction of valve seat
Cylinder Head Overhaul
Page 4 - 50
Groundsmaster® 300 Series
Valve Springs (Fig. 59)
1. Check the valve springs for rust, pitting, cracks or
other damage.
2. Check the squareness of the valve spring by placing
it upright on a level surface. Springs may be out of
square by 1.5 degrees. Springs that are out of square
by 3 degrees or more must be replaced.
3. Measure the spring free length. The standard dimension is 1.69 inches (43 mm). Springs which measure
1.64 inches (41.7 mm) or shorter must be replaced.
4. Over time, valve springs can lose some of their
tension. Test the springs to make sure that the spring
pressure is within the following limits: 23.5 - 28.5 lbs.
(11.2 - 12.4 Kg) with the installed length of 1.46 inches
(37.1 mm). When the spring pressure at the length given
is 20 lbs. (9.5 Kg) or less, the spring must be replaced.
Figure 59
Checking valve spring length
NOTE: Valve springs are inexpensive compared to the
cost of repairing engine damage due to weak valve
springs.
Rocker Arm and Rocker Shaft Service (Fig. 60)
1. Disassemble the rocker shaft by removing the outside
retaining rings on each end and by removing the two
rocker arms stay bolts and seats from the rocker shaft.
2. Inspect each rocker arm for signs of wear where they
contact the valve tip and push rod contact surfaces.
Rocker arms which are worn should be replaced.
3. Examine the rocker shaft for excessive wear or
damage. Replace it if it is defective.
4. Measure the rocker arm inside diameter and the shaft
outside diameter. The maximum clearance between the
rocker arm and the rocker arm shaft should be .0079
inches (0.2 mm). Replace the shaft if clearance is in
excess of this dimension.
Figure 60
Rocker arm and shaft
5. Inspect the oil passages in the rocker shaft and rocker
arms to make sure that they are clear of obstruction.
Clean if necessary.
Groundsmaster® 300 Series
Page 4 - 51
Cylinder Head Overhaul
Cylinder Head Reassembly and Installation (Fig. 61, 62, 63)
1. Ensure that the valve guides are properly installed.
2. Install the valve stem seal onto the valve guide
securely.
3. Apply a coating of oil to the valve stems and insert
them in proper order, into the valve guides. Install the
valve springs, valve retainers and retainer locks.
4. Assemble the rocker arms to the rocker shaft in the
following order. First, attach the front rocker arm stay to
the cylinder head with the bolt hole toward the right
(valve side) of the cylinder head. Next, install the rocker
shaft so that the identification mark (small drilled hole
near the end of the shaft) is located near the front (water
pump), and to the right side of the engine. Install the cap
screw and washer through the stay and into the shaft.
Install the front rocker arm and retaining ring. Next,
install the remaining rocker arms, springs and rocker
shaft stays, and bolt them to the cylinder head.
Figure 61
Valve stem seal
5. Install the glow plugs and glow plug lead wires. The
glow plugs should be torqued to 10.8 - 14.5 ft-lbs (1.5 2.0 KgM).
6. Install the nozzle holder and tighten the bolts evenly
to 10.8 - 14.5 ft-lbs (1.5 - 2.0 KgM).
7. Ensure that the cylinder head and cylinder block
surfaces are clean. Position a new head gasket on the
head and insert some dowel pins into two cylinder head
bolt holes in the cylinder to assist with mounting the
cylinder head. Carefully position the cylinder head over
the dowels onto the cylinder block and remove the
dowel pins. Insert the head bolts.
Figure 62
Rocker arm and shaft assembly
IMPORTANT: Do not coat the cylinder head gasket
with any sealant.
8. Tighten the cylinder head bolts to their specified
torque as in the order shown. A good practice is to
tighten the head bolts in proper order, first to one-third
of their specified torque, then to two-thirds of their torque
and finally to the specified torque.
9. Adjust the valve clearance.
Figure 63
Cylinder head bolt tightening sequence
Cylinder Head Overhaul
Page 4 - 52
Groundsmaster® 300 Series
Cylinder Block Overhaul
This section outlines procedures for disassembly, inspection, repair and reassembly of the cylinder block
and its components, as outlined below:
Cylinder Block Disassembly
Camshaft Service
Injection Pump Camshaft Service
Crankshaft Bearings
Timing Gears
Connecting Rods and Bearings
Cylinders
Oversized Pistons, Cylinder Bore and Rings
Piston and Pin Replacement
Cylinder Block Disassembly
NOTE: It is assumed that the engine has been removed
from the mower, placed on an engine stand, and the
cylinder head removed.
8. Remove the crankshaft pulley, nut, washer, lock
washer and key.
9. Remove the gear case from the front of the motor.
1. Place a drain pan under the engine. Remove the oil
pan drain plug and drain the oil from the engine. Remove the oil filter from the oil pump body. Discard the
oil filter. Dispose of the oil in the proper manner.
NOTE: The front plate is retained to the cylinder block
by bolts that are underneath the cover. Do not attempt
to remove the plate without first removing the gear case
cover and the bolts underneath.
2. Remove the water pump.
3. Remove the fuel injection pump from the cylinder
block body and the fuel filter.
NOTE: It is necessary to remove the tie rod cover, the
control rod, and retaining spring from the control rack
before removing the injection pump.
4. Lift the push rods out of the cylinder block.
5. Remove the valve lifters from their positions in the
cylinder block.
6. Remove the speedometer drive assembly from the
left hand side of the engine by removing the cap screw
and clamp and pulling the gear out.
10. Remove the camshaft and gear by carefully backing
them out from the cylinder block.
NOTE:The speedometer drive and valve lifters must be
removed to remove the camshaft.
11. To remove the injection pump camshaft, first remove
the governor sliding shaft and governor flyweight assembly. Align the hole in the injection pump camshaft
gear with the retaining bolt and washer. Remove the
washer and carefully pull the camshaft gear and bearing
from its location in the cylinder block.
12. Remove the idler gear from its shaft.
13. Remove the flywheel bolts and washers and remove
the flywheel from the crankshaft.
7. Turn the engine upside down on the stand and
remove the oil drain pan and filter screen (spring-like
screen).
Groundsmaster® 300 Series
Page 4 - 53
Cylinder Block Overhaul
14. Remove the ring ridge from each cylinder using a
ridge removing tool. This will prevent damage to the
rings and pistons. Remove the connecting rod cap nuts
and then remove the bearing caps. Place these parts in
cylinder number order. Remove the pistons and connecting rods by pushing them up from the bottom of the
block. Use a wooden block to push the pistons and rods
to avoid damage to the connecting rod.
NOTE: Before removing the pistons scribe the number
of the cylinder onto the top of the piston. When the piston
and rod assembly is removed, use care to prevent
damage to the piston or bearing surfaces.
15. Remove the main bearing caps. Arrange the removed caps and bearings according to cylinder order
so they may be replaced in the same position upon
reassembly.
Figure 64
Main bearing caps
NOTE: Before removing the main bearing caps, measure the crankshaft end play.
16. Remove the crankshaft after removing the main
bearing caps.
17. Remove the crankshaft oil seal and gasket.
18. Check the cylinder block for cracks or damage.
Replace the cylinder block if it is unserviceable.
Cylinder Block Overhaul
Page 4 - 54
Groundsmaster® 300 Series
Camshaft and Bearing (Fig. 65, 66)
1. Inspect the camshaft for evidence of severe wear.
2. Using a micrometer and a hole gauge, measure the
clearance between the camshaft journals and the cylinder block. If the clearance is greater than 0.0059 inch
(0.15 mm) the camshaft or the camshaft bushing must
be replaced.
3. To remove the camshaft bushing in the cylinder block,
carefully drive the bushing from its location using the
camshaft bushing tool (refer to “Special Tools”).
NOTE: You must drive the bushing into the cylinder
block and then crush it to remove it. Be careful not to
damage the valve lifter hole when removing the camshaft bushing.
Figure 65
Removing camshaft bushing
4. To install a new camshaft bushing use the camshaft
bushing tool and drive the bushing in from the outside
of the cylinder block being careful to align the oil delivery
hole in the cylinder block with the oil hole in the bushing.
5. If the cam surface is damaged or the cam lobe is badly
worn it must be replaced. Cam lobe height should be
measured using a micrometer. The standard cam lobe
height for both intake and exhaust valves is 1.4079
inches (35.75 mm). The maximum allowable wear on
cam surface is 0.0394 inch (1.0 mm). Replace the
camshaft if wear exceeds this amount.
Figure 66
Measuring camshaft cam lobe height
Fuel Injection Pump Camshaft (Fig. 67)
1. Inspect the camshaft bearing, replace if defective.
2. Examine the oil pump coupling. The camshaft must
be replaced if this coupling is worn.
3. Examine the cam lobe surfaces. Replace the cam if
they are damaged.
4. Measure the cam lobe height in the same manner as
measuring the valve camshaft lobe height. The standard
lobe height for each cylinder of the injection pump is
1.7323 inches (44 mm). The camshaft must be replaced
if the cam lobe has been worn by 0.0394 inch (1 mm)
or more.
Figure 67
Fuel injection pump camshaft
Groundsmaster® 300 Series
Page 4 - 55
Cylinder Block Overhaul
Crankshaft Bearings (Fig. 68, 69)
1. Measure the crankshaft for “run-out” (bend). Mount
the crankshaft in a pair of V-blocks (or live centers) and
use a dial indicator to measure the run-out in the crankshaft. The maximum allowable crankshaft run-out is
.0012 inch (0.03 mm).
2. Check the crank journals and crank pins for damage
such as galling, seizure, etc. If journals or pins are
seriously damaged they may be reground and oversized bearings installed. The main bearing and connecting rod bearing oil clearances may be measured with a
micrometer or Plastigauge. Crankshaft oil clearances
are: Journal, 0.0039 inch (0.10 mm); Crank pin, 0.0059
inch (0.15 mm).
NOTE: When using Plastigauge to measure the clearance between the crankshaft and its bearings, install the
crankshaft into the cylinder block, place a piece of
Plastigauge onto the crank pin or journal, and torque the
bearing cap (with bearing) in place. DO NOT TURN THE
Figure 68
CRANKSHAFT WHEN PLASTIGAUGE IS IN PLACE SINCE
THE PLASTIGAUGE WOULD BE DESTROYED. Remove
the bearing cap and measure the width of the Plastigauge to determine the clearance. If the oil clearances
exceed these amounts attempt to install a new bearing
to reduce the clearance. If installing a replacement
bearing does not reduce the clearance to within tolerance the crankshaft must be reground and an oversized
bearing installed.
Figure 69
Timing Gears (Fig. 70)
1. Inspect the idler gear, fuel injection pump gear, camshaft gear and crankshaft gear for wear or damage.
Replace these gears if defective.
Figure 70
Cylinder Block Overhaul
Page 4 - 56
Groundsmaster® 300 Series
Connecting Rod and Connecting Rod Bearings (Fig. 71)
1. Check for bending or distortion of the connecting rod.
If excessive, replace the rod (0.002 inch or 0.05 mm
max.).
2. Assemble each connecting rod to the crankshaft in
their proper order. Use a feeler gauge to measure the
connecting rod thrust clearance between the connecting rod and crankshaft. The proper clearance is .0039
-.0138 inch (.1 -.35 mm). If the clearance exceeds this
amount replace the connecting rod assembly.
3. The connecting rod journal to crank pin oil clearance
can be measured using a micrometer or Plastigauge.
Refer to “Crankshaft Bearings,” for tolerances.
Figure 71
Measuring connecting rod thrust clearance
Cylinders (Fig. 72)
1. Measure the cylinder bore size in six locations as
shown. The standard bore diameter is 2.8740 inches (73
mm). The cylinder must be rebored and oversized piston
and rings installed if the diameter exceeds the standard
by .0079 inch (.2 mm). Examine the cylinder bore diameter readings to determine the amount of taper of the
cylinder. If the taper exceeds .0004 inch (.01 mm) the
cylinder must be rebored and oversized piston and rings
installed.
Figure 72
Checking cylinder bore size
Groundsmaster® 300 Series
Page 4 - 57
Cylinder Block Overhaul
Oversized Pistons, Cylinder Bore and Rings (Fig. 73, 74, 75)
1. Check the piston for wear, signs of seizure or nicks.
Replace it if it is defective.
2. Measure the piston outside diameter. If the clearance
between the piston and the cylinder exceeds 0.01 18 in.
(.3 mm), replace the piston.
NOTE: The piston O.D. should be measured at the
lower end of the skirt across the thrust faces, or on
access points perpendicular to the piston pin direction.
3. Thoroughly clean the carbon deposits from the piston
and ring grooves. A ring groove cleaner, or piece of a
discarded ring may be used to clean the ring grooves.
Figure 73
Measuring piston outside diameter
4. Measure the piston ring side clearances using a
thickness gauge.
If the piston ring side clearance exceeds the service limit
in the chart below, the ring must be replaced.
NOTE: In the case of a tapered ring (No. 1), measure
the clearance on the bottom, or widest area of the ring.
Figure 74
Measuring piston ring side clearance
5. Measure the piston ring gap clearance. Insert the ring
into the least worn area of the cylinder by pushing it into
place with the piston. The standard gap is 0.0059 0.0157 inch (0.15 - 0.4 mm). If the gap exceeds 0.0590
inch (1.5 mm) the ring must be replaced.
Figure 75
Measuring piston ring gap clearance
Cylinder Block Overhaul
Page 4 - 58
Groundsmaster® 300 Series
Piston and Pin Replacement (Fig. 76)
To remove a piston from its connecting rod, use the
piston pin tool (see Special Tools section) to press the
pin from the connecting rod.
IMPORTANT: Do not attempt to remove the piston
pins by driving them out with a hammer. A stuck
piston pin, requiring excessive pressure to remove,
should be replaced. 1100 - 3300 lbs (500 - 1500 Kg)
pressure is standard force needed to remove the
piston pin.
1. Press the piston pin from the connecting rod as
described above.
2. Use a micrometer and bore gauge to measure the
clearance between the piston and pin. If the clearance
exceeds 0.0031 inch (0.08 mm) the piston and/or pin
must be replaced.
Figure 76
Piston pin removal tool
Engine Reassembly
The engine should be reassembled in the order given
in this section. The following general precautions should
be observed when reassembling the engine.
3. Replace all gaskets, packings, and oil seals with new
ones. Reuse of these parts is not acceptable.
4. Apply sealant to gaskets and threads.
1. Clean each part carefully. Pay particular attention to
oil holes, bearing surfaces and rotating parts.
2. Before assembly apply engine oil to all sliding and
rotating parts such as bearings and cylinder inner walls.
Groundsmaster® 300 Series
5. Tighten all fasteners to the proper torque as outlined
in the torque specifications.
6. Check clearances and end plays when installing.
Page 4 - 59
Cylinder Block Overhaul
Engine Reassembly Procedures
Follow the procedures listed below in reassembling the
engine.
1. Install the camshaft bushing.
Figure 77
Installing camshaft bushing
2. Install the main bearings to the cylinder block and
main bearing cap. Ensure that these are in proper
position.
3. Install the crankshaft.
4. Install the main bearing caps then tighten the cap
bolts to the specified torque. Each cap carries an embossed arrow mark and letter or numeral to indicate its
position in the cylinder block. When installing the no. 1
and no. 4 bearing caps, apply sealant to the upper
surface (that meets with the cylinder block).
Figure 78
Installed direction of main bearing caps
5. With the bolts torqued use a dial indicator on the end
of the crankshaft to measure the crankshaft end play. If
the end play exceeds .0197 inch (0.5 mm) replace the
No. 3 main bearing.
Figure 79
Measuring crankshaft end play
Cylinder Block Overhaul
Page 4 - 60
Groundsmaster® 300 Series
6. Apply sealant to the outside surface of the front and
rear side seals. The side seals are installed with the
radius towards the outside of the engine.
Figure 80
Installing bearing side cap seals
Figure 81
Direction of side seal installation
7. Insert the oil seal into the crankshaft rear oil seal
case.Apply a light coat of oil to the oil seal lip and install
the seal case to the cylinder block.
NOTE: Use a new gasket.
8. Install the rear engine plate if it has been removed.
9. Install the flywheel onto the crankshaft using the bolts
and special washers. Torque the flywheel bolts to 83 90 ft-lbs (11.5 - 12.5 KgM).
Figure 82
Installing oil seal case
Groundsmaster® 300 Series
Page 4 - 61
Cylinder Block Overhaul
NOTE: Before insertion apply engine oil to the piston pin
O.D. and the connecting rod small end inside diameter.
10. To assemble the piston to the connecting rod, press
the piston pin into the set position. Use the piston pin
setting tool. Make sure the identification mark of the rod
and and the arrow mark on the piston head are directed up.
Pin press fitting force: 500 - 1500 kg (1100 - 3300 lb.)
NOTE: The piston and piston pin are matched parts and
should not be mixed.
After assembling the piston and connecting rod make
certain that the connecting rod small end is properly
positioned at the center of the piston pin.
Figure 83
Installing piston rod
11. Install the piston rings.
IMPORTANT: The piston rings differ in shape from
one another. Be careful to install them in proper
position and with the ring gaps in the directions as
illustrated. In the case of the oil ring with the coil
expander, the gap clearance of the ring should be
positioned 180° away from the joint of the expander.
NOTE: Install the piston rings with the stamped manufacturer mark facing up.
Figure 84
Ring gap positions
Cylinder Block Overhaul
Page 4 - 62
Piston ring shapes
Groundsmaster® 300 Series
12. Insert the piston and connecting rod assembly into
the cylinder block using a ring compressor and a
wooden block. After insertion into the cylinder, properly
install the connecting rod bearings and rod caps and
tighten the bolts to the specified torque.
NOTE: The bearing assembly grooves in the connecting
rod cap should be on the same side when assembled.
13. Install the front plate. Remember to use a new
gasket.
14. Turn the crankshaft until the No. 1 piston is a top
dead center (TDC).
15. Drive the key into the crankshaft and install the
crankshaft gear onto the shaft if it has been disassembled.
Figure 85
Installing piston and rod assembly
16. With the idler gear mating mark “1" properly aligned
with the crankshaft mating mark ”1",install the idler gear
on to the idler shaft.
17. Insert the camshaft and gear assembly into the
cylinder block and align the idler gear mark “2" with the
camshaft gear mating mark ”2".
18. Install the injection pump camshaft assembly into
the cylinder block and align the idler gear mating mark
“3" with the pump gear mark ”3". Remember to install
the bolt and washer which retain the injection pump
camshaft bearing.
19. Install the governor weight assembly and sliding
shaft to the injection pump cam gear.
Groundsmaster® 300 Series
Page 4 - 63
Figure 86
Mating marks of gears
Cylinder Block Overhaul
29. Install the front gear case and gasket, using PERMATEX No. 2 on gasket surfaces. When installing the
gear case insert the tie rod and tie rod stopper spring
into the hole in the cylinder block under injection pump.
Install the crankshaft pulley and key. Torque the retaining nut to 144 - 180 ft-lbs. (20 - 25 KgM).
30. Install the oil screen and the oil pan using a new
gasket.
Figure 87
Installing gear case
31. Reinstall the speedometer unit while rotating the
speedometer shaft. Make sure that the O-ring is properly installed. Apply oil to the outside surface of valve
lifters and insert the lifters into the cylinder block in the
order of which they were removed. Install the push rods
into the lifters in the order in which they were removed.
32. Install the cylinder head assembly.
Figure 88
Inserting tappet
33. Install the fuel injection pump.
34. Install the oil pump and oil filter if they have been
removed.
35. Install the water pump.
36. Install the starter if it has been removed.
37. Install the overhauled engine onto the machine
following the reverse procedure for removing the engine
from the machine.
Figure 89
Installing injection pump
Cylinder Block Overhaul
Page 4 - 64
Groundsmaster® 300 Series
Chapter 4A
(For Groundsmaster 328–D only)
Kubota Diesel Engine
Table of Contents
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General Information
The engine used in the Groundsmaster 328–D is
manufactured by Kubota. Service and repair parts for
this engine are supplied through TORO Distributors.
Repair parts may be ordered by TORO part number. If
no parts list is available be sure to provide your Distributor with the TORO model number and serial number.
Groundsmaster 300 Series
General maintenance procedures are described in your
Operator’s Manual. Information regarding engine troubleshooting, testing, disassembly and assembly is identified in the Kubota 05 Series Service Manual (Toro part
01090SL).
Note: Refer to Chapter 4 – Mitsubishi K3D Diesel Engine for Groundsmaster 328–D engine removal and
installation procedure.
Page 4A – 1
Rev. G
Table of Contents
Specifications
Item
Description
Make / Designation
Kubota Model 1105
4 Cycle, 3 Cylinder Diesel Engine
Number of Cylinders
3
Bore
3.07 in (78.0 mm)
Stroke
3.09 in (78.4 mm)
Total Displacement
68.53 cu in (1123 cc)
Firing Order
1–2–3
Combustion Chamber
Spherical Type
Fuel
No. 2 Diesel Fuel (ASTM D975)
Fuel Capacity
6.5 U.S. gallon (24.6 liter)
Fuel Injection Pump
Bosch MD Type Mini Pump
Injection Nozzles
Mini Nozzle (DNOPD)
Governor
Centrifugal Mechanical
Idle Speed (no load)
1500 – 1650 RPM
High Idle (no load)
3100 – 3250 RPM
Coolant Capacity
6 U.S. quart (5.7 liter)
Engine Oil
See Operator’s Manual
Oil Capacity
4 U.S. quart (3.8 liter) with filter
Starter
12 VDC, 1.4 KW
Alternator/Regulator
12 VDC, 40 AMP
Dry Weight
Specifications
205.0 lbs (93.0 kg)
Page 4A – 2
Rev. G
Groundsmaster 300 Series
Chapter 5
Hydraulic System
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 3
Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic Fitting Installation . . . . . . . . . . . . . . . . 3
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . 6
HYDRAULIC FLOW DIAGRAMS . . . . . . . . . . . . . . . 7
Forward Traction Operation . . . . . . . . . . . . . . . . . 7
Raising the Cutting Unit . . . . . . . . . . . . . . . . . . . 8
Turning Steering Wheel to Right . . . . . . . . . . . . . 9
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . 12
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Test No. 1: Charge Pressure . . . . . . . . . . . . . . . 19
Test No. 2: Implement Relief Pressure . . . . . . . 20
Test No. 3: Traction Pressure . . . . . . . . . . . . . . 21
Test No. 4: Charge Pump Flow and
Implement Relief Pressure . . . . . . . . . . . . . . 22
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Traction Control Rod Adjustment . . . . . . . . . . . 23
Traction Pedal Friction Wheel Adjustment . . . . 23
Traction Control Neutral Adjustment . . . . . . . . . 24
Lift Lever Latch Adjustment . . . . . . . . . . . . . . . . 25
Groundsmaster® 300 Series
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Trunnion Seal Replacement . . . .
Transmission By-Pass Valve . . . . . . . . . . . . . . .
Transmission Acceleration Valves . . . . . . . . . . .
Transmission Implement Relief Valve . . . . . . . .
Transmission Charge Relief Valve . . . . . . . . . . .
Transmission Charge Pump . . . . . . . . . . . . . . .
Transmission Removal and Installation . . . . . . .
Transmission Overhaul . . . . . . . . . . . . . . . . . . .
Separating Transmission Into Sections . . . . . . .
Transmission Pump Section . . . . . . . . . . . . . . .
Transmission Center Section . . . . . . . . . . . . . .
Transmission Motor Section . . . . . . . . . . . . . . .
Assembling Transmission Sections . . . . . . . . . .
Priming After Transmission Overhaul
or Replacement . . . . . . . . . . . . . . . . . . . . . . .
Lift Cylinder Removal and Installation . . . . . . . .
Lift Cylinder Repair . . . . . . . . . . . . . . . . . . . . . .
Lift Valve Removal and Installation . . . . . . . . . .
Lift Valve Repair . . . . . . . . . . . . . . . . . . . . . . . .
Page 5 - 1
26
26
27
28
29
30
31
33
34
34
35
37
38
39
40
41
42
43
44
Table of Contents
Specifications
Item
Description
Standard
________________________________________________________________________________________________________________________
________________________________
Transmission
Sauer-Sundstrand 15 Series In-line
Operating Pressure
Charge pressure
Implement relief pressure
Forward traction relief pressure (4WD only)
500 to 5200 PSI
70 - 150 PSI
700 to 900 PSI
5200 PSI
________________________________________________________________________________________________________________________
________________________________
Oil filter
25 micron rated, screw-on type
________________________________________________________________________________________________________________________
________________________________
Hydraulic oil (Fig. 1)
Extreme (over 90°F)
SAE 30 SF/CC or CD
Normal (40 - 100°F)
SAE 10W30 or 10W40 SF/CC or CD
Cool - Spring/Fall (30 - 50°F)
SAE 5W30 SF/CC or CD
Winter (Below 30°F)
Type “F” or “FA” ATF
Automatic Transmission Fluid
________________________________________________________________________________________________________________________
________________________________
Hydraulic resevoir
Front axle differential housing
5 U.S. qt. (4.7 liter) approx. capacity
________________________________________________________________________________________________________________________
________________________________
Lift control valve
Four-way, three position,
open center
Hydraulic Oil
The hydraulic system is designed to operate on any
high-quality detergent oil having the American
Petroleum Institute (API) service classification SF/CC
or CD. Oil viscosity (weight) must be selected according
to anticipated ambient temperature. (See Hydraulic oil
specifications in above chart).
IMPORTANT: DO NOT mix engine oil and automatic
transmission fluid or hydraulic system component
damage may result. When changing fluids, also
change transmission filter. DO NOT USE DEXRON II ATF.
IMPORTANT: When adding oil to hydraulic system,
use a funnel with a fine wire screen (200 mesh).
Make sure funnel and oil are very clean to prevent
accidental contamination of hydraulic system.
3. Screw dipstick filler cap finger-tight onto filler neck. It
is not necessary to tighten cap with a wrench.
4. Lower the implement.
NOTE: Fluid to operate the power steering is supplied
by the hydraulic system transmission charge pump.
Cold weather start-up may result in “stiff” operation of
the steering until the hydraulic system has warmed up.
Using proper weight hydraulic oil in system minimizes
this condition.
To check oil level:
1. Put machine on a level surface, raise the implement
and stop the engine.
2. Unscrew dipstick cap from filler neck and wipe it with
a clean rag. Screw dipstick cap finger tight onto filler
neck. Unscrew dipstick and check level of oil. If level is
not within 1/2 inch (13 mm) from groove in dipstick, add
enough oil to raise level to groove mark. DO NOT OVERFILL by more than 1/2 inch (13 mm) above groove.
Specifications
Page 5 - 2
Figure 1
1. Dipstick cap
2. Groove
Groundsmaster® 300 Series
General Information
Hydraulic Hoses
Hydraulic hoses are subject to extreme conditions such
as, pressure differentials during operation and exposure
to weather, sun, chemicals, very warm storage conditions or mishandling during operation or maintenance.
These conditions can cause damage or premature
deterioration. Some hoses are more susceptible to
these conditions than others. Inspect the hoses 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.
WARNING
Before disconnecting or performing any work
on the hydraulic system, all pressure in the
system must be relieved by lowering the cutting unit to the ground and stopping the
engine.
Keep body and hands away from pin hole
leaks or nozzles that eject hydraulic fluid
under high pressure. Use paper or cardboard,
not hands, to search for leaks. Hydraulic fluid
escaping under pressure can have sufficient
force to penetrate the skin and do serious
damage. If fluid is injected into the skin, it
must be surgically removed within a few
hours by a doctor familiar with this type of
injury or gangrene may result.
Hydraulic Fitting Installation
O-Ring Face Seal
1. Make sure both threads and sealing surfaces are free
of burrs, nicks, scratches, or any foreign material
(Fig. 3).
Nut
Body
Sleeve
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.
Seal
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
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
16 (1 in.)
Groundsmaster® 300 Series
Mark Nut
and Body
Final
Position
Initial
Position
Extend Line
F.F.F.T.
.75 ± .25
.75 ± .25
.75 ± .25
1.00 ± .25
.75 ± .25
.75 ± .25
Finger Tight
After Proper Tightening
Figure 3
Page 5 - 3
General Information
SAE Straight Thread O-Ring Port (Non-adjustable)
1. Make sure both threads and sealing surfaces are free
of burrs, nicks, scratches, or any foreign material.
2. Always replace the O-ring seal when this type of fitting
shows signs of leakage.
3. Lubricate the O-ring with a light coating of oil.
O-Ring
4. Install the fitting into the port and tighten it down full
length until finger tight (Fig. 4).
5. Tighten the fitting to the correct flats from finger tight
(F.F.F.T.).
Figure 4
Size
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
16 (1 in.)
F.F.F.T.
1.00 ± .25
1.50 ± .25
1.50 ± .25
1.50 ± .25
1.50 ± .25
1.50 ± .25
SAE Straight Thread O-Ring Port (Adjustable)
1. Make sure both threads and sealing surfaces are free
of burrs, nicks, scratches, or any foreign material
(Fig. 5).
2. Always replace the O-ring seal when this type of fitting
shows signs of leakage.
Lock Nut
3. Lubricate the O-ring with a light coating of oil.
Back-Up Washer
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).
O-Ring
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).
Step 1
Step 3
Step 2
Step 4
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
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
16 (1 in.)
General Information
F.F.F.T.
1.00 ± .25
1.50 ± .25
1.50 ± .25
1.50 ± .25
1.50 ± .25
1.50 ± .25
Figure 5
Page 5 - 4
Groundsmaster® 300 Series
Pushing or Towing (Fig. 6)
In an emergency, the traction unit can be pushed or
towed for a very short distance. However, Toro does not
recommend this as a standard procedure.
IMPORTANT: Do not push to tow the traction unit
faster than 2 to 3 mph because the transmission
may be damaged. If traction unit must be moved a
long distance, transport it on a truck or trailer. When
ever traction unit is pushed or towed, the by-pass
valve must be open.
1. Raise and support seat to get access to by-pass
valve.
2. Rotate by-pass valve on transmission counterclockwise 1/2 to 1 turn. Opening the valve opens an internal
passage in the pump to by-pass transmission oil. Because fluid is by-passed, the machine can be pushed
slowly without damaging the transmission.
Figure 6
(4WD unit shown)
1. Bypass valve
3. Close by-pass valve by rotating it clockwise until it is
securely seated. Do not exceed 5 to 8 ft-lb of torque
when tightening.
IMPORTANT: Do not start engine when valve is
open. Running the machine with the by-pass valve
open will cause the transmission to overheat.
Groundsmaster® 300 Series
Page 5 - 5
General Information
Hydraulic Schematics
2 Wheel Drive Traction Unit
4 Wheel Drive Traction Unit
Hydraulic Schematics
Page 5 - 6
Groundsmaster® 300 Series
Hydraulic Flow Diagrams
Forward Traction Operation
The hydrostatic transmission consists of a charge pump, variable displacement pump and a fixed displacement motor. The diagram shows
flow of the hydraulic oil during forward operation.
Groundsmaster® 300 Series
Page 5 - 7
Hydraulic Flow Diagrams
Raising the Cutting Unit
The charge pump supplies oil through the “AUX” port of the steering valve to the lift valve.
When the lift lever is actuated to raise the cutting unit, oil supplied by the charge pump is
directed out the work port of the lift valve to the barrel end of the lift cylinder. Oil displaced
from the rod end of the cylinders goes through the oil cooler and back to reservoir.
NOTE: The steering valve will not allow oil to flow through it to the lift valve when the steering
wheel is being turned. Whenever the steering wheel is not moving, the steering valve allows
oil to flow through it. Oil in the rest of the steering circuit is then trapped.
Pressure
Return
Hydraulic Flow Diagrams
Page 5 - 8
Groundsmaster® 300 Series
Turning Steering Wheel to Right
When the steering wheel is turned to the right the control valve within the steering valve
shifts to close the “AUX” port. This directs oil supplied by the charge pump to the metering
section of the steering valve. As the steering wheel turns, oil is metered out port “RT” to the
steering cylinder. Oil displaced by the other end of the steering cylinder returns to the steering
valve through port “LT” which directs it through the “OUT” port back to reservoir.
When the steering wheel stops turning the control valve within the steering valve shifts back
to neutral allowing oil to flow through the steering valve out the “AUX” port to the lift control
valve. Oil in the rest of the steering circuit is then trapped.
Pressure
Return
4WD Units
2WD Units
Groundsmaster® 300 Series
Page 5 - 9
Hydraulic Flow Diagrams
Special Tools
NOTE: Order special tools from the TORO SPECIAL
TOOLS AND APPLICATIONS GUIDE (COMMERCIAL
PRODUCTS). Some tools may be listed in the Parts
Catalog for your Toro equipment. Some tools may also
be available from a local supplier.
Hydraulic Pressure Gauges (Fig. 7)
Used to take various hydraulic pressure readings for
diagnostic tests.
Low pressure gauge 0 - 1000 psi, high pressure gauge
0 - 5000 psi, and associated hoses and fittings.
Figure 7
Special Tools
Page 5 - 10
Groundsmaster® 300 Series
Hydraulic Tester (With Pressure and Flow Capabilities) (Fig. 8)
Figure 8
You must have o-ring face seal (ORFS) adapter fittings
for this tester to use it on current models of the
Groundsmaster 300 Series.
4. HIGH PRESSURE GAUGE: High range gauge to
accommodate pressure beyond the capacity of the low
pressure gauge, 0 - 5000.
1. INLET HOSE: Hose connected from the system
circuit to the inlet side of the hydraulic tester.
5. FLOW METER: This meter measures actual oil flow
in the operation circuit, with a gauge rated at 15 GPM.
2. LOAD VALVE: If required, upon turning the valve to
restrict flow, a simulated working load is created in the
circuit.
6. OUTLET HOSE: Hose from the outlet side of the
hydraulic tester to be connected to the hydraulic system
circuit.
3. LOW PRESSURE GAUGE: Low range gauge to
provide accurate reading at low pressure, 0 - 1000 psi.
This gauge has a protector valve which cuts out
when pressure is about to exceed the normal range
for the gauge. The cutout pressure is adjustable.
Groundsmaster® 300 Series
Page 5 - 11
Special Tools
Troubleshooting
The cause of an improperly functioning hydraulic system is best diagnosed with the use of proper testing
equipment and a thorough understanding of the complete hydraulic system.
A hydraulic system with an excessive increase in heat
or noise is a potential failure. Should either of these
conditions be noticed, immediately stop the machine,
turn off the engine, locate the cause of the trouble, and
correct it before allowing the machine to be used again.
Continued use of an improperly functioning hydraulic
system could lead to extensive internal component
damage.
The charts that follow contain detailed information to
assist in troubleshooting. There may possibly be more
than one cause for a machine malfunction. All causes
should be checked in the order in which they are listed
on the charts.
Refer to the Testing section of this Chapter for precautions and specific test procedures.
System Operates in Only One Direction
Inspect
traction control
linkage
Ok
Defective
Inspect
acceleration
valves
Defective
Repair
linkage
Repair
acceleration
valves
System Jerky When Starting
Inspect friction
wheel on
traction pedal
Worn
(No contact
with pedal)
Rotate or
replace
wheel
Troubleshooting
Ok
Inspect
traction control
linkage
Ok
Defective
Repair
linkage
Page 5 - 12
Inspect
acceleration
valves
Defective
Repair
acceleration
valves
Groundsmaster® 300 Series
System Operates Hot
Check
engine
rpm
Low
Adjust,
use
tachometer
Ok
Check
hydraulic
oil level
Check radiator,
screen, fan,
fan belt and
coolant level
Ok
Low
Defective
cooling system
Fill to
proper
level
Clean radiator &
screen. Repair fan or
belt. Add coolant
Inspect
by-pass
valve
Ok
Reduce load on
transmission;
non-hydraulic
problem
Ok
Ok
Inspect lift
lever latch
position
Check for kinked
or severely bent
hose or tubing
Ok
Ok
Inspect
acceleration
valves
Open or defective
Incorrect
Kinked or bent
Defective
Close or
repair
Adjust
lever
Replace kinked
or bent hose
or tubing
Repair
acceleration
valves
Check
traction
pressure
Ok
Check
charge pump
flow
Ok
Ok
Inspect
transmission inlet
filter
Low
Repair or replace
transmission
(pump & motor)
Ok
Inspect
charge
pump
Defective
Repair or replace
charge pump
Groundsmaster® 300 Series
Ok
Inspect
implement
relief valve
Defective
Repair or shim
implement
relief valve
Page 5 - 13
Ok
Low
Loose or clogged
Test
steering
valve
Tighten
or
replace
Control valve
sticking
Repair or replace
steering
valve
Troubleshooting
Loss Of Power Or Unit Will Not Operate In Either Direction
Check
engine
rpm
Ok
Low
Adjust,
use
tachometer
Check
engine to
transmission
coupler
Disconnected
or damaged
Repair
Ok
Check
hydraulic
oil level
Ok
Inspect
by-pass
valve
Low
Open or defective
Fill to
proper
level
Close
or
repair
Ok
Inspect
inlet
filter
Ok
Tighten
or
replace
Inspect
charge
pump
Ok
Ok
Loose or defective
Loose or clogged
Inspect
implement
relief valve
OK
Inspect
charge
relief valve
Defective
Repair or replace
charge pump
Repair or shim
implement
relief valve
Repair or shim
charge
relief valve
Page 5 - 14
Ok
Adjust
or
repair
Defective
Ok
Check charge
pump
pressure/flow
Low
Defective
Repair or replace
transmission
(pump & motor)
Troubleshooting
Inspect traction
control linkage
Ok
Inspect
acceleration
valves
Low
Check
traction
pressure
Defective
Ok
Repair
or
replace
Differential
or other
non-hydraulic
problem
Groundsmaster® 300 Series
Check
engine
rpm
Ok
Inspect
underside of
cutting unit
Ok
Inspect lift
valve control
linkage
Ok
Check
hydraulic
oil level
Inspect
lift arm
pivots
Low
Excess debris
Low
Binding, broken
or out of adjustment
Binding
Adjust,
use
tachometer
Clean
Fill to
proper
level
Lubricate
or
repair
Lubricate
or
repair
Check charge
pump
pressure/flow
Ok
Repair or replace
transmission
(pump & motor)
Ok
Inspect
charge
pump
Defective
Repair
charge
pump
Ok
Ok
Test lift
cylinders
for internal
leakage
Ok
Inspect
implement
relief valve
Defective
Repair or shim
implement
relief valve
Ok
Inspect
inlet
filter
Low
Loose or clogged
Test
steering
valve
Tighten
or
replace
Control valve
sticking
Repair or replace
steering
valve
Inspect
lift valve
Defective
Defective
Replace
hydraulic
cylinder
Repair
lift valve
Groundsmaster® 300 Series
Ok
Ok
Ok
Cutting Unit Will Not Lift or Lifts Slowly
Page 5 - 15
Troubleshooting
Check steering
linkage for binding
or damage
High Steering Effort
Ok
Ok
Check
hydraulic
oil level
Defective
Low
Repair
Fill to
proper
level
Check charge
pump
pressure/flow
Ok
Repair or replace
transmission
(pump & motor)
Ok
Inspect
charge
pump
Defective
Repair
charge
pump
Ok
Troubleshooting
Check for restriction in return line
(“OUT” port)
Ok
Inspect
steering valve
Defective
Defective
Replace
hydraulic
cylinder
Repair or
replace valve
Ok
Inspect
implement
relief valve
Defective
Repair or shim
implement
relief valve
Ok
Ok
Inspect
transmission
inlet filter
Low
Loose or clogged
Test
steering
valve
Tighten
or
replace
Control valve
sticking
Repair or replace
steering
valve
NOTE: Sticking steering valve plate can cause high
steering effort in one direction. This is usually
caused by excessive heat in the system.
Page 5 - 16
Groundsmaster® 300 Series
Steering Wander or Shimmy
Inspect for loose
or worn steering
linkage
Defective
Repair linkage and
adjust toe-in
Groundsmaster® 300 Series
Ok
Air in hydraulic
system
Defective
Bleed air from
hydraulic system
Page 5 - 17
Ok
Inspect steering
cylinder for internal
leakage
Defective
Replace steering
cylinder
Troubleshooting
Testing
The most effective method for isolating problems in the
hydraulic system is by using hydraulic test equipment
such as pressure gauges and flow meters in the circuits
during various operational checks. (See the Special
Tools section in this Chapter.)
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.
CAUTION
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.
Failure to use gauges with the recommended
pressure (psi) rating as listed in the test procedures could result in damage to the gauge
and possible personal injury from leaking
hot oil.
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).
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 component is the source of the problem being experienced.
Do electrical diagnostics before performaing hydraulic
tests to make sure the electrical system is operating
properly. If the electrical system is not operating properly
the hydraulic system may appear to malfunction.
WARNING
Before disconnecting or performing any work
on the hydraulic system, all pressure in the
system must be relieved by lowering the cutting unit to the ground and shutting the engine OFF.
5. To minimize the possibility of damaging components,
co mpletely open th e load v alve by tu rning it
counterclockwise (tester with pressure and flow
capabilities).
6. Install fittings finger tight, far enough to insure that
they are not cross-threaded, before tightening with a
wrench.
7. Position the tester hoses so that rotating machine
parts will not make contact with them and result in hose
or tester damage.
8. Check the oil level in the reservoir.
9. Check the control linkage for improper adjustment,
binding or broken parts.
10. All hydraulic tests should be made with the hydraulic
oil at normal operating temperature.
Keep body and hands away from pin hole
leaks or nozzles that eject hydraulic fluid
under high pressure. Use paper or cardboard,
not hands, to search for leaks. Hydraulic fluid
escaping under pressure can have sufficient
force to penetrate skin and do serious
damage. If fluid is injected into the skin, it
must be surgically removed within a few
hours by a doctor familiar with this type of
injury or gangrene may result.
Testing
Page 5 - 18
Groundsmaster® 300 Series
TEST NO. 1: Charge Pressure (Fig. 9)
Using a low pressure gauge: 0 - 1000 psi
1. Engage the parking brake, and block the front wheels
to prevent movement of the machine. Lower the cutting
unit or implement to the floor and turn the engine OFF.
2. Raise and support the seat.
3. Place a drain pan under the transmission. Use a 3/16
inch Allen wrench to remove the 1/8 inch pipe plug
located next the implement pressure port on top of the
transmission.
4. Connect the 0 - 1000 psi hydraulic gauge hose into
the 1/8 inch pipe opening.
NOTE: If adding shims to the relief valve does not
increase the pressure, inspect the condition of the
charge pump gerotor and internal housing.
If the charge pump is in good condition (no scoring,
scratches, or excessive wear), the general condition of
the transmission’s piston pump and piston motor might
be suspected of wear and inefficiency.
A lack of minimum charge pressure or low flow could be
due to the fact that the charge pump is having to direct
all of its flow to the main traction circuit (piston pump
and piston motor). When this occurs, oil pressure may
not increase to the 70 - 150 psi pressure necessary to
open the charge relief valve; therefore, no oil can flow
into the steering and implement circuit.
5. Start the engine and move the throttle to SLOW so
that the engine idles. Use a tachometer to verify that the
engine is running at 1500 ± 50 rpm. The engine must
idle at this speed to provide sufficent charge pump flow
and pressure to lubricate the internal parts of the transmission.
6. Allow the engine to run for approximately 5 minutes
so that the hydraulic oil reaches normal operating
temperature.
7. Increase the engine speed to the FULL throttle setting
and use a tachometer to verify that the engine is running
at 3200 ± 50 rpm.
8. Observe the pressure measurement on the low pressure gauge. The reading should be 70 - 150 psi.
NOTE: A higher reading may be obtained due to the
back pressure in the system. This is acceptable.
9. If the pressure is below 70 psi, adjust the charge relief
valve by adding the required amount of shims from the
shim pack.
Figure 9
1. Low pressure gauge (0 - 1000 psi)
Groundsmaster® 300 Series
Page 5 - 19
Testing
TEST NO. 2: Implement Relief Pressure (Fig. 9)
Using a low pressure gauge: 0 - 1000 psi
1. Perform steps 1 - 7 under Charge Pressure Test.
2. While observing the gauge, move the lift control lever
to the RAISE position. While holding the lever in the
RAISE position, look at the pressure reading on the
gauge. The gauge should show 700 - 800 psi. Stop the
engine and move the lift control lever to the LOWER
position to lower the implement to the ground.
3. If the pressure is below 700 psi, adjust the implement
relief valve by adding the required amount of shims from
the shim pack.
If adding shims to the relief valve does not increase the
pressure, inspect the condition of the charge pump
gerotor and internal housing.
If the charge pump is in good condition (no scoring,
scratches, or excessive wear), the general condition of
the transmission’s piston pump and piston motor might
be suspected of wear and inefficiency.
A lack of sufficient implement pressure could be due to
the fact that the charge pump is having to direct most of
its flow to the main traction circuit (piston pump and
piston motor). When this occurs, oil pressure may not
increase to the 700 - 800 psi pressure necessary to raise
the heavy implement.
CAUTION
The implement relief pressure must not exceed 800 psi.
NOTE: When testing the implement relief valve pressure, it may be found that the pressure is already set to
the 800 psi maximum. If this is so, a slow or no lift
condition is most likely caused by an added force being
applied to the lift system and not a fault within the
Testing
hydraulic circuit. This is can be caused by parts that are
binding or build up of debris under the cutting unit. This
adds to the amount of force that the hydraulic cylinder
must overcome. Repair such items before continuing
with the hydraulic tests.
At this point, a traction pressure test could be used to
determine whether the hydrostatic transmission has
excessive piston group leakage and needs to be
repaired. (See Traction Pressure Test.)
Page 5 - 20
Groundsmaster® 300 Series
TEST NO. 3: Traction Pressure (Fig. 10)
Using a high pressure gauge: 0 - 5000 psi
CAUTION
Failure to use a high pressure gauge 0 - 5000
psi during this traction pressure test could
result in damage to the gauge and possible
personal injury due to leaking, hot oil.
1. Before beginning the traction test, drive the machine
to an open area, lower the cutting unit, turn the engine
OFF and engage the parking brake. Connect a chain to
the rear axle. Connect the other end of the chain to an
immovable object and remove all slack from the chain.
2. Place a drain pan on the floor beneath the transmission. Remove the hex head plug from the transmission.
3. Connect the high pressure hydraulic gauge hose to
the gauge port.
4. Start the engine and allow it to run for approximately
5 minutes so that the hydraulic oil reaches normal
operating temperature.
5. Increase the engine speed to the FULL throttle setting
and use a tachometer to achieve 3200 ± 50 rpm.
Figure 10
1. High pressure gauge (0 - 5000 psi)
CAUTION
To prevent damage to gauge and possible
personal injury due to leaking, hot oil, do not
exceed 5000 psi during traction pressure test.
6. Sit on the seat, and with the brakes locked, slowly
depress the top of the traction pedal. While pushing the
top of the traction pedal down, look at the pressure
reading on the gauge. The gauge should show 4000 4500 psi. DO NOT exceed 5000 psi.
7. If the traction pressure is lower than 4000 psi, check
the acceleration valves. If the acceleration valves are in
good condition and there is no foreign material in the
ports of the transmission, inspect the charge check
valves. If the charge check valves are in good condition,
overhaul the transmission because either the pump,
motor, or both piston groups are at fault.
Groundsmaster® 300 Series
Page 5 - 21
Testing
TEST NO. 4: Charge Pump Flow and Implement Relief Pressure (Fig. 11)
Using a hydraulic tester with flow meter
1. Engage the parking brake and block the front wheels
to prevent movement of the machine. Lower the cutting
unit or implement to the floor and turn the engine OFF.
2. Raise and support the seat or remove the seat and
seat mounting plate.
3. Put a drain pan below the transmission. Disconnect
the hydraulic hose from the charge pump outlet (pressure) fitting on the transmission.
4. Connect the inlet hose of the tester to the fitting on
the transmission. Connect the tester outlet hose to the
hose that was disconnected in step 3.
IMPORTANT: Make sure that the oil flow indicator
arrow on the flow gauge is showing that the oil will
flow through the tester from the pump to the steering valve.
If adding shims to the relief valve does not increase the
pressure, inspect the condition of the charge pump
gerotor and internal housing.
If the charge pump is in good condition (no scoring,
scratches, or excessive wear), the general condition of
the transmission’s piston pump and piston motor might
be suspected of wear and inefficiency.
A lack of sufficient implement pressure could be due to
the fact that the charge pump is having to direct most of
its flow to the main traction circuit (piston pump and
piston motor). When this occurs, oil pressure may not
increase to the 700 - 800 psi pressure necessary to raise
the heavy implement.
At this point, a traction pressure test could be used to
determine whether the hydrostatic transmission has
excessive piston group leakage and needs to be
repaired. (See Traction Pressure Test.)
5. Make sure that the tester load valve is fully open
(counterclockwise). Start the engine and allow it to run
for approximately 5 minutes so that the hydraulic oil
reaches normal operating temperature.
6. Increase the engine speed to the FULL throttle setting
and use a tachometer to verify that the engine is running
at 3200 ± 50 rpm.
7. While watching the flow and pressure gauges, slowly
close the flow control valve (load valve) until the flow
gauge reads 1.0 GPM.
8. If the pressure is below 700 psi or 1.0 GPM could not
be achieved, adjust the implement relief valve by adding
the required amount of shims from the shim pack.
CAUTION
The implement relief pressure must not exceed 800 psi.
Figure 11
1. Transmission
2. Tester
3. Load valve
Testing
Page 5 - 22
Groundsmaster® 300 Series
Adjustments
Traction Control Rod Adjustment (Serial Numbers Below 50000) (Fig. 12)
1. Check traction drive neutral position to assure front
wheels do not creep; refer to “Traction Drive Neutral Adjustment”.
2. Depress traction pedal fully. There must be 1/16 inch
(1.6 mm) between inside front edge of pedal and triangular support brace. If distance is as specified, the control rod is adjusted correctly. If distance is not as
specified, proceed to step 3 for an adjustment.
3. Loosen jam nut away from front of control rod. Remove cotter pin and slotted nut retaining tapered socket
in pivot mount on bottom of traction pedal.
4. Adjust tapered socket as required. Slide end of tapered socket through traction pedal pivot mount. Then
depress pedal and check for 1/16 inch (1.6 mm) clearance between front edge of pedal and top of support
brace. Adjust tapered socket until correct adjustment results.
5. After control rod is adjusted correctly, secure tapered
socket and traction pedal together with slotted nut and
cotter pin. Also tighten jam nut against front of control
rod.
Figure 12
1. 1/16 in. (1.6 mm)
2. Jam nut
3. Cotter pin & slotted nut
4. Nuts
5. Friction wheel
Traction Control Rod Adjustment (Serial Numbers Above 50000) (Fig. 12A)
1. Check traction drive neutral position to assure front
wheels do not creep; refer to “Traction Drive Neutral Adjustment”.
.120” (3.05 mm)
1
2. Loosen lock nuts and adjust traction pedal stop screw
to a length of 3” (76.2 mm).
3. Rotate traction pump lever on transmission to full forward speed location.
2
4. Adjust traction control rod end until there is a .120”
(3.05 mm) gap between top of traction pedal stop screw
and pedal.
5. Make sure that all nuts are properly secured after adjustment.
3” (76.2 mm)
Figure 12A
1. Traction pedal
2. Stop screw
Traction Pedal Friction Wheel Adjustment (Fig. 12)
1. Loosen two nuts securing traction pedal shaft on right
side of pedal.
3. Tighten nuts to secure shaft and wheel in position.
2. Rotate shaft to relocate worn surface of friction wheel
away from underside of traction pedal.
Groundsmaster 300 Series
Page 5 – 23
Rev. G
Adjustments
Traction Control Neutral Adjustment (Fig. 13)
1. Park vehicle on a level surface and turn engine off.
Apply the parking brake, tip seat forward, and actuate
pump lever (Fig. 13) to ensure assembly is properly
seated and operating freely. Correct any discrepancy.
2. Jack up frame so left front wheel is off the ground. On
four wheel drive machines, jack up frame so at least one
rear wheel is also off the ground. Use jack stands to support the raised machine.
3. Block wheels that are on the ground so vehicle cannot
roll forward or backward.
4. Start engine and allow it to idle for 5 minutes to heat
oil in transmission to operating temperatures.
5. Release parking brake; then check that wheel(s) that
are off the ground are NOT rotating. Check for wheel
rotation with throttle in both SLOW and FAST position.
If wheel(s) that are off the ground are NOT rotating, proceed to step 8 as no adjustment is necessary.
6. If the wheel(s) that are off the ground ARE rotating,
the pump plate must be adjusted as follows:
A. Move throttle to SLOW.
D. Weak or damaged leaf springs.
E. Pump lever loose on transmission control shaft.
Make sure that fasteners are tight (bolts or spring pin).
If necessary, remove pump lever from control shaft,
apply Loctite #680 (or equivalent) to shaft and reattach pump lever.
F. Internal transmission component malfunction (see
Repairs section of this chapter).
8. Shut engine off.
9. Adjust traction control rod; refer to Traction Control
Rod Adjustment in this section.
10. Check operation of neutral switch and adjust if necessary.
SWITCH
ADJUSTING
SCREW
CAPSCREW
B. Loosen three (3) capscrews that secure pump
plate to transmission.
C. If wheel is rotating forward, lightly tap bottom of
pump plate counterclockwise. By contrast, tap pump
plate clockwise if wheel is rotating backward. When
wheel stops rotating, tighten capscrews to secure
pump plate.
BALL
BEARING
LEAF
SPRINGS
D. Check that wheel(s) that are off the ground are
NOT rotating with throttle in both SLOW and FAST
position. If necessary, repeat pump plate adjustment
until wheels do not rotate.
PUMP
PLATE
PUMP
LEVER
Figure 13
7. Should wheel(s) that are off the ground continue to rotate after adjustment procedure, check for the following:
A. Ball bearing is loose or worn.
B. Plunger on interlock switch is sticking.
C. Fasteners on pump control assembly are loose or
missing.
Adjustments
Page 5 -- 24
Rev. I
Groundsmaster 300 Series
Lift Lever Latch Adjustment (Fig. 14)
A lift lever latch that is positioned incorrectly can cause
the lift lever to hold the spool in an actuated position
when the implement is in the FLOAT position. This
causes oil in the hydraulic system to overheat. When lift
lever latch is adjusted correctly, the lift lever should just
clear the rounded part of the latch as lever is moved into
FLOAT position.
1. Unscrew ball from lift lever.
2. Remove self tapping screws and lift cover off
lift lever to expose the latch.
3. Loosen two capscrews on top of the lift lever latch.
Place lever on rounded tip of latch, and slide latch
w/lever forward until stopping resistance is felt. Then
tighten capscrews to lock the latch in place. Check for
free operation of the lift lever by moving lever from
RAISE or TRANSPORT to FLOAT position. Lift lever
should just clear rounded position of latch as lever is
moved into FLOAT position.
Figure 14
1. Capscrews
2. Rounded tab
3. Lift lever
4. Slide cover into place and install it with self tapping
screws. Screw ball onto lift lever.
Groundsmaster® 300 Series
Page 5 - 25
Adjustments
Repairs
Transmission Trunnion Seal Replacement (Fig. 15)
1. Remove the control lever and the interlock switch
assembly from the trunnion shaft on the right side of the
transmission.
2. Remove the snap ring from the end of trunnion shaft
and slide the flat washer off of the shaft. Using a seal
puller; pull the seal out of the housing. Do not scratch
the shaft.
NOTE: Since oil drains out of the transmission when the
seal is removed, use a drain pan to catch the oil;
however, do not use this oil again.
3. Examine the trunnion shaft and remove all burrs,
sharp edges and residue.
4. Using a seal protector, press a new seal into the
transmission housing and assure that it is seated
properly.
Figure 15
NOTE: In place of a seal protector, use plastic wrap or
a similar material to wrap the shaft. This protects the lip
of the seal from possible damage when sliding it onto
the shaft and pressing it onto the housing.
5. Slide the flat washer onto the shaft and install the
snap ring into the groove at the end of the shaft. Do not
use a flat washer that is bent.
6. Install the control lever and the interlock switch assembly on the right side of the transmission. Adjust the
traction pedal control rod and linkage for neutral, refer
to "Traction Control Neutral Adjustment".
7. Since some oil drained out of the transmission when
the seals were replaced, check the oil level in the axle
housing. Start the engine and let it run for about one or
two minutes. Then turn the engine off and check the oil
level in the axle housing again. Also check the seals in
the transmission for oil leaks.
Repairs
Page 5 - 26
Groundsmaster® 300 Series
Transmission By-Pass Valve (Fig. 16)
1. Place a drain pan below the by-pass valve.
2. Remove the by-pass valve assembly from the center
section by turning it counterclockwise. Some oil may
flow into the drain pan.
3. Inspect the threads on the by-pass valve. Replace the
valve if the threads are damaged.
4. Check the O-ring and back-up ring for damage.
If the parts are damaged, replace them.
5. If the O-ring or back up ring was removed
because of damage, slide the new back up ring into the
groove at the center of the valve, then install the O-ring
into the same groove.
Figure 16
1. Transmission by-pass valve
6. To install the by-pass valve, screw it into the center
section. Tighten the valve to 5 - 8 ft-lb.
7. Since some oil drained out of the transmission when
the by-pass valve was removed, check the oil level in
the axle housing. Start the engine and let it run for about
one or two minutes. Then turn the engine off and check
the oil level in the axle housing again. Also, inspect the
by-pass valve area for oil leaks.
Groundsmaster® 300 Series
Page 5 - 27 (Rev. H)
Repairs
Transmission Acceleration Valves (Fig. 17)
1 . Place a drain pan below the acceleration valves.
2. Remove both acceleration valve plugs and O-rings
from the sides of the center section. Some oil may flow
into the drain pan.
3. Slide the acceleration valve and spring out of the
center section. Also slide the other acceleration valve
out of the opposite side of the center section.
NOTE: There are two acceleration valves in the center
section, but only one spring.
4. Remove the O-rings from the plugs.
5. Inspect the plugs, valves and center section for
damage or stripped threads. Replace any damaged
part.
Figure 17
6. Inspect the bore of the acceleration valve for damage
and foreign material. If the valve is damaged, replace it;
however, clean the valve with cleaning fluid and use it
again if foreign material is in its bore.
7. Check the spring for damage and correct specifications. Replace the spring if its condition is doubtful.
Spring specifications are listed in the table below.
Acceleration Valve Spring Specifications
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25 in.
Number of Coils . . . . . . . . . . . . . . . . . . . . . . . . . . 23-1/2
Outside Diameter . . . . . . . . . . . . . . . . . . 0.297-0.303 in.
Pounds per Inch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8. To install acceleration valves, place a new O-ring onto
both acceleration valve plugs.
9. Slide one acceleration valve into the center section,
then install plug. Then, slide the spring and remaining
acceleration valve into the opposite side of the center
section. Install the remaining plug to retain the parts in
place.
10. Since some oil has drained out of transmission when
the acceleration valves were removed, check the oil
level in the axle housing. Start the engine and let it run
for about one or two minutes. Then turn the engine off
and check the oil level in the axle housing again. Also
inspect the acceleration valve areas for oil leaks.
Repairs
Page 5 - 28
Groundsmaster® 300 Series
Transmission Implement Relief Valve (Fig. 18)
1. Place a drain pan below the implement relief valve.
2. Remove the implement relief plug and O-ring from the
side of the pump housing. Slide the shim pack, spring
and cone out of the pump housing. Some oil may flow
out of the transmission.
NOTE:Count the shims when they are removed. The
same number of shims must be installed when assembling the parts. Do not interchange implement relief
shims with charge relief shims.
3. Remove the O-ring from the plug.
4. Inspect the plug and the pump housing for stripped
threads. Replace any part that is damaged. Also, check
the seat inside the pump housing for damage and
foreign material.
Figure 18
5. Inspect the relief valve cone for noticeable damage.
If cone is damaged, replace it.
6. Check the spring for damage and correct specifications. Replace the spring if its condition is doubtful.
Spring specifications are listed in the table below.
Implement Relief Spring Specifications
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.804 in.
Number of Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Outside Diameter . . . . . . . . . . . . . . . . . 0.260 - 0.262 in.
Pounds per Inch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
7. To install the implement relief valve, slide the new
O-ring onto the implement relief plug.
8. In sequence, install the cone, spring, and shim pack
into the pump housing. Install the plug to retain the parts
in place.
9. Since some oil drained out of the transmission when
the implement relief valve was removed, check the oil
level in the axle housing. Start the engine and let it run
for about one or two minutes.Then turn the engine off
and check the oil level in the axle housing again. Also,
inspect implement relief plug area for oil leaks.
Groundsmaster® 300 Series
Page 5 - 29
Repairs
Transmission Charge Relief Valve (Fig. 19)
1 . Place a drain pan below the charge relief valve.
2. Remove the charge relief plug and O-ring from the
side of the pump housing. Slide the shim pack, spring
and ball or cone out of the housing. Some oil may flow
out of the transmission.
NOTE: Count the shims when they are removed. The
same number of shims must be installed when assembling the parts. Do not interchange charge relief shims
with implement relief shims.
3. Remove the O-ring from the plug.
4. Inspect the plug and pump housing for stripped
threads. Replace any part that is damaged. Also check
the seat inside the pump housing for damage and
foreign material.
Figure 19
5. Check the spring for damage and correct specifications. Replace the spring if is condition is doubtful.
Spring specifications are listed in the table below.
Charge Relief Spring Specifications
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.051 in.
Number of Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Outside Diameter . . . . . . . . . . . . . . . . . 0.249 - 0.251 in.
Pounds per Inch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.8
6. To install the charge relief valve, slide a new O-ring
onto the charge relief plug.
7. In sequence, insert the check ball or cone, spring, and
shim pack into the pump housing. Install the plug to
retain the parts in place.
8. Since some oil drained out of the transmission when
the charge relief valve was removed,check the oil level
in the axle housing. Start the engine and let it run for
about one or two minutes. Then turn the engine off and
check the oil level in axle housing again. Also inspect
the charge relief plug area for oil leaks.
Repairs
Page 5 - 30
Groundsmaster® 300 Series
Transmission Charge Pump (Fig. 20, 21)
1. Remove the drive coupling from between the engine
pulley and the transmission hub; refer to "Removing
Drive Coupling" in Chapter 10.
2. Remove the taper lock (if applicable) and the hub from
the transmission shaft.
3. Examine the transmission pump shaft and remove all
burrs, sharp edges and residue to prevent possible
damage to the lip seal.
NOTE: Disassembly of the charge pump is not necessary when the seal is the only part that must be replaced
(see step four). Servicing any other part of the charge
pump requires disassembly (see step 5).
4. If the charge pump seal is the only part being serviced, pull the seal out of the charge pump housing
using the oil seal puller or similar tool. Do not scratch
the pump shaft. Since oil flows out of the transmission
when the seal is removed, use a drain pan to catch the
oil; however, do not use this oil again.
Figure 20
5. If the charge pump must be disassembled, scribe a
mark on charge pump housing and adjacent pump
housing to assure correct installation when parts are
assembled.
NOTE: Charge pump housings that have the letters LH
and RH on the external surface must be installed with
the letters LH positioned closest to the top of the
transmission.
6. Remove the cap screws holding the charge pump
housing against the adjacent pump housing. Using a
seal protector, slide the charge pump housing and
gerotor wheel off of the pump shaft. The O-ring will
probably stay in the groove on the inside of the pump
housing.
NOTE: If a seal protector is not used, wrap the pump
shaft with plastic wrap to protect the seal. When sliding
the housing and gerotor wheel off of the pump shaft, the
drive pin may drop out of the pump shaft. Do not lose
the pin because it is the only part that drives the gerotor
wheel. Without the pin, the gerotor wheel will not rotate;
thus, no "charge pressure" and no hydraulic functions.
7. Examine the gerotor wheel and the inside of the
charge pump housing for excessive wear patterns,
scratches or score marks. If a part is damaged beyond
repair, replace it.
IMPORTANT: If either the gerotor wheel or the
charge pump housing is damaged, replace both
parts. Never replace only one part because the
charge pump housing and gerotor wheel have a
definite wear-in characteristic.
Groundsmaster® 300 Series
Page 5 - 31
Repairs
8. Examine the bearing in the charge pump housing for
damage and free rotation. If the bearing is damaged,
replace the bearing and seal.
9. To assemble the charge pump, install a new O-ring
into the groove in charge pump housing.
10. Apply transmission oil on the gerotor wheel and the
inside of the charge pump housing. Slide the drive pin
through the hole in the pump shaft. (It is helpful to have
this hole positioned horizontally, as shown, to keep the
pin in place during reassembly.) Then slide the gerotor
wheel onto the pump shaft and drive pin so positive
engagement results.
11. Using a seal protector for the lip seal, slide the
charge pump housing onto the pump shaft and against
the side of the adjacent pump housing. Align the scribe
marks in both housings to assure proper assembly and
to prevent damage to the transmission.
Most Sundstrand charge pump housings are marked
with the letters RH and LH. These are used to denote
which side of the charge pump is mounted towards the
top of the transmission for a given direction of engine
rotation (i.e. clockwise). The GROUNDSMASTER
mower application requires that the "LH" markings be
toward the top of the transmission. Having "LH" toward
the bottom of the transmission will result in a complete
loss of hydraulic functions.
Figure 21
NOTE: In place of a seal protector, use plastic wrap or
a similar material to wrap the pump shaft. This protects
the seal from possible damage when sliding it onto the
pump shaft. Apply transmission oil on the plastic wrap
to make the seal slide freely.
12. Secure the charge pump housing against the adjacent housing with four cap screws. Tighten the cap
screws to 12 - 15 ftlb.
IMPORTANT: Excessive pressure on the pump shaft
will shear the pin that propels the gerotor wheel. If
the pin should shear, the transmission will not
operate.
13. Install the drive coupling and transmission hub to the
engine pulley; refer to "Installing Drive Couplings" in
Chapter 10.
14. Since some oil has drained out of the transmission
when the charge pump was serviced, check the oil level
in axle housing. Start the engine and let it run for about
one or two minutes. Then turn the engine off and check
oil level in the axle housing again. Also check the seal
in the charge pump for oil leaks.
Repairs
Page 5 - 32
Groundsmaster® 300 Series
Transmission Removal and Installation
1. Position the machine on a level surface in a clean
area of the workshop.Block all four wheels of the unit to
prevent it from moving.
7. Loosen and remove the engine to transmission
coupler; refer to "Removing Drive Coupling" of Chapter
10.
2. Lower the cutting unit or implement to the shop floor.
Turn the engine off and remove the key from the ignition
switch.
8. Disconnect and remove the traction pedal rod where
it fastens to the transmission.
3. Disconnect the positive battery terminal from the
battery. Place the cable out of the way and in such a
position that it cannot spring back and make contact with
the positive battery terminal.
4. Raise the seat of the machine and secure it in that
position.
5. Place a drain pan underneath the differential.
Remove any loose sand, grass, or debris from the top
of the transmission. Place a drain pan underneath the
differential and hydrostat. Remove the oil line that connects the differential to the transmission or hydraulic
filter. Allow oil to drain. Cap or plug the lines and fittings.
6. Remove the hydraulic lines that connect to the transmission. Cap or plug all hoses and fittings to prevent
contamination. NOTE: To ease reassembly, tag all lines
as to their proper location.
Groundsmaster® 300 Series
9. Support the transmission to prevent it from failing
while removing the two cap screws that secure the
transmission to the differential.
10. Carefully pull the transmission out of the differential
and guide it down and out from under the machine.
11. Remove the gasket that fits between the transmission and differential.
12. Thoroughly clean the area of the differential. where
the new or rebuilt transmission will be installed.
13. Reverse steps 1 - 10 to reinstall the transmission
and use Loctite 271 on the two cap screws that hold the
hydrostat to the differential.
14. Replace the hydraulic oil filter and fill the system
with oil.
Page 5 - 33
Repairs
Transmission Overhaul
As the transmission components are removed for service and inspection, it should be noted that nominal
wear to the components is acceptable. Critical contact
surfaces (i.e. charge pump gerotor, piston slippers, etc.)
must be in good condition or the system will be
inefficient.
When components have circumferential scratches or
grooves noted on the running surfaces, it is an indication
of foreign material in the hydraulic oil.
If upon inspection of the critical contact surfaces you
notice circumferential scratches that might be removed
by a minimum amount of polishing or touch lapping;
rework and use them again.
When scratches or grooves can be detected by "feel"
with a fingernail or lead pencil, the part should be
replaced. Polishing or touch lapping can be accomplished using 4/0 grit sandpaper on a flat lapping
table (table must be kept flat). Polish parts using polishing solvent or equivalent. Do not polish parts dry.
IMPORTANT: Lapping plate must be flat within
0.00005 inch.
Separating Transmission Into Sections (Fig. 23)
The transmission must be separated into three main
sections to perform major overhaul. The three sections
are: pump section, center section, and motor section.
6. Pull the pump housing away from the center section.
Do not let the internal parts fall out of the housing
because damage may result.
NOTE: The following procedures are for major overhaul
of the in-line transmission. Servicing the charge pump,
seals and valves is covered on previous pages.
NOTE: The pump valve plate will probably adhere to the
side of the center section. Do not let it fall when separating the pump housing from the center section.
1. Before separating the transmission, scribe or paint an
alignment mark on each housing to assure correct
reassembly of the sections.
7. Remove the pump valve plate and gasket.
2. Remove the four cap screws in small increments so
the three main sections separate evenly. As the cap
screws are loosened, oil will drain from the housings.
8. Set the pump housing and pump valve plate aside.
Keep the pump valve plate separate from the motor
valve plate becaus e these par ts are not
interchangeable.
NOTE: When the cap screws are first loosened, an
internal spring load causes the sections to separate
slightly.
3. When the four cap screws are removed, pull the motor
housing away from the center section. Do not let the
internal parts fall out of the housing because damage
may result.
NOTE: The motor valve plate will probably adhere to the
side of the center section. Do not let it fall when separating the motor housing from the center section.
4. Remove the motor valve plate and gasket.
5. Set the motor housing and motor valve plate aside.
Keep the motor valve plate separate from the pump
valve plate becaus e these par ts are not
interchangeable.
Repairs
Page 5 - 34
Figure 23
Groundsmaster® 300 Series
Transmission Pump Section (Fig. 24, 25, 26, 27)
1. Separate the pump housing from the center section;
refer to "Separating Transmission Into Sections,".
2. Lift the cylinder block assembly out of the pump
housing. Do not be concerned if the pistons come out
of the cylinder block because they do not have a special
order in the cylinder block
NOTE: Since the entire cylinder block assembly must
be replaced if it is defective, do not disassemble the
spring and other parts from the center bore of the
cylinder block. Cylinder block components are not interchangeable.
3. Remove the thrust plate from the counterbore in the
variable position swash plate.
4. Wrap the port side of the pump housing with a clean
rag to protect the face of the housing. Set the pump
housing on to a clean work bench.
Figure 24
5. Drive the spring pins through the swash plate and out
of the trunnion and control shafts.
NOTE: There are two spring pins on the control shaft
side of the pump housing and one pin on the trunnion
shaft side. The control shaft must have two pins because of the continuous "applied force" from the traction
pedal during operation.
6. Mark the control shaft and housing so the shaft can
be installed correctly when the parts are reassembled.
Slide a long punch through the hole at the end of the
control shaft and pull the shaft out of the bore in the
swash plate and pump housing.
7. Slide a 3/8 x 7 inch wooden dowel into the bore at the
control shaft side of the housing. Place the dowel
against the end of the trunnion shaft and drive it out of
the housing.
Figure 25
8. Lift the swash plate out of the pump housing and off
of the pump shaft.
9. If the pump shaft or bearing must be serviced, use
the following steps to remove the parts:
A. Remove the snap ring from the housing.
B. Slide the pump shaft and bearing out of the
housing, toward the large open end.
C. Remove the snap ring from the shaft.
D. Press the bearing off of the pump shaft, toward
the keyed end.
Groundsmaster® 300 Series
Page 5 - 35
Repairs
10. Clean and inspect the following parts:
A. Thrust Plate - Check both sides for damage and
flatness.
B. Cylinder Block Assembly - Check surfaces for
wear, scratches and scoring. Also, check the slippers for damage and make sure the pistons are free
in the bores.
be 1/4 inch below the surface of the swash plate.
Make sure the swash plate swings freely; 15
degrees to each side of center.
14. Lubricate the thrust plate with transmission oil. Slide
the thrust plate onto the pump shaft and into the counterbore of the swash plate.
D. Pump Shaft - Check for scratches, scoring,
damaged splines and burrs near keyway.
15. Lubricate the pump cylinder block parts with oil.
Assemble the cylinder block parts and slide the cylinder
block assembly onto the pump shaft. The cylinder block
must slide onto the splines near center of the shaft.
Assure that the thrust plate remains seated in the
counterbore and that the piston slippers contact the face
of the thrust plate.
E. Control and Trunnion Shafts - Check for wear,
scratches and burrs.
16. Push against the back of the cylinder block. A slight
spring pressure assures correct installation of the parts.
F. Needle Bearings - Check needle bearings in the
pump housing for free rotation and any noticeable
damage.
17. Assemble the transmission sections if no other
service work is required, refer to "Assembling Transmission Section".
C. Ball Bearing - Check for free rotation and noticeable damage.
G. Swash Plate - Inspect the swash plate for damage
and any noticeable imperfections.
NOTE: Replace any defective part. Remember that the
cylinder block assemblies must be replaced as a complete component, not individual parts. Interchanging
parts between the pump cylinder block assembly and
the motor cylinder block assembly will cause the transmission to malfunction.
11. Lubricate the bearing with transmission oil and press
the bearing onto the shaft. Install the snap ring onto the
shaft. Then slide the shaft and bearing into the pump
housing from the large open side. Install the large snap
ring into the pump housing.
12. Slide the swash plate onto the pump shaft and into
the pump housing. The counterbore side of the swash
plate must face up.
Figure 26
13. Align the holes on both sides of the swash plate with
the holes on both sides of the pump housing. Next, slide
the control and trunnion shafts into the housing and
swash plate. Make sure the control shaft is on the
implement relief side of the housing - see alignment
marks on the shaft and housing. Secure the shafts and
swash plate together with the spring pins.
IMPORTANT: Use only new spring pins when as­
sembling the swash plate and shafts - two pins
through the control shaft and one pin through the
trunnion shaft. When installing two pins through the
swash plate and control shaft, drive the first pin
flush with the swash plate and install the other pin
onto the top of the first pin. Drive both pins in until
the top pin is 1/4 inch below the surface of the swash
plate. The pin holding the trunnion shaft must also
Repairs
Page 5 - 36
Figure 27
Groundsmaster® 300 Series
Transmission Center Section (Fig. 28)
1 . Separate the center section from the motor and pump
housings; refer to "Separating Transmission Into
Sections".
2. Wrap the pump side of the center section with a clean
rag to protect its face. Set the center section on a clean
work bench so that the motor side faces up. The rag will
protect the pump side of the center section from direct
contact with the top of the work bench.
3. Remove the two slotted directional charge check
plugs from the motor side of the center section. Invert
the center section and allow the two valve springs and
check balls to fall into your cupped hand. Also remove
the two O-rings from the pump side of the center section.
4. If the needle bearings must be serviced, press them
out of the center section.
5. Clean and inspect the following parts:
A. Slotted plugs and O-rings - Check the slotted
plugs for damaged threads and burrs. Also check the
O-ring for tears. It is a good practice to install new
O-rings whenever the slotted plugs are removed.
NOTE: Replace any defective parts. The slotted plugs,
valve springs, and check balls are interchangeable.
6. If the needle bearings were removed, press new
bearings into the center section. Allow 3/32 - 1/8 inch of
the bearing to extend beyond the face of the center
section because the motor valve plate and pump valve
plate pilot on the two bearings.
7. Press the locating pins into the holes in the motor side
and pump side of the center section.
8. Insert the check balls and valve springs into the two
holes in the motor side of the center section. Slide the
O-rings onto the slotted plugs and install the plugs into
the two holes in the motor side of center section. Insert
the two new O-rings into the holes in the pump side of
the center section.
9. Assemble the transmission sections if no other service work is required; refer to "Assembling Transmission
Sections".
B. Valve Springs and Check Balls - Check the valve
springs and check balls for damage. Spring
specifications are listed in the table below.
Check Valve Spring Specifications
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.550 in
Number of Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Outside Diameter . . . . . . . . . . . . . . . . . 0.217 - 0.219 in.
Pounds Per Inch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.67
C. Needle Bearings - Check for free rotation and any
noticeable damage.
Figure 28
D. Dowel Pins - Check the dowel pin on the motor
side and the pump side of the center section for wear
and damage.
Groundsmaster® 300 Series
Page 5 - 37
Repairs
Transmission Motor Section (Fig. 29, 30)
1. Separate the motor housing from the center section;
refer to "Separating Transmission Into Sections".
NOTE: Make sure the splines at the end of the motor
shaft are toward the flange side of the motor housing.
2. Lift the cylinder block assembly out of the motor
housing. The pistons may come out of the cylinder
block, but do not be concerned; they do not have a
special order in the cylinder block.
7. Lubricate the thrust plate with transmission oil. Slide
the thrust plate onto the motor shaft and into the
counterbore of the motor housing.
NOTE: Since the entire cylinder block assembly must
be replaced if it is defective, do not disassemble the
spring and other parts from center bore of the cylinder
b lo c k . C yl i nd er b lo c k c o m po nent s ar e no t
interchangeable.
3. Remove the thrust plate from the counterbore in the
motor housing.
4. If the motor shaft or bearing must be serviced, remove
the snap ring from the motor housing. Slide the motor
shaft and bearing out of the housing toward the
flange end. If the shaft sticks in the housing, tap it lightly
with a rubber hammer to remove it.
8. Lubricate the motor cylinder block parts with transmission oil. Assemble the cylinder block parts and slide
the cylinder block assembly onto the motor shaft. The
cylinder block must slide onto the splines near the
center of the shaft.
NOTE: Assure that the thrust plate remains seated in
the counterbore and that the piston slippers contact the
face of the thrust plate.
9. Push against the back of the cylinder block. A slight
spring pressure assures the correct installation of parts.
10. Assemble the transmission sections if no other
service work is required; refer to "Assembling Transmission Sections" which follows.
5. Clean and inspect the following parts:
A. Motor Valve Plate - Check for wear, scratches and
scoring.
B. Thrust Plate - Check both sides for damage and
flatness.
C. Cylinder Block Assembly-Check the surfaces for
wear, scratches and scoring. Also, check the slippers for damage and make sure the pistons are free
in the bores of the cylinder block.
D. Ball Bearing - Check for free rotation and any
noticeable damage.
Figure 29
E. Motor Shaft - Check for scratches, scoring or
damaged splines.
NOTE: Replace any defective part. Remember that the
cylinder block assemblies must be replaced as a complete component, not individual parts. Do not interchange parts between the motor cylinder block
assembly and the pump cylinder block assembly because the transmission will not operate at its optimum
capacity.
6. Lubricate the bearing with transmission oil. Press the
bearing onto the motor shaft. Slide the motor shaft and
bearing into the motor housing from the flange side.
Install the snap ring into the groove at the flange end of
the motor housing.
Repairs
Page 5 - 38
Figure 30
Groundsmaster® 300 Series
Assembling Transmission Sections (Fig. 31, 32)
1. Apply transmission oil on both sides of the center
section. Place the gaskets in position against the pump
and motor sides of the center section.
NOTE: The transmission oil should hold the gaskets
against the sides of the center section.
2. Identify the motor side of the center section by locating the two slotted directional charge check plugs. Apply
transmission oil on the surfaces of the motor valve plate
and install the recessed groove side of the motor valve
plate against the side of the center section. The slot in
the valve plate must fit over the locating pin. Make sure
that the center of the valve plate pilots on the needle
bearing extending out of the center section.
IMPORTANT: The motor valve plate and the pump
valve plate are not interchangeable. Identify the
motor valve plate by the four V-notches in the kidney
shaped grooves. The pump valve plate has two
V-notches in the grooves.
Figure 31
3. Apply transmission oil on the surfaces of the pump
valve plate and install the recessed-groove side of the
pump valve plate against the pump side of center section. The slot in the valve plate must fit over the locating
pin. Assure that the center of the valve plate pilots on
the needle bearing extending out of the center section.
4. Assemble the center section between the motor
housing and the pump housing. The line scribed or
painted on the motor housing, center section, and pump
housing must line up to assure the correct assembly of
the parts.
Figure 32
NOTE: When assembling the three main sections,
make sure the gaskets, valve plates, and cylinder block
assemblies remain in place.
5. Use new capscrews and special flat washer when
assembling the transmission sections. Lubricate the
four cap screws with oil and secure the three main
sections together. Alternately, and in gradual increments, tighten the cap screws to 34 - 37 ft-lb.
Groundsmaster® 300 Series
Page 5 - 39
Repairs
Priming After Transmission Overhaul Or Replacement
Use the following procedures to prime the hydraulic
system whenever the Sundstrand Transmission is overhauled or replaced:
4. Start the engine and operate the traction and lift
system controls for approximately five minutes. Then
turn the engine off.
1. Pour a quantity of transmission oil into the transmission before mounting it to the machine.
5. Allow the machine to stand idle for approximately two
minutes, remove the dipstick and check the oil level. If
the oil level is too high, drain the system until it is at the
correct level. Add oil if the fluid level is too low.
2. Fill a new filter with fresh, clean oil and install it onto
the transmission.
3. Remove the dipstick from the pipe nipple in the
differential assembly and add oil to the proper level.
Repairs
Page 5 - 40
Groundsmaster® 300 Series
Lift Cylinder Removal and Installation (Fig. 33)
1. Lower the cutting unit to the shop floor and turn the
engine off. Jack up the right front side of the traction unit
and support it with a jack stank. Remove the wheel nuts
and slide the wheel off of the mounting studs.
2. Remove the hoses from the lift cylinder and cap the
hoses to prevent contamination.
3. Remove the hair pin cotters and spring from the cotter
pin. Remove the mounting pins and slide the cylinder
from between the lift arm and the stationary mounting
bracket.
4. Install the new or rebuilt cylinder with the pins and
assure the cotter pin which secures the moveable end
of the cylinder is to the outside. Hook the chain tension
spring through the eye of the cotter pin.
Figure 33
5. Connect the hydraulic hoses from the control valve to
the cylinder.
6. Install the wheel and tighten the nuts to 45 - 55 ft-lb.
Remove the jack stank and lower the deck to the shop
floor.
7. Check the level of the hydraulic oil to be sure it is up
to the proper level. Start the engine and operate the lift
cylinder to remove air from the lines. Turn the engine off.
8. Check the level of the hydraulic oil again to be sure it
is up to the proper level.
9. NOTE: The hydraulic fitting elbow located at the back
of the lift cylinder has a special orifice size to determine
the actuation speed of the cylinder. Always use the
proper Toro replacement part for this fitting to prevent
damage to the hydraulic system.
Groundsmaster® 300 Series
Page 5 - 41
Repairs
Lift Cylinder Repair (Fig. 34)
Pump the oil out of the cylinder into a drain pan by
moving the piston back and forth.
10. Use a new seal kit (Items 3, 6 - 10) to replace all
O-rings, seals and back-up rings.
1. Wash the lift cylinder in solvent and dry it thoroughly.
IMPORTANT: The dust seal lips must point outward;
the seal must have the O-ring portion facing
towards the inside of the cylinder.
2. Mount the lift cylinder vertically in a vise so the shaft
end of the cylinder is facing up.
11. The rod end is retained with 75 - 90 ft-lbs torque and
with Loctite Retaining Compound (very strong).
3. Push the head (Item 5) into the barrel (Item 13)
approximately 3/4 inch. Remove the retaining ring
(Item 4).
12. Tighten the piston head locknut to 75 - 90 ft-lb.
Remove the piston, head and shaft assembly from the
vise.
4. Grasp the large end of the shaft and use a twisting
and pulling motion to carefully extract the piston
(Item 11), shaft (Item 2) and head (Item 5) from the
cylinder bore.
NOTE: Coat all O-rings, seals, wiper rings and the
interior bore of the cylinder with a light coating of
hydraulic oil to ease assembly.
5. Remove the cylinder from the vise.
13. Install the barrel into the vise in the vertical position
described in step 3.
6. Securely mount the piston, shaft and head assembly
into the vise so that the large nut (Item 12) is easily
assessable for removal.
14. Slide the shaft, piston and head assembly into the
barrel, aligning the ports for the hydaulic lines as
needed.
7. Remove the large nut from the end of the shaft.
15. Install the retaining ring to secure the head in the
barrel. Pull up on the piston to make sure the retaining
ring is in place.
8. Remove the piston and head from the shaft.
9. Inspect the head, shaft and piston for excessive
scoring, pitting or wear. Replace any defective parts.
13
12
6 7
7
10
6
11
6
5
4
9
8
3
2
1
Figure 34
Repairs
Page 5 - 42
Groundsmaster® 300 Series
Lift Valve Removal and Installation (Fig. 35)
1. Unscrew the ball from the lift lever.
2. Remove the self-tapping screws and lift the cover off
of the lift lever to expose the valve.
3. Loosen and remove the hydraulic lines that are
attached to the valve. Cap or plug all of the fittings and
hoses to prevent contamination.
4. Remove the five cap screws and locknuts that secure
the valve and lever to the main frame.
5. Lift out the control valve.
Figure 35
6. Reverse order to install a new or reconditioned control valve.
Groundsmaster® 300 Series
Page 5 - 43
Repairs
Lift Valve Repair (Fig. 36)
1. After removing the control valve assembly, wash the
valve in solvent and dry it thoroughly.
2. Carefully mount the control valve into a vise so that
the control valve mounting pads are against the jaws of
the vise. The control valve spool snap ring (Item 15)
should be facing up.
3. Remove the hex cap plug (Item 1) from the side of
the valve body. Within the valve body, beneath each hex
cap plug, there is a spring (Item 3), ball (Item 4) and cam
pin (Item 6); withdraw these parts.
4. Remove the snap ring (Item 15) from the spool
(Item 8). Carefully push and twist the spool to remove
the spool from the valve body.
5. Use a hooked scribe or thin screwdriver to remove
the O-rings from the inside bore of the valve body (be
careful not to scratch valve bore finish). These O-rings
are the seals for the spool itself. Inspect all components
for wear, paying special attention to the spool itself.
Signs of wear on one side of the spool may indicate a
bent spool. Inspect the spool for flatness and replace if
necessary.
6. After completing reassembly by reversing these procedures and after having installed new O-rings
and seals.
7. Prior to reassembly coat all the O-rings with oil to ease
assembly. Install the spool into the valve body before
inserting the cam pins, balls, springs and hex plugs.
Repairs
Page 5 - 44
Figure 36
Groundsmaster® 300 Series
Chapter 6
Electrical System
Table of Contents
WIRING SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . 2
Groundsmaster 345. . . . . . . . . . . . . . . . . . . . . . . 2
Groundsmaster 322-D/325-D . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TROUBLESHOOTING (Groundsmaster 345) . . . . . . . . . 6
Starting Problems . . . . . . . . . . . . . . . . . . . . . . . . 6
Operation Problems . . . . . . . . . . . . . . . . . . . . . . 9
Verify Interlock Operation . . . . . . . . . . . . . . . . . . 11
TROUBLESHOOTING (Groundsmaster 322-D/325-D) . . 12
Starting Problems . . . . . . . . . . . . . . . . . . . . . . . 12
Operation Problems . . . . . . . . . . . . . . . . . . . . . 15
Verify Interlock Operation . . . . . . . . . . . . . . . . . 17
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . 18
Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Traction (Neutral) Switch . . . . . . . . . . . . . . . . . . 20
PTO Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Starter Interlock Relay. . . . . . . . . . . . . . . . . . . . 21
Groundsmaster® 300 Series
Glow Plugs (Groundsmaster 322-D/325-D only) . . . . .
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Stop Solenoid
(Groundsmaster 322-D/325-D only) . . . . . . . . . . . . .
Fuel Stop Control Unit
(Groundsmaster 322-D/325-D only) . . . . . . . . . . . . .
Indicator Lights, Buzzers and Gauges. . . . . . . .
Temperature Relay . . . . . . . . . . . . . . . . . . . . . .
Temperature Gauge Sender . . . . . . . . . . . . . . .
Engine Oil Pressure Switch . . . . . . . . . . . . . . . .
Fuel Gauge Sending Unit . . . . . . . . . . . . . . . . .
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Service . . . . . . . . . . . . . . . . . . . . . . . . .
Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Traction (Neutral) Switch Replacement . . . . . . .
PTO Interlock Switch Replacement. . . . . . . . . .
Seat Switch Replacement . . . . . . . . . . . . . . . . .
Page 6 - 1
22
22
23
24
26
27
27
28
29
30
30
31
32
33
35
Table of Contents
Wiring Schematics
Groundmaster 345
(Serial Number less than 40000)
Wiring Schematics
Page 6 − 2
Rev. E
Groundsmaster 300 Series
Groundmaster 345
(Serial Number 40001 to 200999999)
Wiring Schematics
Page 6 − 2.1 Rev. E
Groundsmaster 300 Series
Wiring Schematics
7.5 A
15 A
F2
F3
GY
OR
OFF
BK
GY
N.C.
R
FL3
FL2
FL1
Page 6 − 2.2
Rev. E
ENGINE
GROUND
7.5 A
FRAME
GROUND
R
PK
W
B
R
L
BK = BLACK
GN = GREEN
BR = BROWN GY = GRAY
BU = BLUE
T = TAN
KEY TO WIRE COLORS
R = RED
Y = YELLOW
W = WHITE
PK
OR = ORANGE
PK = PINK
VIO = VIOLET
ALL MAIN HARNESS GROUND POINTS
MARKED AS BLACK WIRE ARE
CONNECTED TOGETHER AND TO
THE ENGINE GROUND
BATTERY
( )
ALTERNATOR
(+)
B
F4
B+
TIE POINT
ON STARTER
NEGATIVE BATTERY CABLE
B
PK
VIO
Y
OPTIONAL LIGHT
/ FUSE BLOCK
Y
S
A
START
RUN
POSITIVE BATTERY CABLE
GY
R
R
BU
X
BI
FUSIBLE LINK HARNESS
15 A
F1
87a
87
86
2
5
+8
7
1
3
4
6
BN
BN
ENGINE
BN
ENGINE OVER TEMP .
(TEMPERATURE OK)
HIGHTEMP OVERRIDE
(MOMENTARY)
(OFF)
GN
PK
TO OVER TEMP
SHUTDOWN RELAY
LGN = LIGHT GREEN
LBU = LIGHT BLUE
GN
30
85
OVER TEMP SHUT DOWN
PK
PK
( )
(+)
BK
HR
PK
OR
GN
G
L
BK
TEMP
I
PK PK
BK
BU
BU
Y
I
G
BK
L
PK PK
FUEL
GN
FUEL
SENDER
S
SEAT SWITCH
(OFF)
PTO SWITCH
(OFF)
TEMPERATURE
SENDER
ENGINE
Y
Y
S
OR
OR
BK
PK
PK
Y
F
GLOW
OIL
PRES
B
ALT
OVER
TEMP
E
A
GY
W
ENGINE
OIL PRESSURE SWITCH
(LOW PRESSURE)
GY
W
BN
PARKING BRAKE SWITCH
(ON)
W
Y
NEUTRAL SWITCH
(NEUTRAL)
GN
CLUSTER GAUGE
C
D
TO HIGH TEMP OVERRIDE SWITCH
(CONNECTED TO GROUND ON OVER TEMP CONDITION)
PK
PK
85
87
87a
87a
87
86
RUN ENABLE
30
85
R/BK
BK
BK
BU
22
3
IGNITION CONTROL
MODULE
SPARK 2&3
Y/W
Y/BK
R/LGN
6
LGN/R
SPARK COM 4
SPARK 1&4
COOLANT TEMP 18
GN/R
G/BK
MAP B 17
SENSOR COM 9
BR/W
Y/LGN
Y/LGN
LGNW
W/LBU
BK
R/LGN
2
MAP A 16
SPARK RETARD B 8
SPARK RETARD A 7
VRS
VRS+ 23
GROUND 10
FORD ENGINE HARNESS
POWER 11
3
7.5A
BK
BK
IGNITION COIL
TEMP SENSOR
MAP SENSOR
CRANK POSITION SENSOR
FUSE
R/LGN
R/BK
BK
ENGINE
FUEL SOLENOID
R/BK
BK
PROTECTION
DIODE (D1)
R/BK
BU
B+
Start
STARTER
GY+BK
BU
B+ TO FUSIBLE LINK HARNESS
CONTROL IGNITION DELAY MODULE
0.5 SECOND 1
4
OFF DELAY
R/BK
OR
W
86
30
START ENABLE
LOGIC
DIODE
(D2)
Y
VIO
Groundmaster 345
(Serial Number higher than 21000000)
Groundsmaster 300 Series
Groundmaster 322−D/325−D
(Serial Number less than 20000000)
Wiring Schematics
Page 6 − 3
Rev. E
Groundsmaster 300 Series
Wiring Schematics
15 A
F3
GY
BK
GY
N.C.
R
Page 6 − 3.1 Rev. E
FL3
FL2
FL1
()
R
PK
W
B
R
L
GN = GREEN
GY = GRAY
T = T AN
KEY TO WIRE COLORS
BK = BLACK
BR = BROWN
BU = BLUE
ENGINE
GROUND
7.5 A
BK
FRAME
GROUND
R = RED
Y = YELLOW
W = WHITE
GN
PK
OR = ORANGE
PK = PINK
VIO = VIOLET
ALL MAIN HARNESS GROUND POINTS
MARKED AS BLACK WIRE ARE
CONNECTED TOGETHER AND TO
THE ENGINE GROUND
BATTERY
BK
F4
B+
TIE POINT
ON STARTER
NEGATIVE BATTERY CABLE
ALTERNATOR
(+)
PK
VIO
Y
OPTIONAL LIGHT
/ FUSE BLOCK
Y
S
A
START
RUN
OFF
POSITIVE BATTERY CABLE
GY
R
R
BU
X
BI
FUSIBLE LINK HARNESS
7.5 A
OR
15 A
F2
F1
87
86
87a
3
4
6
7
BN
BN
LGN = LIGHT GREEN
LBU = LIGHT BLUE
BN
ENGINE OVER TEMP
(TEMPERATURE OK)
2
1
HIGHTEMP OVERRIDE
(MOMENTARY)
(OFF)
5
+8
TO OVER TEMP
SHUTDOWN RELAY
ENGINE
GN
PK
30
85
OVER TEMP SHUT DOWN
PK
PK
()
HR
(+)
PK
OR
GN
BK
G
BK
L
PK
TEMP
I
PK
BK
BU
BU
SEAT SWITCH
(OFF)
PTO SWITCH
(OFF)
TEMPERATURE
SENDER
ENGINE
Y
Y
S
OR
OR
I
G
BK
L
PK
FUEL
PK
FUEL
SENDER
S
Y
GN
BK
PK
PK
Y
W
Y
NEUTRAL SWITCH
(NEUTRAL)
F
GLOW
OIL
PRES
B
ALT
OVER
TEMP
E
A
GY
ENGINE
OIL PRESSURE
SWITCH
(LOW PRESSURE)
GY
W
BN
W
PARKING BRAKE SWITCH
(ON)
GN
CLUSTER GAUGE
C
D
TO HIGH TEMP OVERRIDE SWITCH
(CONNECTED TO GROUND ON OVER TEMP CONDITION)
PK
PK
R/BK
OR
W
86
30
85
87
22
IGNITION CONTROL
MODULE
Y/W
R/LGN
SPARK 2&3
3
SPARK COM 4
SPARK 1&4
Y/BK
LGN/R
GN/R
6
COOLANT TEMP 18
SENSOR COM 9
G/BK
BR/W
MAP A 16
MAP B 17
Y/LGN
Y/LGN
LGNW
W/LBU
BK
R/LGN
SPARK RETARD B 8
SPARK RETARD A 7
VRS
VRS+ 23
GROUND 10
POWER 11
2
1
R/LGN
BK
BK
IGNITION COIL
TEMP SENSOR
MAP SENSOR
CRANK POSITION SENSOR
FUSE (7.5A)
R/BK
R/BK
CONTROL IGNITION
DELAY MODULE
BK
BK
ENGINE
PROTECTION
DIODE (D1)
STARTER
B+
Start
FUEL SOLENOID
R/BK
BU
GY+BK
BU
B+ TO FUSIBLE LINK HARNESS
0.5 SECOND
OFF DELAY
R/BK
BK
BK
BU
FORD ENGINE HARNESS
3
4
87
86
87a
RUN ENABLE
30
85
START ENABLE
LOGIC
DIODE
(D2)
Y
VIO
87a
Groundmaster 345
(Serial Number higher than 21000000)
Groundsmaster 300 Series
Groundsmaster 300 Series
Page 6 − 3.2
B+I+A
B+I+S
2. RUN
3. START
BLACK
NONE
1. OFF
Rev. E
+
BATTERY
BLACK
CIRCUIT
POSITION
IGNITION SWITCH
CIRCUITRY
GLOW PLUGS
RED
X+Y
”MAKE”
F
S
RED
B
E L
N
PINK
GLOW PLUG
INDICATOR
VOLTAGE
REGULATOR
A G
STARTER
BLUE
PINK
BLACK
86
85
RED
PINK
GLOW PLUG
SWITCH
AMMETER
CIRCUIT BREAKER
40 AMP
(MANUAL RESET)
RELAY
BLACK
TAN
VIOLET
PINK
BLACK
FUEL LEVEL
FLOAT
YELLOW
30
87
+
RED
I
HOURMETER
X
BLUE
BLUE
BLACK
BLUE
BLUE
YELLOW
RED
RED
GREEN
WHITE
RED/WHT
SOLENOID
TEMP RELAY
FUSE
(SFE 14A)
LIGHT GREEN
WHITE
OIL PRESSURE
LIGHT
CONTROL UNIT
ASSEMBLY
TEMP SW GAUGE
WHITE
NEUTRAL SWITCH
(SWITCH CLOSED WITH
TRACTION PEDAL
IN NEUTRAL)
SEAT SWITCH
(SWITCH OPEN WITH
NO OPERATOR IN SEAT)
BLACK
OIL PRESSURE
BUZZER
BLACK
P.T.O. SWITCH
(SWITCH CLOSED WITH
P.T.O. DISENGAGED)
ORANGE
BROWN
BROWN
RED/WHT
GREEN
IGNITION SWITCH
(REAR VIEW)
BLACK
FUSE
(10 AMP AGC)
Y
INJECTION
PUMP
B
A
S
YELLOW
YELLOW
BLUE
RED
FUEL
PUMP
IGN
SEND
ALTERNATOR
BLUE
FUEL GAUGE
OIL PRESSURE
SWITCH
Groundmaster 322−D/325−D
(Serial Number less than 20000000)
Wiring Schematics
Wiring Schematics
Page 6 − 3.3
B+I+A
B+I+S
2. RUN
3. START
BLACK
NONE
1. OFF
Rev. E
+
BATTERY
BLACK
CIRCUIT
POSITION
IGNITION SWITCH
CIRCUITRY
GLOW PLUGS
RED
X+Y
”MAKE”
S
RED
B
E L
N
F
A G
PINK
GLOW PLUG
INDICATOR
VOLTAGE
REGULATOR
STARTER
BLUE
PINK
BLACK
86
85
RED
PINK
GLOW PLUG
SWITCH
AMMETER
CIRCUIT BREAKER
40 AMP
(MANUAL RESET)
RELAY
BLACK
TAN
VIOLET
PINK
BLACK
FUEL LEVEL
FLOAT
YELLOW
30
87
+
RED
I
HOURMETER
X
BLUE
BLUE
BLACK
BLUE
BLUE
YELLOW
RED
RED
GREEN
WHITE
RED/WHT
SOLENOID
TEMP RELAY
FUSE
(SFE 14A)
LIGHT GREEN
WHITE
CAPACITOR
RESISTOR
BLACK
WHITE
CONTROL UNIT
ASSEMBLY
TEMP SW GAUGE
NEUTRAL SWITCH
(SWITCH CLOSED WITH
TRACTION PEDAL
IN NEUTRAL)
ORANGE/
WHITE
SEAT
RELAY
OIL PRESSURE
LIGHT
SEAT SWITCH
(SWITCH OPEN WITH
NO OPERATOR IN SEAT)
BLACK
OIL PRESSURE
BUZZER
BLACK
P.T.O. SWITCH
(SWITCH CLOSED WITH
P.T.O. DISENGAGED)
ORANGE
BROWN
BROWN
RED/WHT
GREEN
IGNITION SWITCH
(REAR VIEW)
BLACK
FUSE
(10 AMP AGC)
Y
INJECTION
PUMP
B
A
S
YELLOW
YELLOW
BLUE
RED
FUEL
PUMP
IGN
SEND
ALTERNATOR
BLUE
FUEL GAUGE
OIL PRESSURE
SWITCH
Groundmaster 322−D/325−D
(Serial Number more than 20000000)
Groundsmaster 300 Series
Groundsmaster 300 Series
BK
GY
R
R
GY
R
R
GY
OR
Page 6 − 3.4
Rev. E
W
PK
R
BU
BK
BK
PK
VIO
Y
PK
PK
PK
PK
VIO
R
PK
PK
OR
VIO
OR
GN
OR
BN
BN
BK
BK
OR
OR
OR
PK
GN
GN
PK
OR
PK
PK
GN
BN
BN
BN
Y
BK
GN
PK
BK
Y
Y
Y
W
W
Y
BK
PK PK
OR
W
Y
VIO
BK
BU
BU
BK
PK PK
BK
PK
PK
R/BK
BK
BK
BU
R/BK
W
R/BK
GY&BK
BU
BU
OR
GY
GY
W
BN
BK
BK
W
BK
W
Groundmaster 328−D
Wiring Schematics
Special Tools
NOTE: Order special tools from the TO R O S P E C IA L
TO O L S A N D A P P L IC AT IO N S G U ID E (C O M M E R C IA L
P R O D U C T S ). Some tools may be available from a local
supplier.
Continuity Tester (Fig. 1)
Battery powered test lamp which is helpful in testing for
continuity of circuits and electrical components when
the current is off.
Figure 1
Volt - Ohm - Amp Meter (Fig. 2)
The meter can test electrical components and circuits
for current, resistance, or voltage draw.
Figure 2
Special Tools
Page 6 - 4
Groundsmaster® 300 Series
Skin-Over Grease (Fig. 3)
Special non-conductive grease which forms a light protective skin to help waterproof electrical switches and
contacts.
Figure 3
Groundsmaster® 300 Series
Page 6 - 5
Special Tools
Troubleshooting (Groundsmaster 345)
Study the operating characteristics preceding the electrical 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.
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.
Possible Causes and Corrections in the troubleshooting
charts should be checked in the order in which they are
listed.
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.)
If the machine being repaired has any interlock switches
by-passed, they must be reconnected for proper troubleshooting and safety.
Engine Starting Problems
Condition
Possible Cause
Correction
________________________________________________________________________________________________________________________________________________________
Starter solenoid clicks, but
engine will not crank. (If solenoid
clicks, problem is not in interlock
system.)
Troubleshooting (Groundsmaster 345)
Low battery charge
Charge battery. Replace battery if
it will not hold a charge.
Loose or corroded battery cables.
Loose or corroded ground.
Clean and tighten, or repair as
necessary.
Faulty wiring at starter.
Repair wiring.
Loose starter mounting bolts.
Clean mounting surface and
tighten bolts.
Faulty starter.
Repair or replace starter.
Faulty starter solenoid.
Replace starter solenoid.
Engine seized.
Repair engine.
Page 6 - 6
Groundsmaster® 300 Series
Starting Problems (continued)
Condition
Possible Cause
Correction
________________________________________________________________________________________________________________________________________________________
Nothing happens when start
attempt is made.
Groundsmaster® 300 Series
Battery is dead.
Charge battery. Replace battery if
it will not hold a charge.
Loose or corroded battery cables.
Loose or corroded ground.
Clean and tighten or repair as
necessary.
Fuse open.
Check fuse and replace if fuse is
open. If fuse burns out often, find
and correct cause.
Ammeter faulty.
Test ammeter and replace if faulty.
Ammeter wiring loose, corroded or
damaged.
Repair wiring.
Ignition switch faulty.
Test ignition switch. Replace if
faulty.
Ignition switch wiring loose,
corroded or damaged.
Repair wiring.
Traction neutral switch out of
adjustment or faulty.
Test switch and replace if faulty.
Make sure wires are connected
to “COMMON” and “NORMALLY
OPEN” (N.O.) terminals.
Traction neutral switch wiring
loose, corroded or damaged.
Repair wiring.
PTO switch out of adjustment or
faulty.
Test switch and adjust or replace
if faulty.
PTO switch wiring loose, corroded
or damaged.
Repair wiring.
Starter interlock relay wiring loose
corroded or damaged.
Repair wiring.
Starter interlock relay faulty.
Test relay and replaced if faulty.
Starter solenoid wires loose,
corroded or damaged.
Clean and tighten or repair as
necessary.
Starter solenoid faulty.
Test starter solenoid. Replace if
faulty.
Page 6 - 7
Troubleshooting (Groundsmaster 345)
Starting Problems (continued)
Condition
Possible Cause
Correction
________________________________________________________________________________________________________________________________________________________
Engine cranks, but does not start.
Engine wiring connector or wires
loose, corroded or damaged.
Repair wiring.
Temp. gauge switch faulty.
Test temp. gauge switch and
replace if faulty.
Temp. relay faulty.
Test temp. relay and replace if
faulty.
Temp. relay wiring faulty.
Repair wiring.
Engine, engine ignition, or fuel
system problem.
See Ford VSG-411/413 Engine
Service Manual.
________________________________________________________________________________________________________________________________________________________
Engine cranks (but should not)
with traction pedal out of neutral.
Traction neutral switch out of
adjustment or faulty.
Test switch and replace if faulty.
Make sure wires are connected
to “COMMON” and “NORMALLY
OPEN” (N.O.) terminals.
________________________________________________________________________________________________________________________________________________________
Engine cranks (but should not)
with PTO ON.
Troubleshooting (Groundsmaster 345)
PTO switch out of adjustment or
faulty.
Page 6 - 8
Test switch and adjust or replace
if faulty.
Groundsmaster® 300 Series
Operation Problems
Condition
Possible Cause
Correction
________________________________________________________________________________________________________________________________________________________
Engine continues to run (but
should not) when traction pedal is
depressed with no operator on
seat.
Seat switch plunger depressed
with no operator on seat.
Check for seat support spring
that is broken, missing or stuck in
down position.
Check for binding seat pivot
hinge.
Check for waterlogged seat.
Seat switch faulty or out of
adjustment.
Test seat switch. Adjust or
replace if faulty.
Traction neutral switch faulty or out
of adjustment.
Test switch, Adjust or replace if
faulty. Check for correct terminal
connections.
________________________________________________________________________________________________________________________________________________________
Engine kills when traction pedal
is depressed or PTO is engaged.
Operator sitting too far forward on
seat (seat switch not depressed).
Instruct operator.
Seat hinge, support pin or spring
binding, preventing seat switch
from closing.
Repair seat pivot and support.
Seat switch is faulty or out of
adjustment.
Test seat switch. Adjust or
replace if faulty.
Seat switch wiring loose, corroded
or damaged.
Repair wiring.
________________________________________________________________________________________________________________________________________________________
Battery does not charge.
Loose, corroded or broken wire(s).
Repair wiring.
Faulty alternator.
Test alternator and replace if
faulty.
Dead battery.
Charge battery. Replace battery if
it will not hold a charge.
________________________________________________________________________________________________________________________________________________________
Battery continuously charges at
high rate.
Groundsmaster® 300 Series
Regulator / rectifier faulty.
Page 6 - 9
Replace regulator / rectifier.
Troubleshooting (Groundsmaster 345)
Operation Problems (continued)
Condition
Possible Cause
Correction
________________________________________________________________________________________________________________________________________________________
Engine continues to run (but
should not) when PTO is ON with
no operator on the seat.
Seat switch plunger depressed
with no operator on seat.
Check for seat support spring
that is broken, missing or stuck in
down position.
Check for binding seat pivot
hinge.
Check for waterlogged seat.
Seat switch faulty or out of
adjustment.
Troubleshooting (Groundsmaster 345)
Page 6 - 10
Test seat switch. Adjust or
replace if faulty.
Groundsmaster® 300 Series
Verify Interlock System Operation
The machine has interlock switches in the electrical
system. These switches are designed to stop the engine
when operator gets off the seat while either the PTO
lever is engaged or traction pedal is depressed. However, operator may get off the seat while engine is
running. Although engine will continue to run if PTO
lever is disengaged and traction pedal is released, it is
strongly recommended that the engine be stopped before dismounting from the seat.
2. Sit on seat. Move PTO lever to ON position. With the
traction pedal in neutral position, try to start the engine.
The engine should not crank. If the engine cranks, there
is a malfunction in the interlock system that should be
corrected before beginning operation.
3. Sit on seat. Move PTO lever to OFF and depress the
traction pedal. Try to start the engine. The engine should
not crank. If the engine cranks, there is a malfunction in
the interlock system that should be corrected before
beginning operation.
CAUTION
Do not disconnect the interlock switches.
Check operation of switches daily to assure
interlock system is operating correctly. If a
switch is malfunctioning, replace it before
operating the machine. To ensure maximum
safety, replace all switches after every two
years or 1000 hours, whichever comes first.
CAUTION
Do not operate machine without implement
unless the PTO drive shaft is also removed.
4. Sit on seat and start the engine. Raise off the seat
and move the PTO lever to ON. The engine should stop
within 2 - 3 seconds. If the engine does not stop, there
is a malfunction in the interlock system that should be
corrected before beginning operation.
To check operation of interlock switches:
1. Drive the machine slowly to a large, relatively open
area. Lower cutting unit, stop the engine and apply
parking brake.
Groundsmaster® 300 Series
Page 6 - 11
Troubleshooting (Groundsmaster 345)
Troubleshooting (Groundsmaster 322-D/325-D)
Study the operating characteristics preceding the electrical 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.
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.
Possible Causes and Corrections in the troubleshooting
charts should be checked in the order in which they are
listed.
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.)
If the machine being repaired has any interlock switches
by-passed, they must be reconnected for proper troubleshooting and safety.
Starting Problems
Condition
Possible Cause
Correction
________________________________________________________________________________________________________________________________________________________
Starter solenoid clicks, but starter
will not crank. (If solenoid clicks,
problem is not in interlock
system.)
Low battery charge
Charge battery. Replace battery if
it will not hold a charge.
Loose or corroded battery cables.
Loose or corroded ground.
Clean and tighten, or repair as
necessary.
Faulty wiring at starter.
Repair wiring.
Loose starter mounting bolts.
Clean mounting surface and
tighten bolts.
Faulty starter.
Repair or replace starter.
Faulty starter solenoid.
Replace starter solenoid.
Engine seized.
Repair engine.
Troubleshooting (Groundsmaster 322-D/325-D)
Page 6 - 12
Groundsmaster® 300 Series
Starting Problems (continued)
Condition
Possible Cause
Correction
________________________________________________________________________________________________________________________________________________________
Nothing happens when start
attempt is made.
Groundsmaster® 300 Series
Battery is dead.
Charge battery. Replace battery if
it will not hold a charge.
Loose or corroded battery cables.
Loose or corroded ground.
Clean and tighten or repair as
necessary.
Circuit breaker open.
Reset circuit breaker. Correct
cause of open circuit breaker.
Ammeter faulty.
Test ammeter and replace if faulty.
Ammeter wiring Loose, corroded or
damaged.
Repair wiring.
Ignition switch faulty.
Test ignition switch. Replace if
faulty.
Ignition switch wiring loose,
corroded or damaged.
Repair wiring.
Traction neutral switch out of
adjustment or faulty.
Test switch and replace if faulty.
Make sure wires are connected
to “COMMON” and “NORMALLY
OPEN” (N.O.) terminals.
Traction neutral switch wiring
loose, corroded or damaged.
Repair wiring.
PTO switch out of adjustment or
faulty.
Test switch and adjust or replace
if faulty.
PTO switch wiring loose, corroded
or damaged.
Repair wiring.
Temp. gauge switch faulty.
Test temp. gauge switch and
replace if faulty.
Temp. relay faulty.
Test temp. relay and replace if
faulty.
Temp. relay wiring loose, corroded
or damaged.
Repair wiring.
Starter interlock relay wiring loose
corroded or damaged.
Repair wiring.
Starter interlock relay faulty.
Test relay and replaced if faulty.
Starter solenoid wires loose,
corroded or damaged.
Clean and tighten or repair as
necessary.
Starter solenoid faulty.
Test starter solenoid. Replace if
faulty.
Page 6 - 13
Troubleshooting (Groundsmaster 322-D/325-D)
Starting Problems (continued)
Condition
Possible Cause
Correction
________________________________________________________________________________________________________________________________________________________
Engine cranks, but does not start
(if engine cranks, cause of
problem is not in interlock
system).
Glow plugs not used properly
before starting.
Use glow plugs to pre-heat
engine cylinders before and
during cold starting. Hold glow
plug switch in ON position until
indicator glows red, or as
specified in Operator’s Manual
for ambient temperature. DO
NOT exceed 2 minutes of
continuous use.
Glow plug circuit malfunctioning.
Test glow switch, glow plug
indicator and glow plugs and
replace if faulty.
Check glow plug circuit wiring
and repair if loose, corroded or
damaged.
Fuel shut-off solenoid is IN (should
be OUT).
Engine or fuel system problem.
Check for voltage at solenoid
connector while cranking. If no
voltage, but solenoid is IN,
solenoid is faulty. If there is
voltage, control unit is faulty.
See Troubleshooting section of
Chapter 4 - Mitsubishi Diesel
Engine.
________________________________________________________________________________________________________________________________________________________
Engine cranks (but should not)
with traction pedal out of neutral.
Traction neutral switch out of
adjustment or faulty.
Test switch and replace if faulty.
Make sure wires are connected
to “COMMON” and “NORMALLY
OPEN” (N.O.) terminals.
________________________________________________________________________________________________________________________________________________________
Engine cranks (but should not)
with PTO ON.
PTO switch out of adjustment
or faulty.
Troubleshooting (Groundsmaster 322-D/325-D)
Page 6 - 14
Test PTO switch and adjust or
replace if faulty.
Groundsmaster® 300 Series
Operation Problems
Condition
Possible Cause
Correction
________________________________________________________________________________________________________________________________________________________
Engine continues to run (but
should not) when traction pedal is
depressed with no operator on
seat.
Check for seat support spring
that is broken, missing or stuck in
down position.
Seat switch plunger depressed
with no operator on seat.
Check for binding seat pivot
hinge.
Check for waterlogged seat.
Test seat switch. Adjust or
replace if faulty.
Seat switch faulty or out of
adjustment.
________________________________________________________________________________________________________________________________________________________
Engine kills when traction pedal
is depressed or PTO is engaged.
Operator sitting too far forward on
seat (seat switch not depressed).
Instruct operator.
Seat hinge, support pin or spring
binding, preventing seat switch
from closing.
Repair seat pivot and support.
Seat switch is faulty or out of
adjustment.
Test seat switch. Adjust or
replace if faulty.
Seat switch wiring loose, corroded
or damaged.
Repair wiring.
________________________________________________________________________________________________________________________________________________________
Battery does not charge.
Groundsmaster® 300 Series
Loose, corroded or damaged
wire(s).
Repair wiring.
Faulty alternator.
Check alternator belt tension.
Test alternator and replace if
faulty.
Dead battery.
Charge battery. Replace battery if
it will not hold a charge.
Page 6 - 15
Troubleshooting (Groundsmaster 322-D/325-D)
Operation Problems (continued)
Condition
Possible Cause
Correction
________________________________________________________________________________________________________________________________________________________
Engine continues to run (but
should not) when PTO is ON with
no operator on the seat.
Seat switch plunger depressed
with no operator on seat.
Check for seat support spring
that is broken, missing or stuck in
down position.
Check for binding seat pivot
hinge.
Check for waterlogged seat.
Seat switch faulty or out of
adjustment.
Test seat switch. Adjust or
replace if faulty.
________________________________________________________________________________________________________________________________________________________
Engine continues to run (but
should not) when ignition switch
is turned off.
Engine will not restart after manual
shut-down.
See listings under Starting
Problems.
10 AMP fuse open.
Replace fuse. Correct cause of
blown fuse.
Faulty wiring between ammeter
and control unit.
Repair wiring.
Ignition switch faulty.
Test ignition switch and replace if
faulty.
Faulty wiring between ignition
switch and control unit.
Repair wiring.
Fuel shut-off solenoid faulty.
Test fuel shut-ff solenoid. Adjust
or replace fuel shut-off solenoid if
faulty.
Fuel shut-off solenoid wiring faulty.
Repair wiring.
Control unit faulty.
Test control unit and replace if
faulty.
Troubleshooting (Groundsmaster 322-D/325-D)
Page 6 - 16
Groundsmaster® 300 Series
Verify Interlock System Operation
The machine has interlock switches in the electrical
system. These switches are designed to stop the engine
when operator gets off the seat while either the PTO
lever is engaged or traction pedal is depressed. However, operator may get off the seat while engine is
running. Although engine will continue to run if PTO
lever is disengaged and traction pedal is released, it is
strongly recommended that the engine be stopped before dismounting from the seat.
2. Sit on seat. Move PTO lever to ON position. With the
traction pedal in neutral position, try to start the engine.
The engine should not crank. If the engine cranks, there
is a malfunction in the interlock system that should be
corrected before beginning operation.
3. Sit on seat. Move PTO lever to OFF and depress the
traction pedal. Try to start the engine. The engine should
not crank. If the engine cranks, there is a malfunction in
the interlock system that should be corrected before
beginning operation.
CAUTION
CAUTION
Do not disconnect the interlock switches.
Check operation of switches daily to assure
interlock system is operating correctly. If a
switch is malfunctioning, replace it before
operating the machine. To ensure maximum
safety, replace all switches after every two
years or 1000 hours, whichever comes first.
Do not operate machine without implement
unless the PTO drive shaft is also removed.
4. Sit on seat and start the engine. Raise off the seat
and move the PTO lever to ON. The engine should stop
within 2 - 3 seconds. If the engine does not stop, there
is a malfunction in the interlock system that should be
corrected before beginning operation.
To check operation of interlock switches:
1. Drive the machine slowly to a large, relatively open
area. Lower cutting unit, stop the engine and apply
parking brake.
Groundsmaster® 300 Series
Page 6 - 17
Troubleshooting (Groundsmaster 322-D/325-D)
Testing
This section will define components, and the tests that
can be performed on those components, when those
parts are disconnected from the electrical system.
CAUTION
For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the
circuit (e.g. unplug the seat switch connector before
doing a continuity check).
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.
NOTE: Electrical troubleshooting of any 12 Volt power
connection can also be performed through voltage drop
tests without disconnection of the component.
Ignition Key Switch (Fig. 5)
The circuitry of the ignition switch is shown in the charts.
With the use of a continuity tester, the switch functions
may be tested to determine whether all circuits are being
completed while the key is moved to each position.
POSITION
CONTINUITY AMONG TERMINALS
Y
A
1.
X
OFF
NONE
I
B
S
Y
A
2.
X
ON
B+I+A
X+Y
I
B
S
Y
A
3.
START
X
B+I+S
I
B
S
Figure 5
Testing
Page 6 - 18
Groundsmaster® 300 Series
Seat Switch (Fig. 6, 7)
The seat switch is a normally open (N.O.) switch that
closes when the operator is on the seat. If the PTO
switch or traction switch is open and the operator raises
off the seat, the engine will stop.
1. Raise the seat to get access to the seat switch wiring
connector.
2. Disconnect the seat switch wiring connector and
install a continuity tester or ohm meter between the two
leads of the seat switch.
3. Lower the seat. The continuity tester should show no
continuity.
NOTE: Make sure the compression spring and pin holds
the 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 continuity as the seat approaches the bottom of its travel.
(See Replacing Seat Switch in Repairs section of this
chapter for replacement and adjustment procedures.)
Figure 6
(S/N Below 30001)
1. Connectors
2. Capscrew & locknut
3. Switch
4. Mounting bracket
Figure 7
(S/N 30001 and UP)
1. Seat switch
2. Seat support bracket
3. Connector
Groundsmaster® 300 Series
Page 6 - 19
4. Spring
5. Pin
Testing
Traction (Neutral) Switch (Fig. 8)
The traction switch is normally open and closes when
traction pedal is in neutral.
TRACTION
NEUTRAL SWITCH
IMPORTANT: The traction switch has three (3) ter­
minals. Make sure the wires are connected to the
“COMMON” and “N.O.” terminals.
Test switch by disconnecting wires from switch terminals and connecting a continuity tester across COMMON and N.O. terminals. With engine off, slowly push
traction pedal in forward and reverse direction while
watching continuity tester. There should be indications
that traction switch is opening and closing. Allow traction
pedal to return to neutral. There should be continuity
across the terminals. (See Replacing Traction Switch in
Repairs section of this chapter for replacement and
adjustment procedures.)
NOTE: Apply “Loctite 271” or equivalent to threads of
switch screws before installing.
Figure 8
PTO Switch (Fig. 9, 10)
The PTO switch is normally open and closes when the
PTO lever is pushed forward to ON position.
Test the switch by disconnecting the wires from the
switch terminals and connecting a continuity tester
across the terminals. With the PTO lever pushed forward (ON), there should be continuity across the terminals. With the PTO lever pulled back (OFF) there should
be no continuity across the terminals. (See Replacing
the PTO Switch in the Repairs section of this chapter for
replacement procedures).
Figure 9
(S/N Below 30001)
1. Connectors
2. PTO lever
3. Capscrew & locknut
4. Switch
5. Mounting bracket
6. Switch arm
7. 1/2 inch (13 mm)
Figure 10
(S/N 30001 and UP)
1. PTO switch
Testing
Page 6 - 20
Groundsmaster® 300 Series
Starter Interlock Relay (Fig. 11, 12, 13)
To test the relay (Fig. 11, Item 22 or Fig. 12, Item 42),
disconnect the relay wire connector and install a continuity tester between the relay terminals (terminals 30
and 87). The relay should make and break continuity at
terminals 30 and 87 as 12 V.D.C. is connected and
disconnected to terminal 85 with terminal 86 connected
to ground.
Figure 11
(Groundsmaster 345)
Figure 12
(Groundsmaster 322-D/325-D)
Figure 13
Groundsmaster® 300 Series
Page 6 - 21
Testing
Glow Plugs (Groundsmaster 322-D/325-D only)
See Chapter 4 - Diesel Engine.
Battery (Fig. 14, 15)
Use a hydrometer to test the battery. Charge the battery
if necessary (see Battery Service).
Electrolyte specific gravity
Fully charged: 1.250 - 1.280
Discharged: less than 1.240
Figure 14
(Groundsmaster 345)
1. Wing nuts
2. Hold down strap
3. Positive (+) terminal
4. Negative (–) terminal
Figure 15
(Groundsmaster 322-D/325-D)
1. Wing nuts
2. Hold down strap
Testing
Page 6 - 22
3. Positive (+) terminal
4. Negative (–) terminal
Groundsmaster® 300 Series
Fuel Stop Solenoid (Groundsmaster 322-D/325-D only) (Fig. 16)
Test the fuel stop solenoid by connecting the two solenoid lead wires to a 12 volt battery (fused at 10 AMPS).
When the battery is connected, the plunger of the solenoid should be activated (for replacement instructions
see Chapter 4 - Diesel Engine).
Figure 16
Groundsmaster® 300 Series
Page 6 - 23
Testing
Fuel Stop Control Unit (Groundsmaster 322-D/325-D only) (Fig. 17)
The control unit (Fig. 17, Item 27) is a solid-state timing
device that controls a fuel stop solenoid for shutting the
engine off with the ignition key switch.
To check operation of the control unit and fuel stop
solenoid, listen for an audible “click” when the key is
turned to the OFF position (after having been in the RUN
position), and then once again approximately 7 to 15
seconds after the key switch has been turned off. The
“clicking” should is made by the solenoid (on back of
injection pump). These sounds signify that the system
is functioning properly electrically.
Detailed testing of the control unit, alone, is provided in
the chart that follows. These tests must be performed
with the control unit installed in the machine and connected to the electrical system.
IMPORTANT: Testing the control unit by any other
method, especially when using a battery powered
meter or tester, may cause damage to the solid state
circuitry in the control unit.
Testing
Page 6 - 24
Figure 17
Groundsmaster® 300 Series
Groundsmaster® 300 Series
Page 6 - 25
Testing
Indicator Lights, Buzzers and Gauges
Test the indicator by disconnecting the wires and checking for continuity across the terminals.
Oil Pressure Light and Buzzer
Oil pressure lamp and buzzer should come on when the
ignition key switch is in the RUN position with the engine
not running or if the oil pressure switch closes during
operation - oil pressure below 7 psi (0.5 kg/cm2).
Hourmeter
Test the light and buzzer by disconnecting the wire from
oil pressure switch and grounding it against the engine.
The light and buzzer should come on when the wire is
grounded with the ignition switch in the ON position.
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 negative (–) battery terminal to the negative (–) terminal on
the alternator. The hourmeter should operate as
12 V.D.C. is applied between the terminals.
Ammeter
Engine Temperature Gauge and Fuel Level Gauge
Check the ammeter by comparing it to another ammeter. Replace it if it registers incorrectly.
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.
Glow Indicator (Groundsmaster 322-D/325-D only)
The glow indicator should glow red after holding the
glow plug switch on for approximately 20 seconds.
Testing
Page 6 - 26
Groundsmaster® 300 Series
Temperature Relay (Fig. 18)
The temperature relay (Fig. 18, Item 18) works with the
temperature gauge to disconnect battery voltage to the
ignition system (gas engine) or fuel shut stop control unit
(diesel engine) if the engine temperature gets too hot.
The B & C terminals of the temperature relay have a
normally closed connection between them. If there is no
continuity between terminals B & C check the SFE-14
fuse inside the relay box.
A coil resistance may be read on the ohmmeter between
terminals B & S. No resistance, indicates an open coil.
If the coil is open, replace the temperature relay device.
Figure 18
Temperature Gauge Sending Unit (Fig. 19)
The temperature gauge sending unit is located on the
top of the cylinder head, near the thermostat .
1. Lower the coolant level in the engine and remove the
temperature gauge sending unit located near engine
thermostat.
2. Put the sending unit in a container of oil with a
thermometer and heat the oil.
3. With an Ohm meter connected as shown, the resistance readings should changed as the temperature
increases (resistance should get lower as temperature
gets higher).
Figure 19
CAUTION
Handle hot oil with special care to prevent
personal injury or fire.
Groundsmaster® 300 Series
Page 6 - 27
Testing
Engine Oil Pressure Switch (Fig. 20)
The oil pressure switch is located on the cylinder block
and has a brown wire attached. The switch is normally
closed (NC) and opens with pressure.
Turn ignition key switch ON. Oil pressure lamp and
buzzer should be on.
If lamp and buzzer are not on:
1. Disconnect wire from oil pressure switch and touch
wire to a good ground, such as the engine block.
2. If lamp and buzzer come on, replace switch.
3. If lamp and buzzer do not come on check wiring
between switch, lamp and buzzer for continuity.
Figure 20
If lamp and buzzer are on with engine running:
1. Shut off engine immediately.
2. Check switch by disconnecting wire with ignition
switch in ON position. Light should go out.
3. If light is still on, check for short circuit in wiring.
4. Install test gauge in engine oil pressure switch port.
Start engine and check oil pressure. If engine oil pressure is good, replace switch. If engine pressure is low,
DO NOT operate the engine.
Testing
Page 6 - 28
Groundsmaster® 300 Series
Fuel Gauge Sending Unit (Fig. 21)
1. Remove the two wires from top of sending unity.
2. Loosen and remove screws securing sending unit to
fuel tank.
DANGER
Because fuel is flammable, caution must be
used when the sending unit is removed. Va­
pors may build up and be ignited by a spark
or flame source many feet away. Prevent
sparks and DO NOT smoke while working on
the fuel system, to avoid the possibility of an
explosion and personal injury.
3. Carefully remove sending unit from fuel tank.
Figure 21
4. Connect an ohmmeter (set on the R x 1 scale) across
the two terminals of the sending unit. As the float is
moved up and down, the resistance (in Ohms) will be
registered on the meter. The resistance should vary
between 90 and 0 Ohms.
5. If not change in the resistance is measured as the
float is moved up and down, the sending unit is faulty
and must be replaced.
6. Reverse steps 1 - 4 to install the sending unit.
Groundsmaster® 300 Series
Page 6 - 29
Testing
Repairs
IMPORTANT: Before welding on the machine, dis­
connect both battery cables from the battery and
disconnect the terminal connector from the alterna­
tor to prevent damage to the electrical system.
Battery Service (Fig. 22)
IMPORTANT: To prevent damage to electrical com­
ponents, do not operate the engine with the battery
cables disconnected.
Keep the terminals and entire battery case clean. To
clean the battery, wash the entire case with a solution
of baking soda and water. Rinse with clear water. Do not
get the soda solution into the battery because damage
to the battery will result. Coat the battery posts and cable
connectors with skin-over grease, or petroleum jelly to
prevent corrosion.
Reelmaster 345
Battery Specifications
BCI Group 24 Battery
370 Amp Cranking Performance at 0o F (17 o C)
45 min. Reserve Capacity at 80o F (27 o C)
Reelmaster 322-D/325-D
Battery Specifications
BCI Group 24 Battery
550 Amp Cranking Performance at 0o F (–17 o C)
140 min. Reserve Capacity at 80o F (27 o C)
Check for loose battery hold-downs. A loose 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 water only until the plates are covered and then
charge the battery. After charging, fill the battery to the
proper level.
Electrolyte Specific Gravity
Fully charged: 1.250 - 1.280
Discharged: less than 1.240
Figure 22
CAUTION
Do not charge a frozen battery because it can
explode and cause injury. Let the battery
warm to 60o F (16o C) before connecting to a
charger.
Charge the battery in a well-ventilated place
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.
Repairs
Page 6 - 30
Groundsmaster® 300 Series
Fuses and Circuit Breaker (Fig. Figure 23, 24)
Groundsmaster 345
An engine temperature reset relay fuse – SFE 14 AMP
– is located behind the reset relay. An inline fuse – SFE
14 AMP – protects the entire electrical system. Get
access to the fuses by removing the instrument panel
cover.
Groundsmaster 322-D/325-D
An engine temperature reset relay fuse – SFE 14 AMP
– is located behind reset relay. An inline fuse – AGC 10
AMP – protects the engine control module. Access to
the fuses can be gained by removing the instrument
panel cover.
A 40 AMP circuit breaker protects the entire electrical
system. A reset button is located on the lower side of the
instrument panel which can be reached after removal of
the battery cover. The button should be depressed if a
total loss of all electrical functions should occur.
Figure 23
(Groundsmaster 322-D shown)
1. SFE 14 AMP fuse – engine temp. reset relay
2. In-line fuse
3. Starter interlock relay
Figure 24
1. Circuit breaker reset button
Groundsmaster® 300 Series
Page 6 - 31
Repairs
Traction (Neutral) Switch Replacement (Fig. 25)
1. Remove the two wires that are connected to the
traction switch.
TRACTION
NEUTRAL SWITCH
2. Loosen two (2) screws and remove the switch.
3. Install new switch. DO NOT over-tighten screws as
the switch case could break.
NOTE: Apply “Loctite 271” or equivalent to threads of
switch screws before installing.
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.
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.
Figure 25
CAUTION
If the wires are not correctly installed to the
switch, the engine could start with the trac­
tion pedal in forward or reverse.
5. Coat the switch terminals and wires with skin-over
grease.
6. Check traction control neutral adjustment. (See Traction Control Neutral Adjustment in the Adjustments section of Chapter 4 - HYDRAULIC SYSTEM.
7. Actuate the pump lever to insure all parts are operating freely and seated properly.
8. Loosen jam nut. Rotate switch adjusting screw until
there is a gap between head of screw and switch button.
9. Rotate adjusting screw until it contacts the switch
button. Continue to rotate the screw until the circuit is
completed (switch “clicks”). After the switch clicks, rotate the adjusting screw an additional 1/2 turn. Tighten
jam nut.
Repairs
Page 6 - 32
Groundsmaster® 300 Series
PTO Switch Replacement (Fig. 26, 27)
Lever Type Switch (S/N Below 30001) (Fig. 26)
1. Disengage latches and remove instrument cover.
2. Disconnect negative battery cable from battery and
separate wire harness connectors.
3. Move PTO lever to the ON position and remove
capscrew and locknut holding switch against mounting
bracket.
4. Install new switch with capscrew and locknut. Move
PTO lever to OFF position. When lever is in its normal,
released position, the switch arm must bend about 1/2
inch (13 mm). If switch arm does not bend 1/2 inch
(13 mm), bend the mounting bracket to get the correct
adjustment.
5. Connect a continuity tester or ohm meter to switch
connector. With PTO lever in forward (ON) position, the
switch circuit should have no continuity. If there is continuity, check switch installation. If there is no continuity,
go to next step.
Figure 26
(S/N Below 30001)
1. Connectors
2. PTO lever
3. Capscrew & locknut
4. Switch
5. Mounting bracket
6. Switch arm
7. 1/2 inch (13 mm)
6. Move PTO lever to OFF position. When PTO lever is
in its normal, released position, the PTO switch should
have continuity. If there is no continuity, check switch
installation. If there is continuity, go to next step.
7. Liberally coat inside of wiring connectors with skinover grease. Push wire harness connectors together.
Connect negative battery cable to battery.
8. Install instrument cover and lock the latches.
Groundsmaster® 300 Series
Page 6 - 33
Repairs
Plunger Type Switch (S/N 30001 and UP) (Fig. 27)
1. Disengage latches and remove instrument cover.
2. Disconnect negative battery cable from battery.
3. Move PTO lever forward to ON position.
4. Disconnect PTO switch electrical connector.
5. Remove boot from button end of switch. Keep boot
for installation later.
6. Remove front jam nut securing switch to mounting
bracket and remove switch.
Figure 27
(S/N 30001 and UP)
1. PTO switch
7. Install new switch to mounting bracket. Adjust switch
so it is depressed 1/2" (13 mm) when PTO lever is
moved to OFF position. Tighten jam nuts to 75 in-lb.
Install rubber boot on switch.
IMPORTANT: Threads on PTO switch will be dam­
aged if jam nuts are over-tightened.
8. Connect a continuity tester or ohm meter to switch
connector. With PTO lever in forward (ON) position, the
switch circuit should have no continuity. If there is continuity, check switch installation. If there is no continuity,
go to next step.
9. Move PTO lever to OFF position. When PTO lever is
in its normal, released position, the PTO switch should
have continuity. If there is no continuity, check switch
installation. If there is continuity, go to next step.
10. Push switch connectors together.
11. Install instrument cover and lock the latches.
Repairs
Page 6 - 34
Groundsmaster® 300 Series
Seat Switch Replacement (Fig. 28, 29)
Lever Type Switch (S/N Below 30001) (Fig. 28)
1. Remove instrument cover and disconnect negative (–) battery cable from battery.
2. Pivot seat forward and secure with support rod to
prevent it from falling.
3. (4WD units only) Remove (4) flange screws and (2)
locknuts securing sealing plate to frame above fuel tank.
Remove sealing plate.
4. Disconnect electrical connectors for seat switch. Remove capscrew and locknut securing switch to mounting bracket.
5. To install new seat switch, set it on mounting bracket
and make sure locating pin on bottom of switch fits hole
in bracket. Secure switch in place with capscrew and
locknut.
6. Carefully lower seat, but do not sit on, or apply
pressure to the seat. There should be a slight gap
between the switch and seat plate.
Figure 28
(S/N Below 30001)
1. Connectors
2. Capscrew & locknut
3. Switch
4. Mounting bracket
7. Connect a continuity tester or ohm meter to switch
connector. With seat in down position and no one on
seat, the switch circuit should have no continuity. If there
is continuity, check switch installation. If there is no
continuity, go to next step.
8. Set on the seat. The seat switch should have continuity. If there is no continuity, check switch installation.
If there is continuity, go to next step.
9. Liberally coat inside of wiring connectors with skinover grease and push wire harness connectors together.
10. (4WD units only) Install sealing plate to frame above
fuel tank.
11. Disengage support rod lower the seat. Install lynch
pin through rod to hold seat in place. Connect negative
battery cable to battery.
Groundsmaster® 300 Series
Page 6 - 35
Repairs
Plunger Type Switch (S/N 30001 and UP) (Fig. 29)
1. Remove instrument cover and disconnect negative (–) battery cable from battery.
2. Pivot seat forward and secure with support rod to
prevent it from falling.
3. (4WD units only) Remove (4) flange screws and (2)
locknuts securing sealing plate to frame above fuel tank.
Remove sealing plate.
4. Remove boot from button end of seat switch. Keep
boot for installation later. Disconnect seat switch wiring
connector.
5. Remove top jam nut securing seat switch to mounting
bracket and remove switch.
6. Install new seat switch to support bracket. Adjust
switch height so it is 3/32" (2.4 mm) below top of spring
pin. Tighten jam nuts to 75 in-lb. Install rubber boot.
Figure 29
(S/N 30001 and UP)
1. Seat switch
2. Seat support bracket
3. Connector
4. Spring
5. Pin
IMPORTANT: Threads on seat switch will be dam­
aged if jam nuts are over-tightened.
7. Carefully lower seat, but do not sit on, or apply
pressure to the seat. There should be a slight gap
between the switch and seat plate.
8. Connect a continuity tester or ohm meter to switch
connector. With seat in down position and no one on
seat, the switch circuit should have no continuity. If there
is continuity, check switch installation. If there is no
continuity, go to next step.
9. Set on the seat. The seat switch should have continuity. If there is no continuity, check switch installation.
If there is continuity, go to next step.
10. Push switch connectors together.
11. (4WD units only) Install sealing plate to frame above
fuel tank.
12. Connect battery cable and install instrument cover.
Repairs
Page 6 - 36
Groundsmaster® 300 Series
Chapter 6A
For GM 345 (Serial Number above 21000000) and GM 328–D
Electrical System
Table of Contents
ELECTRICAL SCHEMATICS . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEM QUICK CHECKS . . . . . . . .
Battery Test (Open Circuit Test) . . . . . . . . . . . . . . .
Charging System Test . . . . . . . . . . . . . . . . . . . . . . . .
Glow Plug System Test (Groundsmaster 328–D) .
COMPONENT IDENTIFICATION AND TESTING . .
Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Temperature Override Switch . . . . . . . . . . . . .
Start Enable, Run Enable, Over Temperature
and Seat Delay (GM 328–D) Relays . . . . . . . . . .
Fuel Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fusible Link Harness . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
3
3
3
3
4
4
4
5
6
7
Diode Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Control Ignition Delay Module
(Groundsmaster 345) . . . . . . . . . . . . . . . . . . . . . . . 8
Glow Relay (Groundsmaster 328–D) . . . . . . . . . . . 8
Glow Controller (Groundsmaster 328–D) . . . . . . . 9
Run Solenoid (Groundsmaster 328–D) (Solenoid
with 3 Wire Connector) . . . . . . . . . . . . . . . . . . . . 10
Run Solenoid (Groundsmaster 328–D) (Solenoid
with 2 Wire Connector) . . . . . . . . . . . . . . . . . . . . . 11
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 12
Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Note: Only new information for Groundsmaster 345
machines with serial numbers above 21000000 and
Groundsmaster 328–D machines is provided in this
Chapter. See Chapter 6 – Electrical System for addition
al component identification and testing information.
Electrical Schematics
The electrical schematics for all Groundsmaster 300
models are provided in Chapter 6 – Electrical System.
Groundsmaster 300 Series
Page 6A – 1
Electrical System (Rev. G)
Special Tools
Digital Multimeter
The Digital Multimeter can test electrical components
and circuits for current, resistance, or voltage drop. Obtain Digital Multimeter from a local supplier.
Note: Toro recommends the use of a DIGITAL multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital meter will ensure
that excess current is not allowed through the meter. Excess current can cause damage to a circuit that is not designed to carry it.
Figure 1
Skin–Over Grease
Special non–conductive grease which forms a light protective skin to help waterproof electrical switches and
contacts.
Toro P/N 505–47 8 oz. (.24 L) can
Figure 2
Inductive Ammeter (AC/DC Current Transducer – Hall Effect)
Use this tool, connected to a Digital multimeter for doing
current draw tests. This tool can be useful when checking glow plug and starter circuits. Obtain the Inductive
Ammeter from a local supplier.
Electrical System (Rev. G)
Page 6A – 2
Groundsmaster 300 Series
Electrical System Quick Checks
Battery Test (Open Circuit Test)
Use a multimeter to measure the voltage between the
battery terminals.
Voltage Measured
Battery Charge Level
12.68 v (or higher)
Fully charged (100%)
Set the multimeter to the DC volts setting. The battery
should be at a temperature of 60o to 100o F (16o to 38o
C). The ignition key should be in the OFF position and
all accessories turned off. Connect the positive (+) meter lead to the positive battery post and the negative (–)
meter lead to the negative battery post. Use the table to
the right to determine charge level of the battery.
12.45 v
75% charged
12.24 v
50% charged
12.06 v
25% charged
11.89 v
0% charged
Note: This test provides a relative condition of the battery. Load testing of the battery will provide additional
and more accurate information.
Charging System Test
This is a simple test used to determine if the charging
system is functioning. It will tell you if the charging system has an output, but not its capacity.
Use a multimeter set to the DC volts position. Connect
the positive (+) meter lead to the positive battery post
and the negative (–) meter lead to the negative battery
post. Leave the multimeter test leads connected to the
battery and record the battery voltage.
Note: Upon starting the engine, the battery voltage
will drop and then should increase once the engine is
running.
After allowing the engine to run for at least three (3) minutes, battery voltage should be at least 0.5 volts higher
than initial battery voltage (see example in table to the
right).
Note: While engine is running, if battery voltage exceeds 16 volts, the regulator in the charging system
should be inspected.
After allowing the engine to run for at least three (3) minutes, if battery voltage does not increase at least 0.5
volts, additional testing of the battery and/or charging
system should be performed.
Note: Depending upon the condition of the battery
charge and battery temperature, the charging system
voltage will increase at different rates as the battery
charges.
Acceptable voltage increase:
Start the engine and run at high idle speed. Allow the
battery to charge for at least three (3) minutes. Record
the battery voltage.
Initial Battery Voltage
= 12.25 v
Battery Voltage after 3 Minute Charge
= 12.80 v
Difference
= +0.55 v
Glow Plug System Test (Groundsmaster 328–D)
This is a fast, simple test that can help to determine the
integrity and operation of the Groundsmaster 328–D
glow plug system. The test should be run anytime hard
starting (cold engine) is encountered on a diesel engine
equipped with a glow plug system.
ter pickup around the main glow plug power supply wire.
Adjust the meter to read zero (if applicable). Cycle the
glow plug system at least two times (per instructions in
Traction Unit Operator’s Manual) and record the final results.
Use a digital multimeter and/or inductive Ammeter (AC/
DC Current Transducer) set to the correct scale. With
the ignition switch in the OFF position, place the amme-
The Groundsmaster 328–D glow plug system should
have a reading of approximately 27 Amps. If low current
reading is observed, one (or more) glow plugs is faulty.
Groundsmaster 300 Series
Page 6A – 3
Electrical System (Rev. G)
Component Testing
Note: See Chapter 6 – Electrical System for additional
component identification and testing information. Only
new information for Groundsmaster 345 machines with
serial numbers above 21000000 and Groundsmaster
328–D machines is provided in this Chapter.
Seat Switch
The seat switch is normally open and closes when the
operator is on the seat. The switch is located directly under the seat (Fig. 3).
1
1. Make sure the engine and ignition switch are Off. Remove key from ignition switch.
2. Tilt operator seat up. Disconnect machine wire harness connector from seat switch.
3. Check the continuity of the switch by connecting a
multimeter (ohms setting) across the switch connector
terminals.
4
4. With no pressure on the seat cushion, there should be
no continuity between the switch terminals.
3
5. Press directly onto the seat switch through the seat
cushion. There should be continuity as the seat cushion
approaches the bottom of its travel.
6. Connect machine wire harness connector to seat
switch.
If switch removal is necessary, remove seat with sliders
from seat plate. Remove switch from bottom of seat.
2
Figure 3
1. Seat
2. Seat plate
3. Screw (2 used)
4. Seat switch
5. Switch harness
High Temperature Override Switch
The high temperature override switch is located on the
control console.
The switch terminals are marked as shown in Figure 4.
The circuitry of the switch is shown in the chart below.
With the use of a multimeter (ohms setting), the switch
functions may be tested to determine whether continuity
exists between the various terminals for each position.
Verify continuity between switch terminals.
SWITCH
POSITION
NORMAL
CIRCUITS
OTHER
CIRCUITS
ON
2+3
5+6
OFF
1+2
4+5
Electrical System (Rev. G)
Page 6A – 4
BACK OF SWITCH
Figure 4
Groundsmaster 300 Series
Start Enable, Run Enable, Over Temperature and Seat Delay (GM 328–D) Relays
Three (3) relays (start enable, run enable and over temperature) are used on the Groundsmaster 328–D and
Groundsmaster 345 to control engine operation. The
Groundsmaster 328–D uses an additional relay (seat
delay) to allow the engine to continue to run when the
operator lifts from the seat momentarily. The relays are
attached to a bracket under the instrument panel next to
the battery. These relays are identical. Refer to electrical
schematics in Chapter 6 – Electrical System for relay
identification.
86
87A
87
87
86
87A
85
30
85
30
Testing
Note: Prior to taking small resistance readings with a
digital multimeter, short the meter test leads together.
The meter will display a small resistance value (usually
0.5 ohms or less). This resistance is due to the internal
resistance of the meter and test leads. Subtract this value from the measured value of the component you are
testing.
Figure 5
1. Locate relay to be tested. Disconnect the machine
wire harness connector from the relay.
2. Using a multimeter (ohms setting), measure coil resistance between terminals 85 and 86 (Fig. 5). Resistance should be between 70 and 90 ohms.
3. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12
VDC to terminal 85. The relay should make and break
continuity between terminals 30 and 87 as +12 VDC is
applied and removed from terminal 85.
4. Disconnect voltage from terminal 85 and multimeter
lead from terminal 87.
5. Connect multimeter (ohms setting) leads to relay terminals 30 and 87A. Apply +12 VDC to terminal 85. The
relay should make and break continuity between terminals 30 and 87A as +12 VDC is applied and removed
from terminal 85.
6. Disconnect voltage and multimeter leads from the
relay terminals. Reconnect relay to machine wire harness.
Groundsmaster 300 Series
Page 6A – 5
Electrical System (Rev. G)
Fuel Sender
The fuel sender is located on top of the fuel tank.
Testing
1. Remove blue wire and black ground wire from the
sender.
CAUTION
FULL POSITION
If testing circuit wiring and fuel gauge, make sure
wire connections are secure before turning ignition switch ON to prevent an explosion or fire
from sparks.
EMPTY POSITION
2. To test the circuit wiring and fuel gauge, connect blue
and black wires and turn ignition switch to ON. Fuel
gauge needle should point to the right edge of the green
area (full). Turn ignition switch OFF and continue testing
fuel sender if circuit wiring and gauge are acceptable.
3. Remove five (5) screws that secure the sender to the
fuel tank.
Figure 6
4. Remove sender and gasket from the fuel tank. Clean
any fuel from the sender.
Note: Before taking small resistance readings with a
digital multimeter, short meter test leads together. The
meter will display a small resistance value. This internal
resistance of the meter and test leads should be subtracted from the measured value of the component.
CAUTION
Make sure sending unit is completely dry (no fuel
on it) before testing. Perform test away from the
tank to prevent an explosion or fire from sparks.
5. Check resistance of the sender with a multimeter
(Fig. 6).
A. Resistance with the float in the full position should
be 27.5 to 39.5 ohms.
B. Resistance with the float in the empty position
should be 240 to 260 ohms.
6. Replace sender as necessary. Reinstall sender into
fuel tank.
7. Reconnect wires to fuel sender. Apply skin–over
grease (Toro Part No. 505–47) to sender terminals.
Electrical System (Rev. G)
Page 6A – 6
Groundsmaster 300 Series
Fusible Link Harness
The Groundsmaster 328–D and Groundsmaster 345
use three (3) fusible links for circuit protection. These
fusible links are located in a harness that connects the
starter B+ terminal to the main wire harness. If any of
these links should fail, current to the protected circuit will
cease. Refer to wire harness drawings in Chapter 6 –
Electrical System for additional fusible link information.
FUSIBLE LINK
FUSIBLE LINK
FUSIBLE LINK
Use a multimeter to make sure that continuity exists between each terminal pin in connector P1 and connector
J1 at the starter (Fig. 7). If any of the fusible links are
open, replace the complete harness.
Figure 7
Diode Assembly
Two (2) diode assemblies (Fig. 8) are used in the machine wire harness. Diode D1 is used for circuit protection from inductive voltage spikes that occur when the
starter motor is shut off. Diode D2 provides logic for the
interlock switches to allow the engine to run when the
traction pedal is in neutral and the PTO switch is off. The
diodes plug directly into the wiring harness.
2
Testing
3
1
The diodes can be individually tested using a digital
multimeter (diode test or ohms setting) and the table below.
Multimeter
Red Lead (+)
on Terminal
Multimeter
Black Lead (–)
on Terminal
Continuity
Female
Male
YES
Male
Female
NO
Groundsmaster 300 Series
1. Diode
2. Male terminal
Page 6A – 7
Figure 8
3. Female terminal
Electrical System (Rev. G)
Control Ignition Delay Module (Groundsmaster 345)
The control ignition delay module on the Groundsmaster 345 is one of the components in the interlock system.
Whenever the run enable relay is energized, the control
ignition delay module is energized and allows current to
the engine ignition control module. If the run enable
relay is de–energized (e.g. operator gets off the seat),
the control ignition delay module will de–energize after
.5 second and will cause the engine to stop running as
power to the engine ignition control module is shut off.
The module is attached to a bracket under the instrument panel next to the battery.
5. Connect a second jumper lead to module terminal
P1–3 and touch terminal P1–4. The multimeter display
should show 12 VDC as long as the jumper is connected
to P1–4.
6. Disconnect the jumper wire from module wire connector J1 while watching the multimeter display. The
meter should show 0 VDC after .5 seconds.
P1–3
Testing
P1–2
1. Locate control ignition delay module. Unplug wire
harness connectors from module.
P1–4
P1–1
2. Connect multimeter (DC volts setting) leads to module terminals P1–2 (meter + lead) and P1–1 (meter –
lead) (Fig. 9).
3. Connect a jumper lead from module terminal P1–4
to module wire connector J1.
J1
4. Using a 12 VDC power source, apply +12 VDC to terminal P1–3 and ground terminal P1–1.
Figure 9
Glow Relay (Groundsmaster 328–D)
The Groundsmaster 328–D (diesel engine) uses a relay
to energize the engine glow plugs. This glow relay is attached to the frame below the radiator assembly.
86
87
85
30
87
Testing
1. Verify coil resistance between terminals 86 and 85
with a multimeter (ohms setting) (Fig. 10). Resistance
should be from 41 to 51 ohms.
2. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12
VDC to terminal 85. The relay should make and break
continuity between terminals 30 and 87 as +12 VDC is
applied and removed from terminal 85.
85
86
30
Figure 10
3. Disconnect voltage and leads from the terminals.
Electrical System (Rev. G)
Page 6A – 8
Groundsmaster 300 Series
Glow Controller (Groundsmaster 328–D)
The glow controller used on the Groundsmaster 328–D
(diesel engine) is located under the instrument panel.
Note: Refer to Groundsmaster 328–D electrical schematic in Chapter 6 – Electrical System when troubleshooting the glow controller circuit.
Controller Operation
1. When the ignition switch is placed in the RUN position, the controller energizes the glow plugs and lights
up the glow lamp for approximately 6 seconds.
2. When the ignition switch is held in the START position, the glow plugs will energize while the switch is held
in START and the glow lamp will not light.
3. When the ignition switch is released from START to
RUN, the glow plugs will de–energize and the glow lamp
will remain off.
5. If any of the conditions in Step 3 are not met or power
to terminal 1 exists and any of the other conditions in
Step 4 are not met:
A. Verify continuity of the circuitry from the battery to
the glow relay and glow plugs (see Groundsmaster
328–D electrical schematic in Chapter 6 – Electrical
System).
B. Verify continuity of the circuitry from the battery to
ignition switch, glow controller, glow lamp, glow relay
and ground (see Groundsmaster 328–D electrical
schematic in Chapter 6 – Electrical System).
C. Replace parts as necessary.
6. Connect electrical connector to the fuel stop solenoid.
2
Controller Checks
1. Make sure there is power from the battery.
3
6
2. Disconnect electrical connector to the fuel stop solenoid to prevent the engine from starting.
2
5
1
4
3. Place ignition switch in the RUN position. Verify the
following while in the RUN position:
A. Glow indicator lamp is on.
1
B. Glow relay is energized.
3
C. Glow plugs are energized.
D. Glow indicator lamp goes out and glow plugs de–
energize after approximately 6 seconds.
Figure 11
1. Glow controller end view
2. Top view
3. Side view
4. Place ignition switch in the START position. Verify
the following while in the START position:
A. Glow indicator lamp is out.
B. Glow relay is energized.
C. Glow plugs are energized.
D. Power exists at terminal 1 of the glow controller.
Note: If there is no power to terminal 1 of the glow controller, verify continuity of the circuitry from the ignition
switch to the glow controller and perform Step 4 again
(see Groundsmaster 328–D electrical schematic in
Chapter 6 – Electrical System).
Groundsmaster 300 Series
Page 6A – 9
Electrical System (Rev. G)
Run Solenoid (Groundsmaster 328–D) (Solenoid With 3 Wire Connector)
The run (ETR) solenoid must be energized for the engine to run. The solenoid is mounted on the engine block
near the injection pump.
4. Touch a negative (-) test lead from the 12 VDC
source to the pin of the black wire. The solenoid should
engage making an audible ”click”.
In Place Testing
5. Remove positive (+) voltage from the pin of the white
wire. The solenoid should stay engaged.
Note: Prior to taking small resistance readings with a
digital multimeter, short the test leads together. The meter will display a small resistance value (usually 0.5
ohms or less). This resistance is due to the internal resistance of the meter and test leads. Subtract this value
from from the measured value of the component you are
testing.
6. Remove positive (+) voltage from the pin of the red/
black wire. The solenoid should release.
7. Reconnect the wires to the solenoid.
1. Disconnect the wire harness connector from the solenoid.
5
2. Using a digital multimeter, touch one lead to the pin
of the black wire and the other lead to the pin of the
white wire. The resistance of the pull coil should be
about 0.33 ohms.
3. Using a digital multimeter, touch one lead to the pin
of the black wire and the other lead to the pin of the red/
black wire. The resistance of the hold coil should be
about 12.2 ohms.
4. Connect solenoid to the wiring harness.
6
3
4
2
1
Figure 12
1. Cap screw
2. Fuel stop solenoid
3. Gasket
4. Common (black wire)
5. Hold coil (red/black wire)
6. Pull coil (white wire)
Live testing
1. Disconnect the wire harness connector from the solenoid.
Note: The solenoid may be removed from the engine
or tested in place.
2. If the solenoid is removed from the engine, make
sure that the solenoid plunger moves freely and is free
of dirt, debris and corrosion.
3. Connect a positive (+) test lead from a 12 VDC
source to the pins of the red/black and white wires.
Electrical System (Rev. G)
Page 6A – 10
Groundsmaster 300 Series
Run Solenoid (Groundsmaster 328–D) (Solenoid With 2 Wire Connector)
The run (ETR) solenoid must be energized for the engine to run. The solenoid is mounted on the engine block
near the injection pump.
In Place Testing
Note: Prior to taking small resistance readings with a
digital multimeter, short the test leads together. The meter will display a small resistance value (usually 0.5
ohms or less). This resistance is due to the internal resistance of the meter and test leads. Subtract this value
from from the measured value of the component you are
testing.
4. Touch a negative (–) test lead from the 12 VDC
source to the fuel stop solenoid frame (ground) (Fig. 13).
The solenoid should engage, making an audible “click,”
and the plunger should retract.
5. Remove positive (+) voltage from the pull coil terminal. The solenoid should stay engaged.
6. Remove positive (+) voltage from the hold coil terminal. The solenoid should release.
7. Connect the wire harness connector to the run solenoid.
1. Disconnect machine wire harness connector from
solenoid.
2
1
2. Using a digital multimeter, touch one test lead to the
pull coil terminal and the other test lead to the fuel stop
solenoid frame (ground) (Fig. 13). The resistance of the
pull coil should be less than 1 ohm (but not zero).
3. Using a digital multimeter, touch one test lead to the
hold coil terminal and the other test lead to the fuel stop
solenoid frame (ground) (Fig. 13). The resistance of the
hold coil should be approximately 15 ohms.
4. Connect solenoid to the machine wire harness.
3
Figure 13
1. Fuel stop solenoid
2. Pull coil terminal
3. Hold coil terminal
Live testing
1. Disconnect wire harness connector from run solenoid.
Note: The solenoid may be removed from the engine
or tested in place.
2. If the solenoid is removed from the engine, make
sure that the solenoid plunger moves freely and is free
of dirt, debris and corrosion.
Note: When testing run solenoid, use test leads with
at least 14 gauge wire.
3. Connect a positive (+) test lead from a 12 VDC
source to the pull coil and hold coil terminals.
Groundsmaster 300 Series
Page 6A – 11
Electrical System (Rev. G)
Service and Repairs
Battery Service
The battery is the heart of the electrical system. With
regular and proper service, battery life can be extended.
Additionally, battery and electrical component failure
can be prevented.
Inspection, Maintenance and Testing
1. Perform the following inspection and maintenance
tasks:
A. Check for cracks caused by overly tight or loose
hold–down clamp. Replace battery if cracked and
leaking.
Note: Battery information for all Groundsmaster
322/325 machines and Groundsmaster 345 machines
with serial number below 21000000 is included in Chapter 6.
B. Check battery terminal posts for corrosion. Use
a terminal brush to clean corrosion from the battery
terminal posts.
Electrolyte Specific Gravity
Fully charged: 1.265 corrected to 80o F (26.7o C)
Discharged: less than 1.240
Battery Specifications Groundsmaster 328–D
BCI Group 24
660 Amp Cranking Performance at 0o F (–17.8o C)
110 Minute Reserve Capacity at 80o F (26.7o C)
Battery Specifications Groundsmaster 345
BCI Group 24
420 Amp Cranking Performance at 0o F (–17.8o C)
67 Minute Reserve Capacity at 80o F (26.7o C)
IMPORTANT: Before cleaning the battery, tape or
block the vent holes to the filler caps and make sure
the caps are on tightly.
FILLER CAPS
CAP TUBES
CORRECT
WATER
LEVEL
COVER SEAL
CAUTION
Figure 14
Wear safety goggles and rubber gloves
when working with electrolyte. Charge
the battery in a well ventilated so gases
produced while charging can dissipate.
Since the gases are explosive, keep open
flame and electrical spark away from the
battery; do not smoke. Nausea may
result if the gases are inhaled. Unplug
charger from electrical outlet before connecting to, or disconnecting charger
leads from battery posts.
Electrical System (Rev. G)
C. Check for signs of wetness or leakage on the top
of the battery which might indicate a loose or missing filler cap, overcharging, loose terminal post or
overfilling. Also, check the battery case for dirt and
oil. Clean the battery with a solution of baking soda
and water, then rinse it with clean water.
D. Check that the cover seal is not broken away.
Replace the battery if the seal is broken or leaking.
E. Check the electrolyte level in each cell. If the level is below the tops of the plates in any cell, fill all
cells with distilled water to the bottom of the cap
tubes. Charge at 15 to 25 amps for 15 minutes to allow sufficient mixing of the electrolyte.
Page 6A – 12
Groundsmaster 300 Series
2. Conduct a hydrometer test of the battery electrolyte.
A. Check the voltage across the battery terminals
prior to testing the battery. If the voltage is less than
12.0 VDC, recharge the battery.
IMPORTANT: Make sure the area around the cells is
clean before opening the battery caps.
B. If the battery has been charged, apply a 150 amp
load for 15 seconds to remove the surface charge.
Use a battery load tester following the manufacturer’s instructions.
A. Measure the specific gravity of each cell with a
hydrometer. Draw electrolyte in and out of the
hydrometer barrel prior to taking a reading to warm–
up the hydrometer. At the same time take the temperature of the cell.
C. Make sure the battery terminals are free of corrosion.
B. Temperature correct each cell reading. For each
10o F (5.5o C) above 80 F (26.7o C) add 0.004 to the
specific gravity reading. For each 10o F (5.5o C) below 80o F (26.7o C) subtract 0.004 from the specific
gravity reading.
Example:
Cell Temperature 100o F
Cell Gravity
ADD (20o above 80o F)
Correction to 80o F
D. Measure the temperature of the center cell.
E. Connect a battery load tester to the battery terminals following the manufacturer’s instructions. Connect a digital multimeter to the battery
terminals.
1.245
0.008
1.253
C. If the difference between the highest and lowest
cell specific gravity is 0.050 or greater or the lowest
cell specific gravity is less than 1.225, charge the
battery. Charge at the recommended rate and time
given in Charging or until specific gravity of all cells
is 1.225 or greater with the difference in specific
gravity between the highest and lowest cell less
than 0.050. If these charging conditions can not be
met, replace the battery.
F. Apply a test load of one half the Cranking Performance rating of the battery for 15 seconds.
G. Take a voltage reading at 15 seconds, then remove the load.
H. Using the table below, determine the minimum
voltage for the cell temperature reading.
Minimum
Voltage
3. Perform a high–discharge test with an adjustable
load tester.
This is one of the most reliable means of testing a battery
as it simulates the cold–cranking test. A commercial battery load tester is required to perform this test.
CAUTION
Follow the manufacturer’s instructions when
using a battery load tester.
Groundsmaster 300 Series
Page 6A – 13
Battery Electrolyte
Temperature
9.6
70o F (and up)
21.1o C (and up)
9.5
60o F
15.6o C
9.4
50o F
10.0o C
9.3
40o F
4.4o C
9.1
30o F
–1.1o C
8.9
20o F
–6.7o C
8.7
10o F
–12.2o C
8.5
0o F
–17.8o C
I. If the test voltage is below the minimum, replace
the battery. If the test voltage is at or above the minimum, return the battery to service.
Electrical System (Rev. G)
Charging
CAUTION
To minimize possible damage to the battery and allow
the battery to be fully charged, the slow charging method is presented here. This charging method can be accomplished with a constant current battery charger
which is available in most shops.
Do not charge a frozen battery because it
can explode and cause injury. Let the battery warm to 60o F (15.5o C) before connecting to a charger.
CAUTION
Charge the battery in a well–ventilated
place to dissipate gases produced from
charging. These 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 battery
posts.
Follow the manufacturer’s instructions when
using a battery charger.
1. Determine the battery charge level from either its
open circuit voltage or specific gravity.
Battery Charge
Level
Open Circuit
Voltage
Specific
Gravity
100%
12.68
1.265
75%
12.45
1.225
50%
12.24
1.190
25%
12.06
1.155
0%
11.89
1.120
3. Following the manufacturer’s battery charger
instructions, connect the charger cables to the battery.
Make sure a good connection is made.
4. Charge the battery following the manufacturer’s
battery charger instructions.
2. Determine the charging time and rate using the
manufacturer’s battery charger instructions or the
following table.
Reserve
Capacity
(Minutes)
Battery Charge Level
(Percent of Fully Charged)
75%
50%
25%
0%
80 or less
3.8 hrs
at
3 amps
7.5 hrs
at
3 amps
11.3 hrs
at
3 amps
15 hrs
at
3 amps
81 to 125
5.3 hrs
at
4 amps
10.5 hrs
at
4 amps
15.8 hrs
at
4 amps
21 hrs
at
4 amps
126 to
170
5.5 hrs
at
5 amps
11 hrs
at
5 amps
16.5 hrs
at
5 amps
22 hrs
at
5 amps
171 to
250
5.8 hrs
at
6 amps
11.5 hrs
at
6 amps
17.3 hrs
at
6 amps
23 hrs
at
6 amps
above
250
6 hrs
12 hrs
18 hrs
24 hrs
at
at
at
at
10 amps 10 amps 10 amps 10 amps
Electrical System (Rev. G)
5. Occasionally check the temperature of the battery
electrolyte. If the temperature exceeds 125o F (51.6o C)
or the electrolyte is violently gassing or spewing, the
charging rate must be lowered or temporarily stopped.
6. Three hours prior to the end of the charging, measure the specific gravity of a battery cell once per hour.
The battery is fully charged when the cells are gassing
freely at a low charging rate and there is less than a
0.003 change in specific gravity for three consecutive
readings.
Page 6A – 14
Groundsmaster 300 Series
Chapter 7
Differential Axle
Table of Contents
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . .
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . .
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Removal and Installation . . . . . . . . . . . . . . .
1
2
3
3
Axle Shaft Disassembly
and Wheel Bearing Service . . . . . . . . . . . . . . . . . 4
Differential and Housing Disassembly. . . . . . . . . 8
Differential and Housing Reassembly . . . . . . . . 14
Introduction
Groundsmaster® 300 Series traction units are equipped
with a Dana Hydrostatic Axle, model GT-20. The differential and axle form the final drive of the power train
(Fig. 1A).
The differential has a heavy duty case with automotive
type, cut gears that rotate on tapered roller bearings.
Single-row, pre-set, tapered roller bearings are used on
the outside ends of the axle shafts.
The entire drive line of the axle assembly is made of
alloy steel. The axle has a die-cast aluminum housing
that also serves as the hydraulic oil reservoir.
Power is transmitted from the transmission output gear
to the pinion spur gear. The pinion spur gear transmits
power directly to the differential drive gears, to turn the
axles and the wheels.
The differential axle has a one-piece axle shaft with the
flange being part of the axle stem (Fig. 1B).
Figure 1A
Figure 1B
Groundsmaster® 300 Series
Page 7 - 1
Introduction
Specifications
Item
Specification
__________________________________________________________________________________________
Front wheel lug nut torque
45 to 55 ft-lb
________________________________________________________________________________________________________________________
________________________________
Front to rear housing torque
18 to 28 ft-lb
________________________________________________________________________________________________________________________
________________________________
Transmission to axle torque
25 to 30 ft-lb
________________________________________________________________________________________________________________________
________________________________
Differential bearing caps torque
30 to 45 ft-lb
________________________________________________________________________________________________________________________
________________________________
Ring gear to differential case torque
45 to 65 ft-lb
________________________________________________________________________________________________________________________
________________________________
Fill pipe torque
20 to 30 ft-lb
________________________________________________________________________________________________________________________
________________________________
Side plate (gear cover) torque
25 to 40 in-lb
________________________________________________________________________________________________________________________
________________________________
Axle shaft bearing retainer (nut) torque
With hex head screw
With socket head screw (newer models)
37 to 45 ft-lb
16 to 20 ft-lb
________________________________________________________________________________________________________________________
________________________________
Ring gear to pinion gear backlash
0.003 to 0.007 in.
________________________________________________________________________________________________________________________
________________________________
Pinion gear end play
0.00 to 0.005 in.
Special Tools
NOTE: Order special tools from the TORO SPECIAL
TOOLS AND APPLICATIONS GUIDE (COMMERCIAL
PRODUCTS). Some tools may be listed in the Parts
Catalog for your Toro equipment. Some tools may also
be available from a local supplier.
Differential Gear Holder
Remove gear cover from right hand side of differential
and bolt this tool in place to lock spur gear in position
when removing nut that secures drive shaft flange for
4WD drive shaft.
Figure 2
Special Tools
Page 7 - 2 Rev. A
Groundsmaster® 300 Series
Repairs
Axle Removal and Installation
1. Put machine on a level surface, lower cutting unit,
stop the engine and remove key from ignition switch.
Block rear wheels to prevent machine from moving.
2. Remove the cutting unit. (See the Repairs section of
Chapter 11 - Cutting Units.)
3. If unit is equipped with 4WD, remove rear axle drive
shaft (see Chapter 9 - 4WD Rear Axle).
4. Remove hydrostatic transmission. (See Repairs section of Chapter 5 - Hydraulic System.)
5. Slightly loosen all front wheel lug nuts. Jack both front
wheels off the ground and install jackstands or blocks
under traction unit frame (not axle tubes) to prevent
machine from falling. Remove both front wheels.
Figure 3A
6. Remove extension spring and clevis pin to disconnect
brake cable from brake actuating lever on each brake.
7. Remove capscrew securing axle support bracket to
top of differential. Loosen nuts securing axle support
bracket to frame (Fig. 3A).
8. Put a jack or blocking under differential to hold it in
place. Remove capscrews and locknuts securing axle
mounting pads to frame. Note number of shims between
frame and axle mounting pad, which are used to get
correct engine to transmission alignment (Fig. 3B).
Carefully lower axle and pull it out from under traction unit.
Figure 3B
9. If unit is equipped with 4WD, remove nut (Fig. 3C,
Item 20), washer (Item 21) and flange (Item 22) from
differential axle pinion (Item 8). Use Differential Gear
Holder tool to gears when removing nut.
NOTE: Before installing flange (for 4WD drive shaft),
apply Permatex No. 2 to external splines of pinion and
internal splines of flange. Tighten lock nut to secure
pinion coupler 75 - 90 ft-lb (102 - 122 N-m).
10. To install axle, reverse steps 1 - 9. Leave axle
mounting pad nuts loose. Install shims (P/N 42-6080)
between axle mounting pads and frame to get correct
engine to transmission alignment, then tighten axle
mounting nuts.
Figure 3C
Groundsmaster® 300 Series
Page 7 - 3 (Rev. F)
Repairs
Axle Shaft Disassembly and Wheel Bearing Service
NOTE: When servicing the bearing and seal area of the
axle shaft, it is recommended that you replace hex head
screws and flange nuts with socket head screws (946934), washers (94-6936) and nuts (94-6935). See
Figure 18.
1. After the wheel has been removed, slide the brake
drum off of the axle flange (Fig. 5).
NOTE: It may be necessary to loosen the brake shoes
by turning the star wheel inside the brake drum assembly. (See Chapter 7 - Steering and Brakes.)
Figure 5
2. Line up the hole in the axle shaft flange and remove
the backing plate nuts which hold the axle shaft assembly to the axle housing. Use a 1/2 inch socket wrench
(Fig. 6).
Figure 6
3. Pull out the axle shaft and brake assembly (Fig. 7).
NOTE: Bearing races and retainer ring are cemented
together with an epoxy adhesive. If the bearing and race
come apart, remove the bearing cup from the housing
with a puller.
Figure 7
Repairs
Page 7 - 4 Rev. A
Groundsmaster® 300 Series
4. Remove the inner axle shaft seal (Fig. 8). Discard the
seal and replace with a new one at the time of assembly.
Figure 8
5. Center punch the outside of the retaining ring (Fig. 9).
Figure 9
6. Drill a 1/4 inch hole (approximate) into the outside of
the retainer ring to a depth of about 3/4 the thickness of
the ring (Fig. 10).
IMPORTANT: Drilling completely through the re­
tainer ring could damage the shaft.
Figure 10
Groundsmaster® 300 Series
Page 7 - 5
Repairs
7. After drilling, put a chisel in position across the hole
and strike sharply to break the ring. Replace with a new
ring at time of reassembly (Fig. 11).
WARNING
Wear protective safety goggles when break­
ing the retaining ring. Personal injury could
result from flying metal particles. Keep all
personnel away during this procedure.
Figure 11
8. Inspect the shaft for possible damage (Fig. 12).
Inspect the sealing surface of the hub and shaft. Replace it if the seal has grooved the surface more that
1/64 inch (0.4 mm).
9. Put a new grease seal, brake assembly, and a new
grease packed bearing (in that order) onto the axle
shaft.
Figure 12
10. Press the assembly until the bearing is firmly seated
against the axle shaft shoulder (Fig. 13).
Figure 13
Repairs
Page 7 - 6
Groundsmaster® 300 Series
11. Slide a new retaining ring on the axle shaft and
support the shaft and ring in a suitable press (Fig. 14).
Press the retaining ring firmly against the bearing.
Figure 14
12. Put a light coating of No. 1 Permatex on the outside
diameter of a new grease seal (surface that contacts the
axle housing). Install the new seal to a depth of 1.218
in. into the housing (Fig. 15, 16). After the seal has been
assembled, put grease on the lip of the seal.
Figure 15
1.218" seal
installation depth
Figure 16
Groundsmaster® 300 Series
Page 7 - 7
Repairs
13. Assemble the bearing retainer bolts to the axle
housing. Apply a 0.625 in. (16 mm) bead of gasket
material to flange on end of axle housing, then install
the axle shaft assembly into the axle housing. Be careful
not to damage the oil seal and bearing. Line up the
holes of the brake assembly and oil seal. Push the axle
shaft as far as possible into the axle housing (Fig. 17).
Wheel end gasket material: P/N 92-8775 Liquid Gasket Kit
(Kit contains Loctite Ultra-Gray
gasket eliminator and instructions.
Make sure surface
is flat. File off any
high spots.
Make sure capscrews
are flat against flange.
Grind off any material
from tube that interferes.
Figure 17
Socket Hd Screw
(94-6934)
14. Start the nuts by hand. Tighten the nuts so the
bearing assembly is drawn evenly into the axle housing
(Fig. 18). NOTE: It is recommended that you replace
hex head screws and flange nuts with socket head
screws, washers and nuts (Fig. 18). If installing socket
head screws, tighten the nuts to a torque of 16 - 20 ft.-lb.
(2 - 3 Kgm). If reinstalling hex head screws, tighten the
nuts to a torque of 37 - 45 ft.-lb. (5 - 6 Kgm).
IMPORTANT: Hold the socket head screw or hex
head screw when tightening the nut to prevent the
head from turning into the tube radius.
Nut (94-6935)
Washer (94-6936)
Hold socket head screw and tighten
nut to 16 - 20 ft-lb (2 - 3 Kgm)
Figure 18
Differential and Housing Disassembly
1. Remove the right and left-hand axle assemblies. (See
Axle Shaft Disassembly and Wheel Bearing Service in
this section of the book.)
Remove the eight (8) housing cap screws and separate
the upper and lower axle housings (Fig. 19). Clean the
gasket material from the mating surfaces before reassembly.
NOTE: A complete Upper Housing Assembly for Differential repairs is available. Using this assembly
eliminates the need for “trial and error” shimming procedures to establish the correct contact pattern between
ring and pinion gears.
Figure 19
Repairs
Page 7 - 8 Rev. A
Groundsmaster® 300 Series
2. Remove the four bearing cap screws and remove the
caps. Place the caps in a safe place to avoid damaging
their machined surfaces (Fig. 20).
The bearing caps are marked for identification. The
letters or numbers are in horizontal and vertical positions. When reassembling, place them back in the same
position.
Figure 20
3. To remove the differential assembly, place two
wooden devices (i.e. hammer handles) under the differential case and pry firmly upward. The bearing cups
must be kept with their mating cones (Fig. 21).
Figure 21
4. Remove the ring gear cap screws. Using a hard
wooden block and a hammer, drive the ring gear off of
the differential case. Be prepared to protect the ring gear
when removing it from the differential case; this will
avoid damage of the ring gear teeth (Fig. 22).
NOTE: It is recommended that whenever the ring gear
screws are removed, they are to be replaced with new
screws.
Figure 22
Groundsmaster® 300 Series
Page 7 - 9
Repairs
5. Do not remove the bearings from the differential case
unless bearing failure is evident. It is recommended that
whenever bearings are removed (regardless of usage)
they must be replaced with new ones. Remove the case
side bearing with a puller as shown (Fig. 23).
Figure 23
6. Put the case in a vise. Drive the lock pin out of the
pinion shaft (Fig. 24). Use a small drift punch as shown.
WARNING
To prevent personal injury, always wear a face
shield or safety goggles when striking a drift
punch with a hammer.
Figure 24
7. While supporting the differential in a vise, drive the
pinion mate shaft from the differential with a long drift
punch (Fig. 25).
Figure 25
Repairs
Page 7 - 10
Groundsmaster® 300 Series
8. To remove the side gears and pinion mate gears,
rotate the side gears. This will allow the pinion mate
gears to turn to the opening of the case (Fig. 26).
Remove the pinion mate gears and the spherical washers behind the gears.
Figure 26
9. Remove the eight side cover capscrews. Remove the
the side cover from the carrier assembly (Fig. 27). Clean
the gasket material from the mating surfaces before
reassembly.
Figure 27
10. If unit has an expansion plug, remove it by driving a
pointed punch through the plug about 3/8 inch (10 mm)
from the outer edge. When the hole is large enough,
insert a large screwdriver through it and pry the plug
outward (Fig. 28).
Figure 28
Groundsmaster® 300 Series
Page 7 - 11
Repairs
11. Before pressing pinion out of housing:
If unit was equipped with an expansion plug (removed in step 10), remove the snap ring and shim
from the end of the pinion (Fig. 29).
If unit is equipped with a flange for 4WD (no expansion plug), nut, washer and flange (Fig. 3C) must be
removed before pressing pinion out of housing.
Figure 29
12. Position the housing assembly on a suitable press.
Place a 1/8 inch (3 mm) piece of steel or a screwdriver
blade under the edge of the spur gear. This will prevent
the spur gear from cocking and possibly cracking the
housing (Fig. 30).
When the pinion is close to being pressed completely
out of the bearing, reach under the housing and catch
the pinion in your hand to prevent any damage to the
pinion.
Figure 30
Removing the drive pinion releases the spur gear,
spacer, and outer pinion bearing for removal (Fig. 31).
If unit was equipped with a flange for 4WD (no expansion plug), remove oil seal from housing (Fig. 3C).
Figure 31
Repairs
Page 7 - 12
Groundsmaster® 300 Series
13. Clamp the inner pinion bearing with a universal
bearing remover (Fig. 32). Position the unit in a press
and carefully push the drive pinion out of the bearing.
DO NOT allow the pinion to drop on the floor - damage
will result.
Figure 32
14. To remove the outer pinion bearing cup, position the
housing in a press. Place a press plate of the proper
size against the cup. Press the cup out of the housing
(Fig. 33).
Figure 33
15. Position the front housing on a press bed with the
bearing saddles resting on the press bed. Protect the
bearing saddles with a strip of wood if the press bed is
rough.
Insert a press plate of the proper size and press the
bearing cup toward the inside of the housing. Retain the
shims located under the bearing cup (Fig. 34). If the
shims are damaged, replace with new shims of the
same thickness.
Figure 34
Groundsmaster® 300 Series
Page 7 - 13
Repairs
Differential and Housing Reassembly
1. Inspect the differential parts for damage before
assembling.
A. If any bearings are damaged they must be replaced with new ones.
B. Check the ring, pinion, and spur gear for abnormal
wear and damage; replace worn components.
C. Inspect the housings for cracks and external
damage that could affect the operation of the axle
assembly.
D. Inspect the differential case for wear in the side
gear and pinion mate area. Replace the case if its
machined areas are scored or if the pinion mate shaft
fits loosely in the bore.
Figure 35
2. Press the inner pinion bearing onto the pinion drive
gear. Support the bearing on the inner cup of the bearing
ONLY WHEN INSTALLING (Fig. 35).
3. Put the front housing on a press. Using a press plate,
push the outer pinion bearing cup into the housing until
it bottoms in the housing (Fig. 36).
Figure 36
Repairs
Page 7 - 14
Groundsmaster® 300 Series
Ring and Pinion Set
Rings gears and pinions are supplied in matched sets
only. Matching numbers are etched on both the pinion
and ring gear (Fig. 37).
The mounting distance from the bottom of the differential bearing bores to the button end of the pinion is
1.210 in.
On the button end of each pinion there is a plus (+) or
minus (–) number, or a (0) number. This number indicates the best running position for each particular gear
set. This dimension is controlled by the shimming behind the inner bearing cup.
For example, if a pinion is etched +3, this pinion would
require 0.003 in. less than a pinion etched “0". This
means that by removing shims, the mounting distance
of the pinion is increased to 1.213 in., which is just what
+3 indicates. Or if a pinion is etched –3, we would want
to add 0.003 in. shims, the mounting distance of the the
pinion was decreased to 1.207 in., which is just what a
–3 etching indicates.
Figure 37
If a new gear set is being used, notice the (+) or (–)
etching on both the old and new pinion and adjust the
thickness of the new shim pack to compensate for the
difference of these two numbers.
For example: If the old pinion reads +2 and the new
pinion is –2, add .004 in. shims to the original shim pack.
Groundsmaster® 300 Series
Page 7 - 15
Repairs
4. Install a new inner bearing cup using a press plate of
proper diameter. Reuse the original shims or use new
shims of the same thickness. Push the bearing cup into
the housing until it bottoms against the housing
(Fig. 38).
Figure 38
5. Insert the pinion into the housing.
NOTE: A number marked on the new ring and pinion
set is used to establish the proper amount of shims
required prior to installing the pinion gear (see
page 15). The final pinion position will be verified by
using the gear contact pattern method as described
on page 21of this chapter.
Figure 39
6. Insert the spur gear into the front housing with the
chamfered area of the center spline toward the drive
pinion. Install the drive pinion with a soft mallet to
engage the splines in the spur gear (Fig. 40).
Figure 40
Repairs
Page 7 - 16
Groundsmaster® 300 Series
7. Support the drive pinion in a suitable press (Fig. 41).
Figure 41
8. Install the outer pinion spacer with the chamfer towards the pinion splines and install the new outer pinion
bearing cone (Fig. 42).
Figure 42
9. With a hollow press sleeve of proper diameter, press
on the outer bearing cone race until the drive pinion
seats in the carrier and a slight drag is noticed when the
gear is rotated by hand (2-13 in.-lb. torque to rotate)
(Fig. 43). If the drag is to severe, tap the pinion shaft
with a soft mallet until the drag is reduced.
Figure 43
Groundsmaster® 300 Series
Page 7 - 17
Repairs
10. Install the shim and snap ring onto the end of the
pinion shaft. Use the thickest shim possible which will
permit installation of the snap ring (Fig. 44). Limit the
end play to 0.000 - 0.005 inch (0.000 - 0.127 mm).
Figure 44
11. Apply a small bead of Permatex No. 2 or silicone
sealant to the outer edge of the carrier bore. Install the
expansion plug (or seal if equipped with flange for 4WD)
into carrier until plug or seal seats firmly in carrier bore
(Fig. 45).
Figure 45
12. Install the spur gear cover. Use Permatex No. 2 or
silicone sealant when installing the cover. Tighten the
capscrews to a torque of 25 - 40 in.-lb. (Fig. 46).
Figure 46
Repairs
Page 7 - 18
Groundsmaster® 300 Series
13. Place the differential case in a vise as shown
(Fig. 47). Apply grease to new side gear thrust washers
and hubs of the side gears. Apply grease to new pinion
mate spherical washers and pinion mate gears. Place
the side gears and thrust washers in the case. Install the
pinion gears while holding the side gears in place.
Rotate the side gears until the holes of the washers and
pinion gears line up with the holes of the case. If the
gears cannot be rotated by hand, install one of the axle
shafts into the side gear spline and use a pipe wrench
to turn the shafts.
Figure 47
14. Install the pinion shaft. Grease the shaft to aid
assembly. Be sure the hole in the pinion shaft lines up
with the hole in the differential case (Fig. 48).
Figure 48
15. Assemble the lock pin. Drive the pin to the approximate center location of the pinion mate shaft. Peen the
metal of the case to lock the pin in place (Fig. 49).
Figure 49
Groundsmaster® 300 Series
Page 7 - 19
Repairs
16. Put the ring gear onto the differential case and start
the new capscrews into the gear with your fingers.
Tighten the screws, alternating back and forth across
the gear to allow the gear to be pulled evenly into place.
Tighten the cap screws to a torque of 45 - 65 ft-lb (6.2 9.0 KgM) (Fig. 50).
Figure 50
17. When installing new differential bearings, reuse the
original shims or use new shims of the same thickness.
Press the bearing onto the differential case. If a new
differential case is being installed, start with a .020 inch
pack of shims under each differential bearing. Shims are
available in .003, .005, .010, and .030 inch sizes
(Fig. 51).
18. Assemble new differential bearing cups to differential bearing cones. Seat differential assembly with drive
gear on proper side of carrier into carrier bearing cradles.
NOTE: Groundsmaster 300 Series (S/N 90001 & up)
require that the ring gear teeth face toward the spur gear
cover.
Figure 51
The bearing cradles are designed to apply a slight
preload to the bearings. It is important to push both of
the bearing assemblies simultaneously into their
saddles.
Bearing caps must be installed with indexing marks “P”
adjacent to indexing marks “P” in case. Install the bearing caps into their original position as previously
marked. Tighten the cap screws to a torque of 30 - 45
ft-lb (4.1-6.2 KgM) (Fig. 52).
Figure 52
Repairs
Page 7 - 20
Groundsmaster® 300 Series
19. Using a dial indicator, check the ring gear backlash
in three equally spaced points. Ring gear backlash
should be .003 - .007 inch (.076 - .178 mm) and must
not vary more than .002 in. between points checked
(Fig. 53).
If the backlash is not in this range, move the shims which
are located beneath the differential bearings, from one
side to the other until the correct backlash is attained.
Checking Ring Gear Pattern
Figure 53
Final position of pinion is verified by using the gear
contact pattern method as described in the following
procedure.
Gear tooth Toe - the portion of the tooth surface at
the end towards the center.
Gear tooth Heel - the portion of the gear tooth at the
outer end.
Gear tooth Top Land - top surface of tooth.
Every gear has a characterisitc pattern. The illustrations
show typical patterns only and explaing how patterns
shift as gear location is changed. When making pinion
position changes, shims should be changed in the range
of .002 inch to .004 inch until a correct pattern has been
obtained.
Figure 54
Drive Side
Heel
Toe
When a change in backlash is required, backlash shims
should be changed in the range of 1-1/2 times the
amount of backlash required to bring the gears into
specification. For example, if the backlash needed to be
changed by .004 inch, the shim pack should be changed
by .006 inch as a starting point.
High backlash is corrected by moving the ring gear
closer to the pinion. Low backlash is corrected by moving the ring gear away from the pinion. These corrections are made by switching shims from one side of the
differential case to the other.
Coast Side
Heel
Toe
Figure 54A
To check the ring gear and pinion pattern:
1. Paint the teeth of the ring gear, both drive and coast
side, with a gear marking compound, such as DyKem
Steel Blue.
2. While applying a light load to the ring gear, rotate the
pinion gear until the ring gear has made one complete
revolution. Study the patterns in the following illustrations and correct as necessary.
NOTE: When making changes, note that two variables
are involved. Example: If you have the backlash set
correctly to specifications and you change the pinion
position shim, you may have to readjust backlash to the
correct specification before checking the pattern.
The preferred pattern is shown in Figure 54A. The drive
side pattern should be located at the toe portion of the
tooth. The coast pattern should also be at the toe portion
of the tooth.
Groundsmaster® 300 Series
Page 7 - 21
Repairs
Drive Side
Heel
Toe
Coast Side
Heel
Toe
Backlash correct. Thicker pinion position shims
required.
Figure 55
Drive Side
Heel
Toe
Coast Side
Heel
Toe
Backlash correct. Thinner pinion position shims
required.
Figure 56
Drive Side
Heel
Toe
Coast Side
Heel
Toe
Backlash incorrect. Thinner pinion position shim required. Adjust backlash to match.
Figure 57
Repairs
Page 7 - 22
Groundsmaster® 300 Series
Gear Pattern Movements Summary
1. Decreasing backlash moves the ring gear closer to
the pinion.
Drive pattern (convex side of gear) moves lower
and toward the toe.
Coast pattern (concave side of gear) moves slightly
higher and toward the heel.
2. Increasing backlash moves the ring gear away from
the pinion.
Drive pattern moves higher and toward the heel.
Coast pattern moves slightely lower and toward
the toe.
3. Thicker pinion position shim with the backlash constant moves the pinion closer to the ring gear.
Drive pattern moves deeper on the tooth (flank
contact) and slightly toward the toe.
Coast pattern moves deeper on the tooth and toward the heel.
4. Thinner pinion position shim with backlash constant
moves the pinion further from the ring gear.
Drive pattern moves toward the top of the tooth
(face contact) and toward the heel.
Coast pattern moves toward the top of the tooth
(face contact) and toward the heel.
Apply silicone sealant between the front and rear axle
housings and install the eight housing cap screws.
Tighten the cap screws to a torque of 18 - 23 ft-lb (2.5 3.2 KgM) (Fig. 58).
Figure 58
Groundsmaster® 300 Series
Page 7 - 23
Repairs
Repairs
Page 7 - 24
Groundsmaster® 300 Series
Chapter 8
Steering and Brakes
Table of Contents
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 5
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Steering Valve and Pump Tests . . . . . . . . . . . . . 7
Steering Cylinder Internal Leakage Test . . . . . . . 8
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Rear Wheel Toe-In Adjustment . . . . . . . . . . . . . . 9
Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . 10
Groundsmaster® 300 Series
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Wheel Removal and Installation . . . . .
Rear Axle Bushing Service . . . . . . . . . . . . . . . .
Steering Pivot Bushing Service . . . . . . . . . . . . .
Rear Wheel Spindle Bushing Service . . . . . . . .
Front Wheel Bearing Service. . . . . . . . . . . . . . .
Rear Wheel Bearing Service . . . . . . . . . . . . . . .
Steering Cylinder Removal and Installation. . . .
Steering Cylinder Service . . . . . . . . . . . . . . . . .
Brake Shoe Replacement . . . . . . . . . . . . . . . . .
Steering Valve Removal and Installation . . . . . .
Steering Valve Service . . . . . . . . . . . . . . . . . . .
Page 8 - 1
11
11
12
12
14
15
16
18
19
20
21
22
Table of Contents
Introduction
Power Steering
The Groundsmaster® 300 Series traction units are
equipped with power steering. The power steering valve
is enclosed in the steering tower at the front of the
traction unit. As the steering wheel is turned, the steering valve meters hydraulic fluid to the double-acting
steering cylinder on the rear axle and turns the wheels.
Hydraulic fluid flow for power steering is supplied by the
charge pump on the hydrostatic transmission. The implement/steering hydraulic circuit is designed so priority
flow is provided for steering.
The Model HGF Hydraguide TM steering valve (Fig. 1) is
manufactured by TRW, Ross Gear Division.
NOTE: Because the steering cylinder has different displacements when extended and retracted, the steering
wheel will not return to its original position after making
a turn.
NOTE: The steering system will operate with the engine
off if necessary (with increased effort).
Figure 1
Brakes
The Groundsmaster® 300 Series traction units are
equipped with 7 inch diameter x 1-3/4 inch wide
mechanical drum brakes on the front wheels.
Two pedals are used to control the brakes. When used
separately, the pedals can control each wheel brake to
assist steering or traction on side hills. The two pedals
may be locked together with the brake lock arm. When
the lock arm is engaged both wheels will brake equally
and act as a service brake or parking brake.
The brake pedals operate the brakes through a cable
system to a strut and lever on the brake shoes.
Introduction
Page 8 - 2
Groundsmaster® 300 Series
Power Steering Schematics
FROM
PUMP
STEERING VALVE
When the steering wheel is turned to the right (Fig. 3),
the control valve within the steering valve shifts to close
the “AUX” port. This directs oil supplied by the steering
pump to the metering section of the steering valve. As
the steering wheel is turned, system oil is metered out
port “RT” to the steering cylinder. Oil displaced by the
other end of the steering cylinder returns to the steering
valve through port “LT” and is directed out port “OUT”
back to reservoir.
Right Turn
NOTE: On 2WD units right turn pressure is supplied
to the rod end of the steering cylinder and left turn
pressure to the barrel end as shown. On 4WD units
these hydraulic lines are reversed (right turn pres­
sure to barrel end and left turn pressure to rod end).
STEERING CYLINDER
Figure 3
FROM
PUMP
STEERING VALVE
When the steering wheel is stationary, the control valve
within the steering valve shifts back to neutral (Fig. 4),
allowing system oil to flow through the steering valve
and out the “AUX” port back to reservoir. Oil in the rest
of the steering circuit is then trapped.
Neutral
STEERING CYLINDER
Figure 4
FROM
PUMP
When the steering valve is turned to the left (Fig. 5) oil
is metered out port “LT” to the steering cylinder. Oil
displaced by the other end of the cylinder returns to the
steering valve through port “RT” and is directed out port
“OUT” back to reservoir.
STEERING VALVE
Left Turn
STEERING CYLINDER
Figure 5
Groundsmaster® 300 Series
Page 8 - 3
Power Steering Schematics
Specifications
Item
Specification
__________________________________________________________________________________________
Front wheel lug nut torque
45 to 55 ft-lb
________________________________________________________________________________________________________________________________________________________
Rear wheel lug nut torque
30 to 35 ft-lb
________________________________________________________________________________________________________________________________________________________
Steering cylinder bolt torque
130 to 150 ft-lb
________________________________________________________________________________________________________________________________________________________
Rear wheel toe-in
0 to 1/8 in.
________________________________________________________________________________________________________________________________________________________
Tire pressure
10 to 15 psi, front and rear
________________________________________________________________________________________________________________________________________________________
Brake pedal free travel
1/2 to 1 in.
Special Tools
Steering Valve Service Fixture
To avoid distorting or damaging the steering valve when
repairing, do not clamp it directly into a vise. Fabricate
a service fixture (Fig. 6) and use it as instructed (See
Steering Valve Service in the Repairs section of this
chapter).
Figure 6
Special Tools
Page 8 - 4
Groundsmaster® 300 Series
Troubleshooting
Problem
Possible Causes
___________________________________________________________________________________________
Steering Wander
Tire pressure incorrect or unequal left to right.
Loose or worn steering linkage.
Improperly adjusted or worn rear wheel bearings.
Rear wheels out of alignment; toe-in / toe-out.
Internal leakage of steering cylinder.
________________________________________________________________________________________________________________________________________________________
Poor or No Returnability (Recovery)
Improper rear wheel alignment; toe-in.
Steering linkage binding.
Low tire pressure.
Steering column binding or out of alignment.
________________________________________________________________________________________________________________________________________________________
Shimmy
Steering linkage loose, worn or out of adjustment.
Wheel bearings out of adjustment.
Air in hydraulic system.
Internal leakage of steering cylinder.
________________________________________________________________________________________________________________________________________________________
High Steering Effort in One Direction
Low hydraulic system pressure.
Excessive heat causing steering valve plate valve to
stick (See Excessive Heat in this section).
________________________________________________________________________________________________________________________________________________________
High Steering Effort in Both Directions
Cold hydraulic oil or oil viscosity not correct for
ambinent temperature.
Low hydraulic fluid level.
Low flow or pressure from hydraulic pump.
Steering linkage binding.
Restriction in hydraulic return line.
Groundsmaster® 300 Series
Page 8 - 5
Troubleshooting
Problem
Possible Causes
__________________________________________________________________________________________
Steering Wheel Lash (Free Movement)
Steering wheel loose on column.
Steering linkage loose or worn.
Steering valve loose at mounting.
Air in hydraulic system.
Internal leakage in hydraulic cylinder.
________________________________________________________________________________________________________________________________________________________
Excessive Heat in Hydraulic System
Undersized replacement hose or tube line.
Kinked or severely bent hose or tube line.
Restricted oil cooler.
Restricted recentering of steering valve control valve
plate.
Troubleshooting
Page 8 - 6
Groundsmaster® 300 Series
Testing
Steering Valve Test (Control Valve Section)
Using Hydraulic Tester With Flow Meter
1. Engage the parking brake and block the front wheels
to prevent movement of the machine. Lower the cutting
unit or implement to the floor and turn the engine OFF.
2. Disconnect the hydraulic hose at the charge pump
outlet (pressure) fitting.
3. Connect the inlet hose of the tester to the hydraulic
fitting on the transmission and the outlet hose of the
tester to hose that was disconnected in step 2.
IMPORTANT: Make sure that the oil flow indicator
arrow on the flow gauge is showing that the oil will
flow through the tester from the charge pump to the
steering valve.
4. Make sure that the tester load valve is fully open
(counterclockwise). Start the engine and allow it to run
for approximately 5 minutes so that the hydraulic oil
reaches normal operating temperature.
5. With the tester load valve fully open (counterclockwise) run the engine at full throttle.
6. Turn the steering wheel all the way to the right
(clockwise) and hold it against the right stop. Look at the
flow meter. There should be no flow as the steering
wheel is held against the right stop. Flow should be
approximately 3 gpm when the steering wheel is released. Repeat this procedure with the steering wheel
all the way to the left (counterclockwise). If flow does not
return to approximately 3 gpm when the steering wheel
is released the control valve within the steering valve
may be sticking.
Figure 7
1. Transmission
2. Tester
3. Load valve
If a Hydraulic Tester is Not Available:
1. Engage the parking brake.
2. Run the engine at full throttle.
3. Turn the steering wheel all the way to the right
(clockwise) and hold it against the stop. Pull the lift
control lever back to raise the implement while holding
the steering wheel against the stop. The implement
should NOT raise until the steering wheel is released.
Repeat this procedure with the steering wheel turned all
the way to the left (counterclockwise). If the implement
raises slowly, or not at all when the steering wheel is
released, the control valve within the steering valve may
by sticking. When turning the steering wheel, the wheels
must move from stop to stop. The wheels must move
smoothly in both directions.
Groundsmaster® 300 Series
Page 8 - 7
Testing
Steering Cylinder Internal Leakage Test
1. Engage the parking brake, and lower the cutting unit
to the floor.
2. Turn the steering wheel all the way to the left (counterclockwise) on a 2WD machine or to the right (clockwise) on a 4WD machine, so the steering cylinder rod
is extended all the way.
3. Turn the engine OFF.
4. Disconnect the hydraulic hose from the fitting on the
rod end of the cylinder. Put a plug in the end of the hose
to prevent contamination.
5. With the engine OFF, continue turning the steering
wheel to the left (counterclockwise) with the cylinder rod
completely extended and observe the open fitting on the
steering cylinder. If oil comes out of the fitting while
turning the steering wheel to the left, the steering cylinder has internal leakage and must be repaired or replaced.
NOTE: DO NOT turn the steering wheel to the right
(clockwise) or the steering valve will meter oil out the
disconnected hydraulic hose.
Testing
Page 8 - 8
Groundsmaster® 300 Series
Adjustments
Rear Wheel Toe-in Adjustment
The rear wheels should have 0 to 1/8 of an inch toe-in
when they are pointed straight ahead. To check toe-in,
measure the center-to-center distance, at axle height,
in front and rear of steering tires. If toe-in is not within
specifications, an adjustment is required.
1. Rotate the steering wheel so the rear wheels and
steering plate are straight ahead.
2. Loosen the jam nuts on both tie rods. Adjust both tie
rods until center-to-center distance at front of rear
wheels is 0 - 1/8 of an inch less than at the rear of the
wheels (Fig. 9).
3. When toe-in is correct, tighten jam nuts against tie
rods.
Groundsmaster® 300 Series
Page 8 - 9
Figure 9
1. Steering plate
Adjustments
Brake Adjustment
Adjust the service brakes when there is more that one
inch of “free travel” of the brake pedals. Free travel is
the distance the brake pedal moves before braking
resistance is felt.
Adjust where brake cables connect to brake pedal
mount. When cable is no longer adjustable, star nut on
inside of the brake drum must be adjusted to move
brake shoes outward. Brake cables must be adjusted
again after star nut is adjusted.
1. Disengage lock arm from left brake pedal so both
pedals work independently of each other.
Figure 12
2. To reduce free travel of brake pedals:
1. Jam nuts
A. Loosen front nut on threaded end of brake cable
(Fig. 12).
1
B. Tighten rear nut to move cable toward the rear
until brake pedals have 1/2 to 1 in. of free travel.
C. Tighten front nut after adjusting.
3. When brake cables cannot be adjusted to get free
travel within 1/2 to 1 in., star nut inside brake drum must
be adjusted. Before adjusting the star nut, loosen brake
cable nuts to prevent unnecessary strain on the cables.
Figure 13
4. Loosen (do not remove) the five (5) wheel lug nuts.
1. Brake adjusting slot
5. Jack up machine until front wheel is off the floor. Use
jack stands or block machine to prevent it from falling
accidentally.
6. Remove wheel nuts and slide wheel off the studs.
Rotate the brake drum until adjusting slot is at the top
and centered over star-nut (Fig. 13).
1
2
2
7. Use a brake adjusting tool or a screwdriver to rotate
star nut until brake drum locks because of outward
pressure of brake shoes (Fig. 14).
8. Loosen star nut approximately 12 to 15 notches or
until brake drum rotates freely.
Figure 14
1. Star nut
2. Brake shoe
9. Install wheel onto studs with five (5) wheel nuts.
Tighten the wheel lug nuts.
10. Remove jack stands or blocking and lower machine
to floor. Tighten wheel lug nuts to a torque of 45 to
55 ft-lb.
11. Adjust brake cables (see step 2 of this procedure).
Repairs
Page 8 - 10
Groundsmaster® 300 Series
Repairs
Steering Wheel Removal and Installation
Removing the Steering Wheel
Remove the cover from the steering wheel hub. Remove the locknut that secures the steering wheel to the
shaft (Fig. 15). Pull the steering wheel off the shaft.
NOTE: It may be necessary to use a jaw-type puller to
remove the steering wheel from the steering shaft.
IMPORTANT: DO NOT hit the steering shaft with a
hammer. This could damage the steering valve com­
ponents.
Installing the Steering Wheel
1. Use the steering wheel to put the rear wheels in the
straight ahead position.
2. Slide the steering wheel onto the steering shaft.
3. Secure the steering wheel in place with the jam nut
(Fig. 10). Tighten the nut to 20 to 26 ft-lb.
Figure 15
1. Steering wheel
2. Jam nut
3. Cap
4. Screw
5. Foam seal
4. Install cap to steering wheel with screw.
Groundsmaster® 300 Series
Page 8 - 11 Rev. I
Repairs
Rear Axle Bushing Service (2WD Units)
The rear axle must be held in place snugly by the axle
pin. Excessive movement of the axle, which is characterized by erratic steering, usually indicates worn bushings. To correct the problem, replace the bushings.
1. Disconnect the hydraulic hoses from the steering
cylinder. Put caps or plugs on all the fittings and hoses
to prevent contamination.
NOTE: To ease reassembly, tag each of the hoses to
show their correct position on the steering cylinder.
2. Remove the nut (Fig. 16, Item 9) from the end of the
rear axle pin. Remove the two (2) cap screws (Item 2)
securing the axle pin to the frame.
3. Jack up the frame (just ahead of the rear wheels) until
pressure is taken off the axle pin. Support the machine
with jack stands to prevent it from falling.
4. Pull the axle pin out. This will release the rear axle
and washer(s) from the frame. Carefully pull the entire
axle and wheel assembly out from under the machine.
5. Use a drift punch and hammer to drive both bushings
(Item 4) out of the axle pivot tube. Clean the inside of
the axle pivot tube to remove dirt and foreign material.
6. Apply grease to the inside and outside of the new
bushing. Use an arbor press to install the bushings into
the top and bottom of the axle pivot tube. Bushings must
be flush with the axle tube.
7. Wipe the rear axle pin with a rag to remove dirt and
grease. Inspect the pin for wear or damage and replace
as necessary.
8. Mount the axle to the frame with the axle pin. The
washer(s) (Item 45) must be positioned between the
front end of the pivot tube and the frame (see the NOTE
after step 4). Secure the axle pin in place with the two
(2) cap screws (Item 2). Install the washer (Item 8) and
nut (Item 9).
9. Remove the jackstands and lower the machine to the
floor.
10. Install the hydraulic hoses to the steering cylinder.
NOTE: A varying number of washers (Item 45) may have
been installed between the axle pivot tube and frame
during manufacture. Make sure the same number of
washers are installed during reassembly.
11. Lubricate the rear axle bushings through the grease
fitting on the rear axle.
Steering Pivot Bushing Service (2WD Units)
The steering pivot (Fig. 16, Item 38) must fit snugly onto
the mounting pin. Excessive movement of the steering
pivot may indicate worn bushings or tie rod ball joints.
1. Remove the lock nut (Item 37) and cap screw
(Item 11) securing the steering cylinder rod end to the
steering pivot (Fig. 16).
2. Remove two (2) nuts (Item 43) to disconnect the tie
rod end (Item 39) from the spindle arm (Item 1, 33).
Inspect all tie rod end ball joints for wear or damage and
replace as necessary.
3. Remove the retaining ring (Item 12), washer (Item 17)
and thrust washer (Item 18). Slide the steering pivot off
of the mounting pin on the bottom of the axle.
Repairs
4. Use a drift punch and hammer to drive both bushings
(Item 41) out of the steering pivot. Clean the inside of
the steering pivot tube to remove dirt and foreign material. Also clean the mounting pin on the bottom of the
rear axle.
5. Apply grease to the inside and outside of the new
bushings. Use an arbor press to install the bushings into
the top and bottom of the steering pivot tube. Bushings
must be flush with the end of the tube.
6. Slide the steering pivot onto the mounting pin. Secure
the plate in place with the thrust washer, washer and
retaining ring.
Page 8 - 12
Groundsmaster
®
300 Series
7. Connect the tie rod end to the spindle bracket with
one (1) nut. Tighten the nut to a torque of 25 - 33 ft-lb.
Install the jam nut and tighten against the other nut to
secure tie rod end.
8. Install the lock nut and cap screw to secure the
steering cylinder rod end to the steering pivot. Tighten
the nut to 130 to 150 ft-lb.
9. Lubricate the bushings through the grease fitting on
the steering pivot.
Figure 16
Groundsmaster® 300 Series
Page 8 - 13
Repairs
Rear Wheel Spindle Bushing Service (2WD Units)
The rear wheel spindles must fit snugly in the rear axle.
Excessive movement of the spindle in the axle indicates
that the bushings are probably worn and must be replaced.
7. Apply grease to the inside and outside of the new
bushings. Use an arbor press to install the bushings into
the top and bottom of the axle tube. The bushings must
be flush with ends of the axle tube.
1. Disconnect the hydraulic hoses from the steering
cylinder. Put caps or plugs on all the fittings and hoses
to prevent contamination.
8. Wipe the spindle shaft with a rag to remove any dirt
and grease. Inspect the spindles for wear and replace
as necessary.
NOTE: To ease reassembly, tag each of the hoses to
show their correct position on the steering cylinder.
9. Install the thrust bushing (Item 34) onto the spindle
shaft and push the shaft through the axle tube. Hold the
wheel and spindle shaft assembly in place and install
the thrust washer (Item 18), washer (Item 17) and
retaining ring (Item 12) onto the end of the spindle shaft.
2. Remove nut (Fig. 16, Item 9) and washer (Item 8)
from end of rear axle pin. Remove the two (2) cap
screws (Item 2) securing the axle pin to the frame.
3. Jack up the frame (just ahead of the rear wheels) until
pressure is taken off the axle pin. Support the machine
with jack stands to prevent it from falling.
4. Pull the axle pin out. This will release the rear axle
and washer(s) from the frame. Carefully pull the entire
axle and wheel assembly out from under the machine.
NOTE: A varying number of washers (Item 45) may have
been installed between the axle pivot tube and frame
during manufacture. Make sure the same number of
washers are installed during reassembly.
5. Remove the retaining ring (Item 12) and washers
(Item 17, 18) that secure the wheel spindle (Item 1, 33)
into the axle tube. Slide the spindle and wheel assembly
out of the axle tube to expose the bushings.
10. Connect the tie rod end to the spindle bracket with
one (1) nut. Tighten the nut to a torque of 25 - 33 ft-lb.
Install the jam nut and tighten against the other nut to
secure tie rod end.
11. Mount the axle to the frame with the axle pin. The
washer(s) (Item 45) must be positioned between the
front end of the pivot tube and the frame (see the NOTE
after step 4). Secure the axle pin in place with the two
(2) cap screws (Item 2). Install the washer (Item 8) and
nut (Item 9).
12. Remove the jackstands and lower the machine to
the shop floor.
13. Install the hydraulic hoses to the steering cylinder.
14. Lubricate the steering spindle and rear axle pivot.
6. Use a punch and hammer to drive both bushings
(Item 4) out of the axle tube. Clean the inside of the axle
tube to remove any dirt and foreign material.
Repairs
Page 8 - 14
Groundsmaster
®
300 Series
Figure 17
Front Wheel Bearing Service
See Axle Shaft Disassembly and Wheel Bearing Service in the Repairs section of Chapter 6 - Differential.
Groundsmaster® 300 Series
Page 8 - 15
Repairs
Rear Wheel Bearing Service (2WD Units)
Disassemble, clean, repack and adjust the rear wheel
bearings after each 500 hours of operation or once a
year. Use No. 2 general purpose lithium base grease
containing E.P. additive. If operating conditions are extremely dusty and dirty, it may be necessary to perform
this maintenance more often.
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.
1. Jack up the rear of the machine until the tire is off the
floor. Support the machine with jack stands or blocks to
prevent it from falling.
7. Pack both bearings with grease. Install one bearing
into the cup on inboard side of the wheel hub. Lubricate
the inside of the new lip seal and press it into the wheel
hub.
2. Remove the dust cap from the end of the wheel
spindle (Fig. 18).
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.
3. Remove the cotter pin, slotted nut, and washer. Slide
the wheel off spindle shaft.
8. Pack inside of wheel hub with some grease (not full).
Install remaining bearing into the bearing cup.
4. Pull the seal out of the wheel hub.
5. Remove the bearings from both sides of the wheel
hub. Clean the bearings in solvent. Make sure the
bearings are in good operating condition. Clean the
inside of the wheel hub. Check the bearing cups for
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.
3
2
10
7
1
9
8
6
4
5
11
12
Figure 18
1. Wheel hub
2. Wheel spindle
3. Dust cap
4. Cotter pin
Repairs
5. Slotted nut
6. Washer
7. Seal
8. Bearing cone
Page 8 - 16
9. Bearing cup
10. Stud
11. Wheel
12. Wheel nut
Groundsmaster
®
300 Series
Adjusting Rear Wheel Bearings
1. Remove dust cap from end of wheel spindle. Also
remove cotter pin retaining slotted nut in place (Fig. 18).
2. Rotate the wheel by hand and tighten the slotted nut
(Fig. 19) until the bearing binds SLIGHTLY. Then,
loosen the nut until the nearest slot and hole in the
spindle line up. Reinstall the cotter pin to retain the
slotted nut in place. NOTE: The correct end play of the
adjusted assembly is .002 -. 005 inches.
1
3. Remove jack stands or blocks and lower machine to
floor.
4. Put a coating of grease on the inside of the dust cap.
Install dust cap on the end of the wheel spindle (Fig. 18).
Figure 19
1. Cotter pin and slotted nut
Groundsmaster® 300 Series
Page 8 - 17
Repairs
Steering Cylinder Removal and Installation
1. Engage the parking brakes, lower the cutting units to
the ground, turn the engine OFF and remove the key
from the ignition switch.
2. Disconnect the hydraulic hoses from the steering
cylinder. Put caps or plugs on all the fittings and hoses
to prevent contamination.
NOTE: To ease reassembly, tag each of the hoses to
show their correct position on the steering cylinder.
3. Remove the lock nut and cap screw securing the rod
end of the cylinder to the steering pivot.
4. Remove the lock nut, cap screw and spacer securing
the barrel end of the cylinder to the rear axle.
5. Remove the cylinder.
6. Reverse steps 2 - 5 to install the steering cylinder.
Tighten the cap screw and nut securing the rod end of
the cylinder to the steering pivot to 130 - 150 ft-lb.
7. After installing the cylinder, bleed the hydraulic
system.
Repairs
Page 8 - 18
Groundsmaster
®
300 Series
Steering Cylinder Service
IMPORTANT: To prevent damage to rod or barrel,
clamp vise on pivot ends only. DO NOT clamp
against smooth rod surface.
1. After removing the cylinder, pump oil out of cylinder
into a drain pan by SLOWLY moving piston in and out
of cylinder bore.
2. Plug the ports and clean the outside of the cylinder.
3. Mount cylinder in a vise so rod end of cylinder is tilted
up slightly. Do not close the vise so firmly that the
cylinder barrel could become distorted.
4. Use a spanner wrench to unscrew (counterclockwise)
head (Fig. 21, Item 2) from barrel (Item 1).
5. Grasp large end of piston rod (Item 4) and use a
twisting and pulling motion to carefully extract piston,
rod, and head from cylinder tube.
8. Remove all seals and O-rings (Item 2).
9. Wash parts in a safe solvent. Dry parts with compressed air. DO NOT wipe them dry with a cloth or paper
as lint and dirt may remain.
10. Carefully inspect internal surface of barrel for damage (deep scratches, out-of-round, etc.). Replace entire
cylinder if barrel is damaged. Inspect head, rod, and
piston for evidence of excessive scoring, pitting, or
wear. Replace any damaged parts.
11. Put a light coating of oil on all new seals, and O-rings.
Install new seals and O-rings.
12. Install head onto piston rod.
13. Install piston onto rod and tighten hex nut to 30 34 ft-lb.
14. Put a light coating of oil on all cylinder parts.
6. Securely mount piston, rod, and head into vise so
large nut (Item 6) is easily accessible for removal.
Remove nut by turning it counterclockwise.
7. Remove piston (Item 5). Slide head off of piston rod.
15. Slide piston rod assembly into cylinder tube.
16. Install head into tube and tighten by hand to properly
engage threads. Tighten head with a spanner wrench.
Figure 21
Groundsmaster® 300 Series
Page 8 - 19
Repairs
Brake Shoe Replacement
CAUTION
CAUTION
The brake linings contain asbestos fibers.
Breathing dust containing asbestos fibers
may be hazardous to your health and may
cause serious respiratory or other bodily
harm. When servicing wheel brake parts, do
not create dust by grinding, sanding or filing
brake linings or by cleaning wheel brake parts
with a dry brush or compressed air. (Use a
water dampened cloth.) Use proper protective
equipment when working with asbestos
materials.
Wear a face shield when removing brake re­
turn spring (Fig. 22). The spring is under ten­
sion and could possibly slip during removal.
4. Remove brake lever retainers (cotter pins) with a slip
joint pliers.
5. Pull strut and lever from brake shoes. Remove brake
shoes by sliding them both on one motion straight down
off cast-iron spider.
1. Loosen wheel lug nuts. Jack up machine until front
wheel is off of floor. Use jackstands to prevent machine
from falling accidentally. Remove wheel lug nuts and
slide wheel and tire assembly off of studs.
2. Remove brake drum. If drum will not come off easily,
brake shoes may have to be retracted with star nut (see
Brake Adjustment).
3. Remove brake shoe return spring (Fig. 22) by prying
the end of the spring up and over its retaining boss. Use
a brake spring pliers or flat blade screwdriver.
6. Remove adjusting screw spring and star wheel assembly.
7. Install new brake shoes (reverse steps 2 - 7) Install
new brake drum if it is severely scored.
8. Install wheel and tire assembly on studs with five (5)
wheel nuts. Tighten wheel lug nuts. Remove jack stands
or blocking and lower machine to the floor. Tighten
wheel lug nuts to a torque of 45 - 55 ft-lb.
9. Adjust brakes (see Brake Adjustment).
2
3
1
5
4
Figure 22
1. Return spring
2. Cotter pins
Repairs
3. Strut and lever
4. Adjusting screw spring
Page 8 - 20
5. Star wheel assembly
Groundsmaster
®
300 Series
Steering Valve Removal and Installation
1. Engage the parking brakes, lower the cutting units to
the ground, turn the engine OFF and remove the key
from the ignition switch.
2. Remove the cutting unit or other implement.
3. Remove the steering wheel.
4. Remove the six (6) self-tapping screws securing the
steering tower cover (Fig. 23A). Slide the steering tower
cover off of steering column and parking brake rod.
5. Clean outside of the steering valve and the area
around the hydraulic fittings. Disconnect hydraulic
hoses from steering valve. Put caps or plugs on all
fittings and hoses to prevent contamination.
NOTE: To ease reassembly, tag each hose and tube line
to show their correct position on the steering valve.
6. Remove two (2) capscrews to remove clamp half
securing steering column to column support (Fig. 23B).
7. Remove four (4) locknuts and flat washers securing
steering valve to mounting bracket.
Figure 23A
1. Steering column cover
2. Steering column
3. Self tapping screws
4. Parking brake knob
8. Carefully move hydraulic lines to the side and pull
steering valve and column out through bottom of steering tower.
9. Reverse steps 2 - 8 to install the steering valve.
Figure 23B
1. Column support
2. Clamp half
3. Mounting bracket
Groundsmaster® 300 Series
Page 8 - 21
4. Steering column
5. Valve
6. Pivot plate
Repairs
Steering Valve Service
Before Disassembly
When disassembling any of the parts, use a clean work
bench. Wash all parts in solvent and dry them with
compressed air. DO NOT wipe them dry with a cloth of
paper as lint and dirt may remain. Keep each part
separate to prevent nicks and burrs.
Components of the steering valve are stacked on four
bolts and held in alignment with alignment pins. The
alignment pins are designed to be a slip fit into the
components. Use the minimum force necessary and
maximum care when separating or assembling the components.
The steering valve has several components that are of
brazed laminate construction. These components have
plates and parts bonded together permanently to form
an integral component that cannot be disassembled.
Disassemble the steering valve only to the extent shown
in this book.
IMPORTANT: Do not force or abuse closely fitted
parts, or you may damage them.
Components of the steering valve with alignment
grooves, must be assembled so that their alignment
grooves are positioned as illustrated for the valve to
function correctly (Fig. 24).
Repairs
Page 8 - 22
Figure 24
Groundsmaster
®
300 Series
Disassembly of Steering Valve
1. To avoid distorting or damaging the steering valve, do
not clamp it directly into a vise. Clamp a service assembly fixture securely in a vise (Fig. 25). Put the steering
valve, input shaft first, into the service assembly fixture.
Attache the steering valve to the fixture with four (4)
5/16-24 UNF nuts (Fig. 26).
NOTE: Before beginning the disassembly of the steering valve, study the relative positions of the alignment
grooves on the side of the components in the assembly.
The relative alignment groove positions on the components must be maintained at reassembly (Fig. 24).
Figure 25
Figure 26
2. Use a slot type screwdriver or screwdriver socket to
loosen the plug assembly one turn counterclockwise.
(Fig. 27). Do not remove the plug assembly.
Figure 27
3. Remove the four nuts from the port cover assembly.
Be careful not to damage the ports (Fig. 28).
IMPORTANT: The nuts are a special self-locking
type. Do not substitute any other type.
Figure 28
Groundsmaster® 300 Series
Page 8 - 23
Repairs
4. Grasp the port cover assembly (four plates bonded
together) and lift it from the unit. Remove and discard
the four o-rings and seal ring (Fig. 29).
Figure 29
5. Remove the loosened plug and o-ring assembly from
the port cover. Be ready to catch the steel check ball as
it falls from its cavity (Fig. 30). Discard the o-ring.
6. Inspect the port cover for port fitting sealing surface
scratches and thread damage. Replace the port cover
if it is damaged.
NOTE: Be prepared to catch three springs which may
become disengaged when removing the port manifold.
Figure 30
7. Carefully lift the port manifold (3 plates bonded together) from the unit (Fig. 31).
8. Remove the three springs from the port manifold.
NOTE: The unit has two different length spring sets. The
set you have just removed from the port manifold are
3/4 in. (19 mm) long. Keep this set of three springs
separate from the next set of three springs to be removed.
9. Inspect the springs for bent or distorted coils. If a
spring is broken or deformed, all six springs in the unit
should be replaced.
Figure 31
10. Inspect the ground surfaces of the port manifold. You
should notice a “normal” polished pattern due to the
rotation of the valve plate and hex drive assembly. All
edges should be sharp and free of nicks and burrs. The
surfaces of the port manifold should be free of scratches
or scoring.
NOTE: Scoring is indicated by fine scratches or
grooves. If these scratches can be detected by feel,
finger nail, or lead pencil, the manifold should be replaced.
IMPORTANT: Many components in the unit have
finely ground surfaces. Be careful not nick or
scratch these surfaces.
Repairs
Page 8 - 24
Groundsmaster
®
300 Series
11. Remove the valve ring (Fig. 32). Remove and discard the two seal rings (Fig. 33). The valve ring should
be free of nicks and scoring.
Figure 32
Figure 33
12. Remove the valve plate by lifting it from the isolation
manifold (Fig. 34).
13. Inspect the slot edges and ground surfaces. If the
valve plate shows nicks or scoring or the edges are not
sharp, it must be replaced.
NOTE: The valve ring and valve plate are a matched set
and must be replaced as a set.
Figure 34
Groundsmaster® 300 Series
Page 8 - 25
Repairs
14. Remove three springs from the isolation manifold
pockets (Fig. 35).
NOTE: The unit has two different length spring sets. the
set you have just removed from the isolation manifold is
1/2 in. (13 mm) long. Keep this spring set separate from
the set removed from the port manifold.
Figure 35
15. Inspect the springs for bent or distorted coils. If a
spring is broken or deformed, all six springs in the unit
must be replaced (Fig. 36).
Figure 36
16. Remove the hex drive assembly from the drive link
(Fig. 37).
17. The pin in the hex drive assembly should not show
wear and must be firmly pressed in place. the sides of
the hex and slot should not have grooves or scoring. if
the hex drive assembly shows signs of this type of wear,
it must be replaced.
Figure 37
Repairs
Page 8 - 26
Groundsmaster
®
300 Series
18. Remove the two alignment pins that align the port
manifold, valve ring and isolation manifold (Fig. 38).
Figure 38
19. Remove the isolation manifold (four plates bonded
together) (Fig. 39).
20. Inspect the ground surfaces of the isolation manifold. You should notice a “normal” polished pattern due
to the rotation of the valve plate, and on the opposite
side a “normal” polished pattern due to the action of the
commutator cover and commutator seal. The holes and
edges should be free of nicks. The manifold surfaces
should be free of nicks or scoring. If the manifold has
developed any of these conditions, it must be replaced.
Figure 39
21. Remove the two isolation manifold-metering ring
alignment pins (Fig. 40).
Figure 40
Groundsmaster® 300 Series
Page 8 - 27
Repairs
22. Remove the drive link from the unit (Fig. 41).
23. Inspect each end of the drive link. the four crowned
contact surfaces should not be worn or scored. Replace
if wear or scoring is evident.
Figure 41
24. Remove the metering ring and discard the two seal
rings (Fig. 42). If the metering ring bore is scored, it
should be replaced.
Figure 42
25. The “metering package” components are held together with eleven hex socket head screws. Lift the
metering package from the assembly, and put it on a
clean surface (Fig. 43).
IMPORTANT: Do not clamp the metering package in
a vise, as this could damage the components.
Figure 43
Repairs
Page 8 - 28
Groundsmaster
®
300 Series
26. Remove and discard the commutator seal from the
commutator cover (Fig. 44).
Figure 44
27. Remove the eleven hex socket head screws, that
hold the metering package together (Fig. 45). Use a
3/32 in. allen wrench. Inspect the screws for thread and
socket damage and replace as necessary.
Figure 45
28. Lift the commutator cover from the metering package (Fig. 46).
29. Inspect the ground surfaces of the commutator
cover. You should notice a “normal” polished pattern due
to the rotation of the commutator. If the cover has nicks,
burrs, or scoring, it must be replaced.
Figure 46
Groundsmaster® 300 Series
Page 8 - 29
Repairs
30. Remove the commutator ring (Fig. 47). Inspect for
cracks, burrs and scoring.
IMPORTANT: Handle the commutator ring with care,
as it is easily broken.
Figure 47
31. Remove the commutator from the rotor (Fig. 48).
IMPORTANT: To prevent damage, DO NOT use a
screwdriver to remove the commutator. Use a wood
dowel if necessary.
32. The commutator is made up of two round plates,
pinned and bonded together as a permanent assembly
that cannot be disassembled. Inspect the ground surfaces of the commutator. The holes and edges should
be free of nicks. The ground surfaces should be free of
scoring. The edges should be sharp.
Figure 48
NOTE: The commutator and commutator ring are a
matched set. If either is worn or damaged, the set must
be replaced.
IMPORTANT: Five alignment pins connect the com­
mutator to the rotor with a slip fit. Care and minimum
force should be used to separate the two compo­
nents.
33. Remove the five alignment pins (Fig. 49).
Figure 49
Repairs
Page 8 - 30
Groundsmaster
®
300 Series
34. Remove the drive link spacer (Fig. 50). Replace it if
it grooved or worn.
35. With the rotor set lying on the drive plate, the rotor
should rotate and orbit freely within the stator. The
commutator side of the stator face must be free of
grooves or scoring.
NOTE: the rotor and stator are a matched set. You must
replace them as a matched set, if either is worn or
damaged.
Figure 50
36. Check the rotor lobe “tip” to stator lobe “tip” clearance, with a feeler gauge (Fig. 51). The rotor lobe,
directly across from the rotor lobe tip being measured
(see pointer in Fig. 51) must be centered between stator
lobes during the measurement. A rotor and stator that
exceeds the maximum allowable “tip” clearance, must
be replaced.
Max. rotor to stator “tip” clearance: 0.003 in. (0.08 mm)
37. Remove the rotor set from the drive plate. The drive
plate side of the rotor set also must be free of grooves
or scoring.
Figure 51
NOTE: Handle the rotor set carefully to avoid nicks and
scratches.
38. The rotor side of the drive plate (Fig. 52) should show
the “normal” spiral pattern due to rotor movement.
Figure 52
Groundsmaster® 300 Series
Page 8 - 31
Repairs
39. Inspect the thrust bearing side of the drive plate
(Fig. 53) for brinelling (dents) or spalling (flaking). The
flat sides of the input shaft engagement hole should not
be grooved or worn. If any of these conditions in steps
38 and 39 are present, the drive plate must be replaced.
Figure 53
40.Remove the face seal, back-up ring, and face seal
spacer from the upper cover plate (Fig. 54). Discard the
face seal and back-up ring. Keep the metal spacer.
Figure 54
41. Remove the thrust bearing and bearing spacer from
the upper cover plate (Fig. 55).
42. Inspect the thrust bearing for brinelling (dents) or
spalling (flaking), if either exists, or if one or more of the
rolls are lost or broken, replace the bearing assembly.
Replace the seal spacer or bearing spacer if worn or
broken.
Figure 55
Repairs
Page 8 - 32
Groundsmaster
®
300 Series
43. Remove the upper cover plate (four plates bonded
together) (Fig. 56). Inspect the upper cover plate. You
should notice some polishing due to the action of the
seal. The plate should be free of brinelling (dents) or
spalling (flaking). If it is damaged, the upper cover plate
must be replaced.
Figure 56
44. Slide the seal from the jacket tube (Fig. 57). If the
seal is worn or damaged, it must be replaced.
Figure 57
45. Remove the input shaft and snap ring, sliding it out
of the upper cover end of the assembly (Fig. 58).
46. Inspect the input shaft serrations, threads and flats
for grooves, wear, or damage.
Figure 58
Groundsmaster® 300 Series
Page 8 - 33
Repairs
47. Remove the washer and upper cover & jacket
(Fig. 59).
NOTE: The retaining plate and upper cover & jacket are
a matched set. If either part is worn or damaged, both
must be replaced.
Figure 59
48. Inspect the bushing at the top of the cover & jacket
for wear or damage. If bushing replacement is necessary. put the upper cover & jacket in a vise. Use a pliers
or punch to straighten the crimped areas on the bushing
end of the jacket tube (Fig. 60).
IMPORTANT: Hold the steering tube in a soft-jaw
vise. Be careful not to damage the steering tube.
Figure 60
49. Use a bearing puller to remove the bushing (Fig. 61).
Figure 61
Repairs
Page 8 - 34
Groundsmaster
®
300 Series
50. Remove the nuts holding the four bolts to the fixture,
and remove the bolts (Fig. 62). Check the bolt threads
for wear or damage.
Figure 62
Groundsmaster® 300 Series
Page 8 - 35
Repairs
Assembly of Steering Valve
Replace all seals and o-rings with new ones. Make sure
the seals and o-rings remain seated correctly when
components are assembled.
Before assembling the steering valve, wash all parts in
clean solvent. Dry the parts with compressed air. DO
NOT wipe them dry with a cloth or paper as lint and dirt
may remain.
1. Put the four bolts into the fixture with the shortest
threaded end of the bolts through the fixture holes
(Fig. 63). Secure the bolts to the fixture with four 5/16-24
UNF nuts. Tighten the nuts to secure the assembly to
the fixture, but loose enough to turn the bolts and
facilitate stacking of components.
Figure 63
2. If the bushing was removed from the upper cover and
jacket for replacement, press a new bushing into the
upper end of the jacket tube with the recessed end of
the bushing toward the jacket tube. Use an arbor press
or the wood handle end of a hammer (Fig. 64). Push the
bushing down until it is 0.1 in. (2.5 mm) below the top of
the jacket tube. Use a pliers or punch to “crimp” the end
of the jacket tube over the bushing in two places approximately 90o away from the original crimped areas
(Fig. 65). Put clean multi-purpose grease on the inside
of the bushing.
Figure 64
Figure 65
Repairs
Page 8 - 36
Groundsmaster
®
300 Series
3. Put the upper cover and jacket on the four bolts with
the jacket tube pointing down through the hole in fixture
(Fig. 66). Make sure the square shoulder of the bolts
engage the square holes in the upper cover.
4. Apply a small amount of multi-purpose grease to the
recessed face of the retainer plate and washer. Put the
retainer plate into the upper cover & jacket with the
recessed retainer face out. Put the washer against the
recessed face of the retainer plate.
Figure 66
5. Install the snap ring onto the input shaft if it was
removed (Fig. 67).
Figure 67
6. Slide the input shaft into the upper cover end of the
upper cover & jacket and through the bushing until the
retaining ring bottoms against the washer. Make sure
the washer bottoms against the retainer plate recessed
face and the retainer plate seats against the end of the
jacket tube (Fig. 68).
Figure 68
7. Install the upper cover plate over the four bolts with
the highly polished surface up (Fig. 69).
IMPORTANT: The alignment grooves must be all on
one side of the steering valve for proper operation.
Figure 69
Groundsmaster® 300 Series
Page 8 - 37
Repairs
8. Apply clean multi-purpose grease to the face of the
upper cover plate, input shaft and face seal (Fig. 70).
Figure 70
9. Assemble the seal back-up ring and face seal onto
the seal spacer (Fig. 71).
Figure 71
10. Install the face seal, back-up ring and spacer assembly over the end of the input shaft and onto the upper
cover plate (Fig. 72).
Figure 72
Repairs
Page 8 - 38
Groundsmaster
®
300 Series
11. Put the drive plate on a clean lint-free surface with
the eleven tapped holes facing up. Put the rotor set on
top of the drive plate with the five pin holes facing up.
Rotate the stator until the eleven hex socket head screw
relief slots are aligned with the tapped holes in the drive
plate (Fig. 73).
Figure 73
12. Apply a small amount of clean multi-purpose grease
to the spacer and insert it into the drive slot in the rotor
(Fig. 74). The grease will aid in retaining the spacer
during other assembly procedures.
Figure 74
13. Put the commutator on top of the rotor. Be sure the
correct surface (Fig. 75) is towards the rotor.
Figure 75
Groundsmaster® 300 Series
Page 8 - 39
Repairs
14. Align the five holes and press the five alignment pins
in place (Fig. 76).
IMPORTANT: Make sure the five alignment pins are
pressed below the surface of the commutator.
Figure 76
15. Put a few drops of oil into each recess in the
commutator (Fig. 77).
Figure 77
16. Put the commutator ring (either side up) on top of
the stator (Fig. 78). Align the commutator ring screw
recesses with the stator screw slots.
Figure 78
Repairs
Page 8 - 40
Groundsmaster
®
300 Series
17. Put the commutator cover on top of the commutator
ring with the flat surface towards the commutator (Fig.
79). Align the screw holes in the cover, with the screw
holes in the drive plate.
Figure 79
18. Screw the eleven hex socket head cap screws
loosely into the metering package (Fig. 80).
NOTE: The commutator ring must be concentric with the
drive plate within 0.005 in. (0.127 mm) total indicator
reading AFTER tightening the eleven hex socket head
cap screws. The next two procedures are a method of
achieving the concentricity.
Figure 80
19. Put the metering ring on a hard flat surface. Put the
assembled metering package into the metering ring with
the commutator cover down, so the drive plate is partially out of the metering ring (Fig. 81). (A suitable wood
block under the metering package will hold it in this
position.) Put one piece of 0.007 in. (0.18 mm) shim
stock approximately 0.5 in. (12 mm) wide and 1.5 in.
(38 mm) long between the metering ring and drive plate
in three places approximately equal distance around the
outside diameter of the drive plate.
Figure 81
Groundsmaster® 300 Series
Page 8 - 41
Repairs
20. Put another piece of the 0.007 in. (0.18 mm) shim
stock between the drive plate and each of the three
pieces of shim stock already in place. Lift the metering
ring and metering package and remove the wood block.
Push the metering package and shims into the metering
ring until the drive plate and shims are at least flush with
the metering ring (Fig. 82).
Figure 82
21. Reverse the metering ring and metering package as
a unit on a flat surface. Push down on the metering
package until the drive plate is on the flat surface. Be
sure the cap screws are loose enough to allow the
commutator ring and drive plate to align themselves
concentrically in the metering ring bore. Gradually
tighten the eleven cap screws, following the sequence
shown in Figure 83 at least twice until a final torque of
11 - 13 in-lb (1.24 - 1.47 Nm) is reached (Fig. 83 and
84). Remove the metering package and shims from the
metering ring. Discard the shims.
Figure 83
CAUTION
Use care and eye protection when adding and
removing shims from the metering ring as the
shims will be under spring tension and could
fly into the air and cause injury.
Figure 84
Repairs
Page 8 - 42
Groundsmaster
®
300 Series
22. Insert the LARGE tang of the drive link into the slot
in the rotor (Fig. 85).
IMPORTANT: An incorrect (reversed) assembly of
the drive link will prevent the assembly of the hex
drive.
Figure 85
23. Grasp the drive link and rotate the metering package
by hand to make sure the parts do not bind (Fig. 86).
The rotor should orbit inside the stator. If they bind,
disassemble the metering package, correct the cause
and repeat the assembly and concentricity procedures.
Figure 86
24. Apply clean multi-purpose grease to the metering
ring seal ring. Put the seal ring into position in the
metering ring seal groove opposite to the end with the
alignment pin holes. Stack the metering ring into place,
over the four bolts, with the seal ring towards the upper
cover plate. Make sure an alignment pin hole on the
metering ring is in line with and on the same side as the
alignment groove on the side of the upper cover plate
(Fig. 87). This is required so the other components can
be aligned correctly.
IMPORTANT: Make sure the seal ring does not slip
from position.
Groundsmaster® 300 Series
Page 8 - 43
Figure 87
Repairs
25. Put the bearing spacer onto the face of the upper
cover plate (Fig. 88).
Figure 88
26. Lightly grease the roller thrust bearing and put it on
the upper cover plate, inside the bearing spacer
(Fig. 89).
Figure 89
27. Inspect the exposed face of the drive plate making
sure it is clean and lint free. Apply a small amount of
clean multi-purpose grease on the drive plate (Fig. 90).
Figure 90
Repairs
Page 8 - 44
Groundsmaster
®
300 Series
28. Put the metering package, drive plate side first, into
the metering ring (Fig. 91). Revolve the input shaft or
metering package until the hole in the drive plate engages the end of the input shaft and the drive plate is
seated on the thrust bearing. When properly seated, the
metering package will be below the surface of the
metering ring.
Figure 91
29. Apply clean multi-purpose grease on the new commutator seal and put it into the commutator cover seal
groove (Fig. 92). The rubber portion (the softer side) of
the seal with the yellow mark must be put into the seal
groove.
Figure 92
30. Apply clean multi-purpose grease to the metering
ring seal ring. Put the seal ring into the metering ring
seal ring groove (Fig. 93).
Figure 93
Groundsmaster® 300 Series
Page 8 - 45
Repairs
31. Put two alignment pins into the metering ring
(Fig. 94).
Figure 94
32. Stack the isolation manifold (4 plates bonded together) onto the metering ring, aligning the grooves on
the side of the manifold with the grooves on the side of
the upper cover plate (Fig. 95). Align the alignment pin
holes with the alignment pins in the metering ring. The
isolation manifold surface without the recessed slots
must be toward the metering ring.
Figure 95
33. Install two alignment pins into the isolation manifold
(Fig. 96).
Figure 96
Repairs
Page 8 - 46
Groundsmaster
®
300 Series
34. Put the three 1/2 in. (13 mm) springs into the spring
pockets of the isolation manifold (Fig. 97).
NOTE: Two different length springs are used in the unit.
Be sure to use the 1/2 in. (13 mm) length springs during
this part of the assembly.
Figure 97
35. Apply clean grease to a seal ring and put it in the
valve ring recess that will face down when installed.
Install the valve ring over the bolts and alignment pins
with the seal ring facing the isolation manifold (Fig. 98).
IMPORTANT: Be sure the seal ring is seated cor­
rectly after the valve ring is assembled.
Figure 98
36. Put the hex drive assembly, pin side up, through the
hole in the isolation manifold (Fig. 99). the slot in the hex
drive must be engaged with the SMALL tang of the drive
link. Turn the input shaft to assist the engagement.
NOTE: If the hex drive does not readily assemble on the
drive link, the drive link was assembled incorrectly (See
step 22 of this procedure.)
Figure 99
Groundsmaster® 300 Series
Page 8 - 47
Repairs
37. To install the valve plate correctly, first carefully study
Figures 93 and 94 for positioning of the valve plate
spring slots and other cavities in relation to the spring
and spring recesses on the isolation manifold. Be sure
to use the alignment grooves on the side of the isolation
manifold for orientation.
Put the valve plate with the surface that reads “shaft
side” down over the hex drive assembly. Align the three
spring slots centrally over the three springs installed in
the spring recesses of the isolation manifold. The valve
plate spring slot with the small cavity and the words “port
side” centrally below it (Fig. 100), must be placed over
the spring and spring recess in the isolation manifold at
the top (12 o’clock position) as shown (Fig. 100 and
101). Adjust the valve plate position radially to centralize
the spring slots over the springs and the spring recesses
in the isolation manifold.
Figure 100
IMPORTANT: The unit will not function if the valve
plate is not positioned on the isolation manifold
exactly as shown in Figure 101. If the valve plate
spring slots, isolation manifold spring recesses and
springs are not centrally aligned in this step, the
springs could be damaged when the port manifold
is installed onto the assembly.
Figure 101
38. Apply clean multi-purpose grease to the valve ring
seal ring. Install the seal ring in the valve ring (Fig. 102).
Figure 102
Repairs
Page 8 - 48
Groundsmaster
®
300 Series
39. Put the port manifold (three plates bonded together),
valve side up, in a clean surface. Install three 3/4 in.
springs into the spring pockets (Fig. 103).
Figure 103
40. Apply a few drops of oil to the valve plate. Align the
grooves on the side of the port manifold with the grooves
on the side of the isolation manifold and assemble the
port manifold with the springs toward the valve plate
(Fig. 104). Be careful not to pinch a spring during
installation. The two alignment pins in the valve plate
will engage the holes in the port manifold. The pin on
the hex drive assembly must engage the center hole in
the port manifold.
Figure 104
41. Install a new o-ring on the plug. Insert the check ball
hole in the port cover. Be sure the ball is seated in the
bottom of the check ball hole. Turn the plug assembly
into the port cover until the ball is retained (Fig. 105).
Figure 105
Groundsmaster® 300 Series
Page 8 - 49
Repairs
42. Apply clean multi-purpose grease to the four o-rings
and seal ring. Put the new o-rings and seal ring into their
proper location in the port cover (Fig. 106).
Figure 106
43. Align a groove on the side of the port cover with the
grooves on the side of the port manifold and put the port
cover into position (Fig. 107).
Figure 107
Repairs
Page 8 - 50
Groundsmaster
®
300 Series
44. Install the lock nuts onto the bolts. Tighten each nut
gradually until resistance is felt (Fig. 108). Tighten to a
torque of 20 - 24 ft-lb (27 - 33 Nm) in the sequence
shown (Fig. 109).
Figure 108
Figure 109
45. Tighten the plug to a torque of 8 - 12 ft-lb (11 - 16 Nm)
(Fig. 110).
Figure 110
Groundsmaster® 300 Series
Page 8 - 51
Repairs
46. Apply a small amount of clean multi-purpose grease
on the lip of the seal. Install the seal onto the jacket tube
and input shaft (Fig. 111).
47. Make a final inspection of the relative groove positions on the side of the unit (Fig. 24). Components of the
steering valve with alignment grooves, must be assembled so that their alignment grooves are positioned as
illustrated for the valve to function correctly (Fig. 24).
Disassemble and correct the assembly if necessary.
48. Remove the four nuts holding the unit to the fixture
and remove the unit (Fig. 112).
Figure 111
Figure 112
Repairs
Page 8 - 52
Groundsmaster
®
300 Series
Chapter 9
Transmission Coupler and PTO
Table of Contents
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . .
Engine to Transmission Coupler . . . . . . . . . . . . .
PTO System . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Drive Coupling Alignment . . . . . . . . . .
Adjusting Drive Coupling Alignment . . . . . . . . . .
Correcting PTO Belt Slippage . . . . . . . . . . . . . . .
PTO Pulley and Engine Pulley Alignment . . . . . .
PTO Brake Adjustment . . . . . . . . . . . . . . . . . . . .
Groundsmaster® 300 Series
2
3
3
3
4
4
4
5
5
6
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Drive Coupling Removal and Installation. . . . . . . 7
Engine Pulley Yoke Bearing Replacement . . . . . 8
PTO Brake Replacement. . . . . . . . . . . . . . . . . . . 8
PTO Belt Replacement . . . . . . . . . . . . . . . . . . . . 9
Removing PTO Control Lever and Linkage. . . . 10
PTO Shaft and Bearing Service . . . . . . . . . . . . 11
PTO Drive Shaft Removal and Installation . . . . 12
PTO Drive Shaft Universal Joint Replacement . 13
Installing the PTO Drive Shaft . . . . . . . . . . . . . . 14
Page 9 - 1
Table of Contents
Introduction
Engine to Transmission Coupler (Fig. 1)
Engine power is transmitted from the engine through a
flexible coupling and drive link to the hydrostatic transmission. With this Toro design, there is no clutch used
between the engine and the transmission.
PTO lever fully forward to the ON position; this will start
the implement or cutting unit blades. Slowly pull the
lever backward to the OFF position to stop the implement’s operation. The only time the PTO lever should
be in the ON position is when the implement or cutting
unit is down in the operating position and the operator
is in the seat.
The drive coupling consists of three main components:
a metal drive coupling (shaft), a rubber coupling bolted
to each end of the shaft, and the pump hub.
PTO System (Fig. 1)
The power take-off (PTO) system transmits power from
the engine to the cutting deck or other implement attached to the from of the machine.
The PTO lever has two positions: ON (engage) and OFF
(disengage). To engage the PTO shaft, slowly push the
DANGER
Do not start the engine and engage the P.T.O.
lever when the P.T.O. shaft is not connected
to the gearbox on the cutting unit or other
implement. If the engine is started and the
P.T.O. shaft Is allowed to rotate, serious Injury
could result.
Figure 1
Introduction
Page 9 - 2
Groundsmaster® 300 Series
Troubleshooting
Engine to Transmission Coupler
Problem
Possible Cause
Output shaft bearing failure.
Lack of lubrication.
Output shaft out of alignment.
Excessive vibration of drive coupling.
Drive coupling bent or deformed.
Loose fasteners.
Drive coupling out of alignment.
Flexible (rubber) couplings wear prematurely.
Drive coupling bent or deformed.
Loose fasteners.
Drive coupling out of alignment.
Pump hub damaged.
Drive coupling bent or deformed.
Loose fasteners.
Drive coupling out of alignment.
PTO System
Problem
Possible Cause
Machine vibrates excessively.
PTO shaft not properly aligned.
PTO drive shaft does not telescope.
Worn bearings or U-joints.
Lack of lubrication to splines and tube.
Galling of U-joint journal cross-ends.
Drive shaft RPM to high.
Lack of lubrication.
Abrasive corosion on PTO drive shaft.
Extreme low angle operation.
Broken U-joint journal.
Excessive shock loading to PTO shaft.
Groundsmaster® 300 Series
Page 9 - 3
Troubleshooting
Adjustments
Checking Drive Coupling Alignment (Fig. 2)
When either the hydrostatic axle or the engine is removed and after all parts are reinstalled, the alignment
of the drive coupling must be checked. In addition, any
excess vibration usually indicates misalignment of the
drive coupling. The drive coupling will be damaged
when misalignment is more than 1/8 inch (3 mm).
To check the alignment of the drive couplings, place the
square end of a ruler or scale against the face of the
drive pulley and the bottom of the coupling retainer).If
there is more than 1/8 inch (3 mm) between the ruler or
scale and the opposite coupling retainer, or the scale is
more than 1/8 inch (3 mm) higher than the bottom of the
coupling, an adjustment is required. To correct for a
misaligned drive coupling, proceed to “Adjusting Drive
Coupling Alignment” which follows.
Figure 2
Adjusting Drive Coupling Alignment (Fig. 3, 4)
To correct drive coupling misalignment, first loosen the
axle support nuts at the rear of the floor plate).
A transmission that is too high at the drive coupling end
may be lowered by installing a 1/16 inch (1.6 mm)
spacer between the rear of the mounting pad and the
bottom of the frame. A transmission that is too low is
corrected by installing a 1/16 inch (1.6 mm) spacer
between the front of the mounting pad and the bottom
of the frame.
To install the spacers, remove the appropriate two cap
screws and loosen the other two. If the spacers must be
added to the front of the mounting pad, remove the front
cap screws and loosen the back ones. Do just the
opposite to add spacers at the rear of the mounting
pads.
Figure 3
After adding the spacers, install the two cap screws and
tighten all of the cap screws to secure the axle in place.
Check the alignment again. Continue to check the alignment and add shims as required. When the alignment
is correct, tighten the axle support nuts. Tighten the rear
nut with the fingers until it contacts the frame; then
tighten the front nut securely. Secure the rear nut last.
Figure 4
Adjustments
Page 9 - 4
Groundsmaster® 300 Series
Correcting PTO Drive Belt Slippage (Fig. 5)
If belt begins to slip because it has stretched or because
of worn linkage:
1. Unlatch and remove instrument cover.
2. Move PTO control lever to ON position.
3. Measure length of PTO spring between flat washers.
There should be a spring length of 3-3/16 inches
(81 mm).
4. To adjust, hold head of adjusting screw with wrench
(under PTO actuating arm) and turn locknut.
5. Move PTO lever to OFF position and install instrument cover.
Figure 5
1. 3-3/16 in. (81 mm)
2. PTO actuating arm
3. Locknut
PTO Pulley and Engine Pulley Alignment (Fig. 6, 7)
1. Lower the implement to the shop floor, turn the engine
off, remove the key from the ignition switch and engage
the parking brake.
2. Move the P.T.O. lever to the ON position to move the
pulley away from the brake. Remove the locknut holding
the brake onto the mounting pin, and slide the spacer,
brake and spring off of the pins.
3. Loosen the setscrews in the lock collars at the front
and back of the P.T.O. shaft. Using a punch and hammer, loosen the collars by driving them in the opposite
direction of the normal shaft rotation. The P.T.O. shaft
and P.T.O. pulley assembly should now be free to slide.
4. Using a straight edge, line up the top of the engine
pulley, with the top of the P.T.O. pulley. When the top of
the pulleys are aligned, the bottom of the pulleys are
misaligned by three degrees. Move the P.T.O. pulley
until its top is in line with the top of the engine pulley.
Then lock the pivot shaft and pulley in place by tightening the lock collars in the normal direction of shaft
rotation. Check the alignment of the pulleys again to
assure that the alignment did not change when the
collars were tightened. If alignment is still correct,
tighten the lock collar setscrews.
5. Slide the spring onto the large brake mounting pin.
Then slide the brake onto the mounting pin and the small
locating pin.
Figure 6
Figure 7
6. Move P.T.O. lever to OFF and position brake in
grooves of pulley. Slide spacer onto mounting pin and
secure all parts in place with the locknut. Tighten locknut
until spacer contacts the brake.
Groundsmaster® 300 Series
Page 9 - 5
Adjustments
PTO Brake Adjustment (Fig. 8)
1 . Lower the implement to the shop floor, turn the engine
off, remove the key from the ignition switch, and engage
the parking brake.
2. Move the P.T.O. lever to the ENGAGE position.
Loosen the adjusting locknut so that the brake is free to
move. Then move the P.T.O. lever to OFF and position
the brake in the grooves of the pulley.
3. Tighten the locknut until the spacer contacts the side
of the brake bracket.
Figure 8
Adjustments
Page 9 - 6
Groundsmaster® 300 Series
Repairs
Drive Coupling Removal and Installation (Fig. 9)
Removing Drive Couplings
1. Lower the cutting unit to the shop floor, turn the engine
off, remove the key from the ignition switch and engage
the parking brake.
2. Raise the seat and secure it in that position.
3. Jack up the back end of the machine and support it
with jackstands to prevent it from falling accidentally.
4. Block the front and back of the traction unit’s drive
wheels to prevent the machine from rolling.
5. Remove the two cap screws, lock washers, flat washers and spacers securing the drive coupling assembly
to the engine hub. Remove the two cap screws, flat
washers and locknuts securing the coupler to the transmission hub. Slide the assembly out after the cap
screws have been removed.
Figure 9
6. If the drive coupling assembly must be disassembled,
separate the rubber couplings (Item 17) from the drive
coupling (Item 18) by removing the nuts, flatwashers
and cap screws.
Installing Drive Couplings
1. Assemble the rubber couplings and drive coupling
with the cap screws, flat washers and nuts.
2. Position the drive coupling assembly between the
engine hub and transmission hub; align the holes. Secure the drive coupling to the hubs with cap screws, lock
washers, flat washers, and nuts. Tighten the cap screws
alternately and evenly to prevent distortion of the rubber
couplings.
NOTE: After installing the drive coupling assembly, the
rubber coupling must not be deformed more than .125
in. (3 mm) in either direction. If the rubber coupling is
deformed, correct by loosening the transmission hub
hub setscrews and changing the position of the hub. The
end of the pump hub must be positioned 0.60 - .250 in.
(1.5 - 6 mm) away from the transmission face. Tighten
the setscrews on the hub(s) to a torque of 12 ft-lb
(1.7 Kgm)
3. Remove the wheel blocks and jackstands. Lower the
machine to the shop floor.
4. Lower the seat and start the engine to test for proper
operation of the coupling components.
Groundsmaster® 300 Series
Page 9 - 7
Repairs
Engine Pulley Yoke Bearing Replacement (Fig. 10)
1. Position the machine on a level surface, turn the
engine off, remove the key from the ignition switch, and
engage the parking brake.
2. Remove the drive coupling as described in “Removing Drive Couplings”.
3. Remove the engine hub from the crankshaft pulley
after loosening the two setscrews that secure it in place.
Remove the woodruff key.
4. Use a thin screwdriver to remove the external retaining ring that secures the bearing onto the crankshaft
pulley shaft.
5. Remove the two cap screws and spacers that secure
the large yoke to the bearing collar.
6. Use a pry bar to carefully remove the bearing and
bearing collar from the crankshaft pulley shaft.
7. Remove the bearing from the bearing collar after
removing the large internal snap ring from the bearing
collar. An arbor press should be used to press the
bearing out of the collar.
Figure 10
8. After bearing service, reinstall the components in
reverse order.
9. Lubricate the bearing with No. 2 general purpose
lithium base grease.
PTO Brake Replacement (Fig. 11)
1. Lower the implement to the shop floor, turn the engine
off, remove the key from the ignition switch, and engage
the parking brake.
2. Move the P.T.O. lever to the ENGAGE position to
move the pulley away from the brake.
3. Remove the locknut holding the brake onto the
mounting pin. Slide the spacer, brake and spring off of
the pins.
4. Reverse procedures to install the brake.
5. Adjust the brake as described in “Adjusting the P.T.O.
Brake”.
Repairs
Page 9 - 8
Figure 11
Groundsmaster® 300 Series
PTO Belt Replacement (Fig. 12)
The PTO belt is a special double belt referred to as a
“torque team belt.”
1. To replace the belt, lower the implement to the shop
floor, turn the engine off, remove the key from the
ignition switch, and engage the parking brake.
2. Remove the drive coupling from between the engine
pulley and transmission hub; refer to “Removing Drive
Couplings”.
3. Move the P.T.O. lever to the ON position and remove
the P.T.O. brake; refer to “Replacing The P.T.O. Brake”.
4. Move the P.T.O. lever to the OFF position to release
the tension on the belt.
5. Remove the cotter pin and clevis pin from the P.T.O.
fork and pivot the P.T.O. fork forward, off of the P.T.O.
arm.
6. Roll the old belt off of the engine pulley and P.T.O.
pulley by carefully turning the P.T.O. pulley (by hand)
and moving the belt across the pulley grooves.
Figure 12
7. To install the new belt, roll the belt onto the P.T.O.
pulley and engine pulley, making sure the belt is to the
inside of the three belt guides.
8. Install the P.T.O. fork onto the P.T.O. arm and secure
it with the clevis pin and a new cotter pin.
9. Install the P.T.O. brake between the pulleys and
adjust it; refer to “Adjusting The P.T.O. Brake”.
10. Install the drive coupling between the engine pulley
and transmission hub; refer to “Installing Drive Couplings”.
Groundsmaster® 300 Series
Page 9 - 9
Repairs
Removing PTO Control Lever and Linkage (Fig. 13, 14)
1. Lower the implement to the shop floor and turn the
engine off. Engage the parking brake.
2. Unlatch and remove the instrument panel cover.
3. With the control lever in the OFF position, the P.T.O.
compression spring tension is released and the linkage
can be removed or repaired.
4. Remove the long cap screw (Fig. 14, Item 35) that
passes through the P.T.O. compression spring
(Item 48). Have a helper hold the nuts (Item 33, 34) on
the top of the compression spring using the appropriate
wrench. Then remove the spring, washers and cap
screw.
5. Remove the cotter pin (Item 8) from the clevis pin
(Item 7) that secures the P.T.O. lever to the P.T.O.
compression spring yoke (Item 51). Remove the clevis
pin and yoke.
6. Use locking pliers to grasp the tension spring
(Item 50) which is attached to the frame just forward and
left of the P.T.O. lever. Unhook and remove the tension
spring from the P.T.O. assembly.
Figure 13
NOTE: There is an additional spring hook (Fig. 13) used
in conjunction with the tension spring. Be certain that
this hook is replaced as during reassembly or the spring
itself will soon break due to excessive tension.
7. Remove the four cap screws from the P.T.O. lever
clamp (Item 54). Lift the P.T.O. interlock switch bracket
(Item 6) off and set aside. Remove the clamp and P.T.O.
lever assembly.
8. Reverse steps 2 - 7 to reinstall the assembly.
9. Adjust the compression spring refer to “Correcting
P.T.O. Drive Belt Slippage”.
10. See Chapter 6, Electrical System, for P.T.O. interlock switch repair and replacement.
Repairs
Page 9 - 10
Groundsmaster® 300 Series
PTO Shaft and Bearing Service (Fig. 14)
1. Remove the P.T.O. belt; refer to “Replacing the P.T.O.
Belt”.
2. Remove the clevis pin (Item 7) from the P.T.O. lever
and compression spring yoke.
6. Loosen the setscrews (Item 46) on the P.T.O. shaft
bearing collars (Item 41). Use a punch and hammer to
rotate the collars in the opposite direction of shaft rotation. Remove the shaft (Item 43) and bearings (Item 40).
7. Replace any worn bushings, bearings and shafts.
3. Remove the tension spring (Item 50) using a locking
pliers; refer to instructions and note of step 6 in “Removing Control Lever and Linkage”.
4. Remove the roll pins (Item 49) from the pivot shaft
(Item 9).
5. Remove the pivot shaft and lower the P.T.O. pivot
assembly down and out of the traction frame.
8. Reassemble in reverse order and check the alignment of the P.T.O. pulley. Adjust P.T.O. brake as necessary; refer to “Aligning the P.T.O. Pulley and Engine
Pulley”.
9. Adjust the compression spring; refer to “Correcting
P.T.O. Drive Belt Slippage”.
Figure 14
Groundsmaster® 300 Series
Page 9 - 11
Repairs
PTO Drive Shaft Removal (Fig. 15)
DANGER
Do not start the engine and engage the P.T.O.
lever when the P.T.O. shaft is not connected
to the gearbox on the cutting unit. If the en­
gine is started and the P.T.O. shaft Is allowed
to rotate, serious Injury could result.
1. Position the machine on a level surface, lower the
cutting unit to the shop floor, turn the engine off, remove
the key from the ignition switch, and engage the parking
brake.
2. Remove the self-tapping screws securing the shield
behind the cutting unit gear box and set the shield aside.
Figure 15
1. PTO yoke
2. Yokes in phase
3. Roll pin
4. Capscrews & locknuts
3. Drive the roll pin out of the yoke and the input shaft
of the gearbox. Slide the yoke off of the input shaft. If
the traction unit will be used without the cutting unit,
drive the roll pin out of the yoke at the P.T.O. pivot shaft
and remove the entire universal shaft from the traction
unit.
Repairs
Page 9 - 12
Groundsmaster® 300 Series
PTO Drive Shaft Universal Joint Replacement (Fig. 16, 17)
1 Remove the P.T.O. drive shaft.
2. Separate the two sections of the P.T.O. shaft.
3. Mount the section to be repaired in a vise so that the
U-joint is pointing upward.
NOTE: If the splined portion is to be repaired, protect
the splines from vise damage with wooden blocks, vise
jaw cushions, etc.
4. Use two thin screwdrivers to remove the “C” shaped
snap ring from each of the U-joint rollers (located inside
of each yoke). Remove the shaft from the vise.
5. The vise may now be used as a press by placing a
small socket against one roller and a large socket
against the yoke on the opposite side. As the vise is
closed, the small socket will force the cross to push the
opposite roller partway into the large socket.
6. When the roller is forced partway out, grasp the roller
and strike the yoke to complete removal. Do not spill the
needle bearings.
15. Grease the fitting SLOWLY until grease starts to
show at the seals. Use a low pressure hand grease gun
or a power gun equipped with a pressure relief valve.
Never use a high pressure gun without this adapter as
it is possible to blow the rollers out of the yokes with the
tremendous pressure; seals may also be damaged.
16. Test the action of the assembled joint. It should move
throughout its range without binding. If a slight bind
exists, rap the yoke lugs with a soft hammer. This will
usually free the joint. If it does not, disassemble and
check for the source of the bind.
IMPORTANT: When clamping in the vise, clamp the
solid portion of the U-joint. If the yoke must be
clamped, clamp lightly. Use jaw covers. Avoid
clamping the tube portion of the propeller shaft as
it is thin and easily crushed. Never clamp the tube
portion, even lightly, when it is necessary to ham­
mer on the yoke. Support the free end of the propel­
ler shaft to remove some of the strain from the
clamped end.
7. Follow steps 5 and 6 to complete the removal of the
U-joint from the P.T.O. shaft.
8. When replacing the U-joint, pack the roller bearings
with the recommended lubricant (multi-purpose
grease). Pack carefully to eliminate trapped air. Install
seals.
9. Start one of the rollers in the yoke. Insert from the
bottom with the open side of the roller up to prevent loss
of the needles. Make sure that each roller contains all
of the needles.
Figure 16
10. Insert one of the cross trunnions into the roller. Start
the other roller making certain it slips over the trunnion.
11. When partially seated, place the two rollers between
the vise jaws. Squeeze until FLUSH with the yoke. Stop
when flush; do not over-tighten.
12. Tap one of the rollers (use a brass punch the full
width of the roller) through the yoke until the snap ring
can be inserted. Insert the snap ring. Use new snap
rings. Make certain the snap ring is seated to full depth.
13. Support the cross and strike the yoke to force the
snap ring against the inner face of the yoke. Always seat
the roller in this fashion to prevent improper centering
of the cross.
Figure 17
14. Install the other snap ring or rings and seat the rollers
against the rings.
Groundsmaster® 300 Series
Page 9 - 13
Repairs
Installing the PTO Drive Shaft (Fig. 18, 19)
DANGER
Do not start the engine and engage the P.T.O.
lever when the P.T.O. shaft is not connected
to the gearbox on the cutting unit. If the en­
gine is started and the P.T.O. shaft Is allowed
to rotate, serious Injury could result.
The P.T.O. Drive Shaft has two major components.
When replacing it on the machine, the spline shaft
portion attaches to the traction unit and the tube portion
attaches to the cutting unit gearbox.
IMPORTANT: The P.T.O. shaft yokes must be exactly
in line with each other when the outer P.T.O. sleeve
is installed on the splined shaft. Remove the sleeve
and change the yoke position if alignment is not
correct. Misalignment of the yokes will shorten the
life of the P.T.O. Drive Shaft assembly and cause
unnecessary vibration when the cutting unit is op­
erated.
Figure 18
1. Line up the holes in the yoke and the input shaft of
the gearbox. Slide the yoke onto the shaft and secure
the parts together with the roll pin.
2. Mount the P.T.O. shield over the input shaft and onto
the gearbox mounting plate with the two self-tapping
screws.
Figure 19
1. PTO yoke
2. Yokes in phase
Repairs
Page 9 - 14
3. Roll pin
4. Capscrews & locknuts
Groundsmaster® 300 Series
Chapter 10
GM322-D or GM325-D with Inasaka axle
4WD Rear Axle
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . .
Over-Running Clutch Operation . . . . . . . . . . . . .
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Wheel Toe-in. . . . . . . . . . . . . . . . . . . . . . . .
Groundsmaster® 300 Series
2
3
3
4
4
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Shaft Service . . . . . . . . . . . . . . . . . . . . . . .
Rear Axle Removal and Installation. . . . . . . . . . .
Axle Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page 10 - 1
Rev. C
5
5
7
8
Table of Contents
Specifications
Item
Specification
__________________________________________________________________________________________
Lubricant (Fig. 1, 2)
SAE 80W90 gear lube
________________________________________________________________________________________________________________________________________________________
Rear wheel toe-in
1/8 inch
________________________________________________________________________________________________________________________________________________________
Rear wheel bolt torque
45 - 55 ft-lb
Figure 1
1. Check plugs (2)
Specifications
Figure 2
2. Mounting bolts
1. Drain plugs
Page 10 - 2
Groundsmaster® 300 Series
General Information
Over-Running Clutch Operation
A drive shaft connected to the front axle provides power
for the rear 4WD drive axle. The drive shaft tor the rear
ax l e incorporates an OVER-RUNNING (ROLLER)
49 RPM
Locked
Unlocked
CLUTCH THAT TRANSMITS POWER ONLY IN THE FORWARD DIRECTION (Fig. 4).
50 RPM
49 RPM
Front and rear axle gear ratios and tire sizes were
carefully selected so that during normal operation, the
Rear axle
pinion shaft
49 RPM
REAR AXLE PINION SHAFT TURNS SLIGHTLY FASTER
THAN THE REAR AXLE DRIVE SHAFT.
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 pinion
speed to slow down. As soon as the rear axle pinion is
turning the same speed as the drive shaft, the roller
clutch will engage and power will be transmitted from
the drive shaft to the rear wheels – four wheel drive
(Fig. 4).
Rear axle
drive shaft
Figure 4
When the traction unit is turning, the rear wheels swing
out in a larger arc and must travel faster than the front
wheels. In this condition, the rear wheels and axle pinion
shaft are turning faster than the drive shaft and the roller
clutch is disengaged (Fig. 5).
NOTE: The four wheel drive system may not operate
properly if the tires are replaced by different size tires,
or if proper tire pressure is not maintained.
Figure 5
Groundsmaster® 300 Series
Page 10 - 3
General Information
Adjustments
Rear Wheel Toe-in (Fig. 6)
1. Measure center–to–center distance (at axle height)
at front and rear of steering tires. Front measurement
must be 0 to 1/8 in. less than rear measurement.
2. Remove cotter pin and nut securing one tie rod ball
joint to mounting bracket on axle and disconnect ball
joint from axle (Fig. 7).
3. Loosen screw on tie rod clamp. Rotate ball joint in or
out to adjust length of tie rod.
4. Reinstall ball joint ot mounting bracket and check
wheel toe-in.
5. After getting correct adjustment, tighten screw on tie
rod clamp and connect ball joint to mounting bracket
with nut and cotter pin.
Figure 6
1. Ball joint
2. Tie rod
3. Tie rod clamp
Steering Stop Adjustment (Fig. 7)
The rear axle steering stops help prevent over travel of
the steering cylinder in case of impact on rear wheels.
The stops should be adjusted so there is 0.090 in.
clearance between bolt head and knuckle on axle when
steering wheel is completely turned left or right.
1. Thread bolt in out out unitl 0.090 in. clearance is
attained (Fig. 7)
Figure 7
1. Steering stops
Adjustments
Page 10 - 4
Groundsmaster® 300 Series
Repairs
Drive Shaft Service
0.34 ± 0.03″
Arrow end of roller
clutches must face
6-bolt flange end of
clutch housing
toward rear axle)
31
0.040″ MAX
30
30
A
29
37
B
36
Apply
Never-seeze
34
Detail A
Detail B
B
33
31
32
39
35
Figure 8
Removing Drive Shaft
Clutch Service
1. Put machine on a level surface, lower cutting unit,
stop the engine and remove the key from the ignition
switch. Block the rear wheels to prevent the machine
from moving.
1. To disassemble clutch, remove six (6) capscrews
(Item 17) and lockwashers (Item 16). Remove axle
coupling (Item 15) from clutch housing (Item 23).
2. Use a hammer and punch to drive roll pin (Fig. 8,
Item 35) out of axle coupling (Item 37) and rear axle
shaft. Loosen two (2) capscrews and locknuts securing
coupling to axle shaft. Slide coupling off of shaft.
2. Remove retaining ring (Item 21). Clutch housing
(Item 23), along with thrust washers (Item 14), roller
clutches (Item 22) and seals (Item 13) can now be
removed from yoke shaft (Item 12).
3. Inspect parts and replace as necessary.
3. Remove six (6) socket head capscrews and lockwashers securing drive shaft yoke flange to flange on
front axle differential (not shown).
Groundsmaster® 300 Series
4. Roller clutches (Item 22) must be installed into housing (Item 23) so end is flush to 0.040 in. inset with
shoulder at each end of housing bore. Both roller
clutches must be installed with arrow end toward 6-bolt
flange end of housing as shown in view B - B.
Page 10 - 5
Repairs
0.34 ± 0.03″
Arrow end of roller
clutches must face
6-bolt flange end of
clutch housing
toward rear axle)
31
0.040″ MAX
30
30
A
29
37
B
36
Apply
Never-seeze
34
Detail A
Detail B
B
33
31
32
39
35
Figure 9
5. Put thrust washer (Item 14) in housing adjacent to
roller clutch as shown. Press both seals (Item 13) into
end of housing to dimensions shown. Seals must be
installed with lip facing out.
Installing Drive Shaft.
6. Install clutch assembly onto yoke shaft, then install
other thrust washer. Install retaining ring (Item 29) to
secure clutch assembly to shaft. Install axle coupling
(Item 37) to clutch housing with six (6) capscrews and
lockwashers, then tighten capscrews evenly.
2. Slide clutch end of drive shaft onto rear axle shaft
spline, aligning roll pin hole in shaft with hole in axle
coupling (Item 37). Install roll pin (Item 35) through
coupling and shaft.
7. Lubricate clutch through grease fitting (Item 32) with
No. 2 General Purpose Lithium Grease.
1. Apply never-seize to splines of traction shaft and axle
input shaft.
3. Tighten two (2) capscrews (Item 44) and locknuts
(Item 43) to secure coupling to shaft.
4. Secure drive shaft yoke flange to flange on front axle
differential with six (6) socket head capscrews and
lockwashers (not shown).
Repairs
Page 10 - 6
Groundsmaster® 300 Series
Rear Axle Removal and Installation
45 - 55 ft-lb
Figure 10A
Figure 10B
1. Remove drain plugs from axle and allow oil to drain
into a container (Fig. 2).
2. Remove drive shaft (see Drive Shaft Service).
8. Remove nut (Fig. 10A, Item 14) and flatwasher
(Item 15). Remove capscrews (Item 6) from pin
(Item 7). Remove the pin. This will release the rear axle
and washers from the support (Item 9). Carefully pull the
axle out from under the machine.
3. Disconnect clutch engagement cable from rear axle.
4. Thoroughly clean around hydraulic hoses connections to steering cylinder. Mark hoses so they will be
installed correctly during reassembly. Disconnect hoses
from fittings on steering cylinder. Put plugs or caps on
open hoses and fittings to prevent contamination of
hydraulic system.
5. Loosen rear wheel capscrews (Fig. 10A, Item 23).
6. Block front tires and jack up rear of machine until there
is approximately one inch clearance between rear tires
and the ground. SECURELY BLOCK FRAME.
NOTE: A varying number of washers (Fig. 10B, Item 41,
42) may have been installed between the axle pivot and
axle support during manufacture. Make sure the same
number of washers are installed during reassembly.
9. Reverse steps 1 - 8 to install axle. The washers
(Fig. 10B, Item 41, 42) must be positioned between the
front end of the axle pivot and the axle support (see the
NOTE above). Make sure thrust washer (Fig. 10B,
Item 14) is installed between rear end of axle pivot and
the axle support.
7. Remove rear wheels.
Groundsmaster® 300 Series
Page 10 - 7
Repairs
Rear Axle Repair
Apply Loctite
20 - 24 ft-lb
16 - 20 ft-lb
Shim for
backlash adjustment
Measure
backlash here:
0.003 - 0.01″
16 - 20 ft-lb
Tighten to pre-load
bearings. Pinion shaft
should rotate with
2.0 - 5.5 in-lb torque
Shim for bevel gear to pinion contact adjustment
Figure 12
1. Remove bolts (Fig. 12, Item 60) securing axle tubes
(Item 16, 61) to differential case (Item 24). Separate axle
tubes and axles from differental case.
4. Disassemble differential case (Fig. 12):
A. Remove bolts (Item 53, 56) and remove clutch
cover (Item 53).
2. Remove bolts (Fig. 12, Item 60) securing axle tubes
(Item 16, 61) to gearbox housings (Fig. 13, Item 23) of
knuckle assemblies. Separate axle tubes and axles
from knuckle assemblies.
B. Remove bolts (Item 40) and remove bearing case
(Item 38) and pinion gear (Item 30) from differential
case (Item 24).
C. Remove bolts (Item 1) and remove cover (Item 2).
Remove differential assembly from differential case.
3. Disassemble knuckle assembly (Fig .13):
A. Remove bolts (Item 28, 39) securing covers
(Item 30, 26) to knuckle case (Item 28).
B. Pull out outer axle shaft (Item 35) and bevel gear
(Item 5).
C. Remove capscrews (Item 10) securing knuckle
arm (Item 8) to knuckle case (Item 28). Pull off
knuckle arm toward upper side and pull off case
toward bottom.
D. Remove capscrews (Item 13) and remove bearing retainer (Item 15). Remove bevel gear (Item 18)
and knuckle pin (Item 20).
Repairs
C. Remove bolts (Item 7) to disassemble differential.
Inspection
Inspect shaft splines, gears and bearings for wear and
damage. Replace parts as necessary. Use suitable
bearing pullers and an arbor press when replacing
bearings.
NOTE: Ring gear (Item 6) and pinion (Item 30) are a
matched set that must be replaced together.
Page 10 - 8
Groundsmaster® 300 Series
6 - 8 ft-lb
12 - 20 ft-lb
Apply Loctite
12 - 20 ft-lb
Figure 13
E. Tighten bolts (Item 1, 40) to a torque of 16 - 20 ft-lb
(220-280 Kg-Cm).
Assembly
1. Use new gaskets and seals when reassembling axle.
F. Assemble clutch parts and install clutch cover
(Item 53). Install new oil seals (Item 54, 55).
2. Assemble differential case (Fig. 12):
A. Assemble differential. Use medium strength Loctite on bolts (Item 7) and tighten evenly to a torque
of 20 - 24 ft-lb (270-330 Kg-Cm).
B. Assemble pinion gear (Item 30) and bearing case
(Item 38). Tighten bearing nut (Item 34) to pre-load
tapered roller bearings. Tighten so pinion shaft will
rotate with 2 - 5.5 in-lb (2.0 - 6.5 Kg-Cm) of torque.
Bend washer (Item 33) to prevent nut from loosening.
C. Adjust tooth contact of bevel gear (Item 6) to
pinion (Item 30). Use shims (Item 29) to make good
contact with light load between bevel gear and pinion
(Fig. 13).
Tooth contact between bevel gear
and pinion with light load
Figure 14
D. After adjusting tooth contact, use shims (Item 5)
to make backlash 0.003 - 0.01 in. (0.08 - 0.25 mm).
Check backlash through plug hole (Item 26) with a
dial indicator.
Groundsmaster® 300 Series
Page 10 - 9
Repairs
(Item 38). Note that top two (2) capscrews (Item 39),
securing cover (Item 30) are a shorter length.
3. Assemble knuckle assembly (Fig. 13):
A. Insert needle bearing (Item 22), washer (Item 21),
knuckle pin (Item 20), spacer (Item 19) and bevel
gear (Item 18) into axle gear box (Item 23). Fasten
bearing retainer (Item 15) with bolts (Item 13) and
tighten bolts evenly to a torque of 6 - 8 ft-lb (80120 Kg-Cm).
E. Install bevel gear (Item 5) to knuckle pin and install
cover (Item 26) to knuckle case (Item 38). Use
medium strenght Loctite on capscrews (Item 28)
securing cover (Item 26).
F. Evenly tighten capscrews (Item 28, 39) securing
covers to a torque of 12 - 20 ft-lb (170-280 Kg-Cm).
B. Assemble knuckle pin (Item 20) and knuckle case
(Item 38) to match knuckle arm (Item 8) with knuckle
pin. Fasten capscrew (Item 10) temporarily (will be
removed to fill with lubricant).
4. Install axle on machine (see Rear Axle Removal and
Installation).
C. Assemble wheel shaft (Item 35) to cover
(Item 30).
5. Fill axle with proper lubricant to level of check plugs
(see Specifications).
D. Assemble gear (Item 5) to wheel shaft and install
cover and wheel shaft assembly to knuckle case
Repairs
Page 10 - 10
Groundsmaster® 300 Series
Chapter 10.1
GM 325–D or GM 328–D with Dae Dong Axle
4WD Rear Axle
Table of Contents
NOTE: For GM322–D or GM325–D with Inasaka axle, see Chapter 10 – 4WD Rear Axle in this manual.
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Steering Stop Bolt Adjustment . . . . . . . . . . . . . . . . . 3
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4WD Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Bevel Gear Case and Axle Case . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Differential Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Groundsmaster 328–D
Axle Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Input Shaft/Pinion Gear . . . . . . . . . . . . . . . . . . . . . . 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Differential Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pinion Gear to Ring Gear Engagement . . . . . . . . 17
Gear Pattern Movement Summary . . . . . . . . . . . 18
Bidirectional Clutch . . . . . . . . . . . . . . . . . . . . . . . . . 19
Bidirectional Clutch Service . . . . . . . . . . . . . . . . . . 20
Page 10.1 – 1
4WD Rear Axle (Rev. G)
(Dae Dong Axle)
Specifications
Item
Specification
Wheel lug nut torque (rear)
45 to 55 ft-lbs. (61 to 75 Nm)
Rear wheel toe-in
0.000 in. (0.0 mm)
Tire pressure (front and rear)
21 psi (145 kPa)
Rear axle lubricant
SAE 80W90, API GL-5 gear lube
Bidirectional clutch lubricant
4WD Rear Axle (Rev. G)
(Dae Dong Axle)
Mobil 424 hydraulic fluid
Page 10.1 – 2
Groundsmaster 328–D
Adjustments
Steering Stop Bolt Adjustment
The rear axle steering stop bolts help prevent over–travel of the steering cylinder in case of impacts on rear
wheels. When the steering cylinder is fully extended, a
gap of 1/16” (1.6 mm) should exist between left side bevel gear case casting and stop bolt (Fig. 1). When the
steering cylinder is fully retracted, a gap of 1/16” (1.6
mm) should exist between right side bevel gear case
casting and stop bolt.
2
1
Figure 1
1. Steering stop bolt
Groundsmaster 328–D
Page 10.1 – 3
2. Bevel gear case (LH)
4WD Rear Axle (Rev. G)
(Dae Dong Axle)
Repairs
NOTE: See Traction Unit Operator’s Manual for Maintenance intervals and instructions.
4WD Rear Axle
23
24
32
31
30
29
28
33
27
25
22
56
19
36
55
26
21
18
34
35
35
37
57
20
34
54
53 52 51
58
39
17
49
16
15
13
14
10
40 41
11
9
RIGHT
6
5
4
46
45
1
3
7
8
42
43
44
50
12
2
FRONT
38
48
47
45 to 55 ft–lbs.
(61 to 75 Nm)
Figure 2
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
4WD rear axle
Adaptor
Cap screw (2 used)
Bidirectional clutch
Flat washer
Lock washer
Lock washer (6 used)
Socket head screw (6 used)
Driveshaft
Cap screw
Spacer
Cap screw (2 used)
Cap screw
R–clamp
Washer head screw
Guard
Flange head nut
Rear weight
Jam nut
Thrust washer
4WD Rear Axle (Rev. G)
(Dae Dong Axle)
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
Flange head screw (4 used)
Frame spacer (4 used)
Flange nut (4 used)
Main frame
Axle support
Lock nut (2 used)
Rear axle pin
Grease fitting
Washer head screw
Bumper
Flat washer (2 used)
Lock washer (2 used)
Cap screw (2 used)
Hydraulic fitting
O–ring
Hydraulic hose
Hydraulic hose
Grease fitting (2 used)
Cap screw (4 used)
Page 10.1 – 4
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
Washer (4 used)
Tie rod
Cap screw (2 used)
Cotter pin (2 used)
Tie rod end (2 used)
Grease fitting (2 used)
Hex nut (2 used)
Lug nut (5 used per wheel)
Wheel (2 used)
Slotted hex nut (2 used)
Cylinder support bracket
Jam nut (2 used per ball joint)
Thrust washer (0.0179” thick)
Thrust washer (0.0329” thick)
Steering cylinder
O–ring
Retaining ring (2 used)
Steering cylinder ball joint (2 used)
Oscillation stop (2 used)
Groundsmaster 328–D
Removal (Fig. 2)
Installation (Fig. 2)
1. Park machine on a level surface, lower cutting deck
(or implement), stop engine, engage parking brake and
remove key from the ignition switch.
1. Position rear axle support to axle. Install thrust washers (items 52 and 53) between axle boss and axle support to minimize clearance.
2. Drain oil from rear axle (see Traction Unit Operator’s
Manual).
2. Install rear axle pin (item 27) to secure axle to rear
axle support. Install thrust washer (item 20) and jam nut
(item 19) onto pivot pin. Torque jam nut from 90 to 120
ft–lb (122 to 163 N–m). Secure pivot pin to axle support
with washer head screw (item 29).
CAUTION
When changing attachments, tires, or performing other service, use correct blocks, hoists,
and jacks. Make sure machine is parked on a
solid, level surface such as a concrete floor.
Prior to raising machine, remove any attachments that may interfere with the safe and
proper raising of the machine. Always chock or
block wheels. Use jack stands or solid wood
blocks to support the raised machine. If the machine is not properly supported by blocks or
jack stands, the machine may move or fall,
which may result in personal injury.
3. Chock front wheels and jack up rear of machine.
Support machine with jack stands or solid wood blocks.
3. Position axle and axle support under machine with a
jack. Place frame spacers (item 22) on axle support.
Raise assembly to machine frame and align mounting
holes of axle support, frame spacers and machine
frame.
4. Secure rear axle support to frame with four (4) flange
head screws (item 21) and flange nuts (item 23).
5. Remove plugs and caps from steering cylinder hydraulic hoses and fittings. Connect hoses to fittings on
steering cylinder.
6. Position end of driveshaft to bidirectional clutch on
rear axle. Secure driveshaft to clutch with six (6) socket
head screws (item 8) and lock washers (item 7).
4. Remove wheels from rear axle.
5. Remove six (6) socket head screws (item 8) and lock
washers (item 7) that secure driveshaft to bidirectional
clutch on rear axle. Position end of driveshaft away from
clutch.
WARNING
Failure to maintain proper wheel lug nut
torque could result in failure or loss of wheel
and may result in personal injury.
6. Thoroughly clean around hydraulic hose connections to steering cylinder. Label hoses for assembly purposes. Disconnect hoses from fittings on steering
cylinder. Put plugs or caps on open hoses and fittings to
prevent contamination of hydraulic system.
7. Install wheels to axle. Torque wheel lug nuts from 45
to 55 ft-lbs. (61 to 75 Nm).
7. If machine has rear weight(s) attached to frame, remove weight(s).
9. If any rear weight(s) were removed from machine, attach weight(s) to machine.
8. Support rear axle to prevent it from falling. Remove
four (4) flange head screws (item 21) and flange nuts
(item 23) that secure rear axle support to equipment
frame. Lower rear axle and rear axle support from machine.
10.Fill axle and input gearbox with SAE 80W–90 weight
gear lube (see Traction Unit Operator’s Manual).
9. Locate and retrieve frame spacers (item 22).
12.Start engine and check for component interference
as steering wheel is turned from lock to lock. Also, check
for any hydraulic leaks.
10.Remove jam nut (item 19) and thrust washer (item
20) from rear axle pin (item 27) that attaches rear axle
to rear axle support. Remove washer head screw (item
29) that secures flange of axle pin to rear axle support.
8. Lower machine to ground.
11. Check bidirectional clutch lubricant level (see Traction Unit Operator’s Manual). Adjust if necessary.
13.Check rear wheel toe–in and adjust if necessary (see
Traction Unit Operator’s Manual).
11. Remove rear axle pin. Separate rear axle support
14.Check adjustment of steering stop bolts (see Steerfrom rear axle. Note location and quantity of thrust
ing Stop Bolt Adjustment in the Adjustments section).
washers (items 52 and 53) between axle boss and axle
support.
Groundsmaster 328–D
Page 10.1 – 5
4WD Rear Axle (Rev. G)
(Dae Dong Axle)
Bevel Gear Case and Axle Case
The following procedures assume the rear axle assembly has been removed from the machine.
35 to 41 ft–lbs.
(47 to 56 Nm)
1
Removal
6
1. Remove the mounting screws, nuts, and lock washers. Remove the bevel gear case/axle case assembly
and O-ring from the axle support (Fig. 3).
5
4
2. Mark both right and left bevel gear case/axle case
assemblies.
2
3
35 to 41 ft–lbs.
(47 to 56 Nm)
IMPORTANT: Do not interchange right and left
bevel gear case/axle case assemblies.
1.
2.
3.
4.
Cap screw
Lock nut
Lock washer
Axle support
Figure 3
5. Bevel gear case/axle
case assembly
6. O-ring
3. Remove the axle cover mounting screws. Remove
the axle cover from the axle case as an assembly
(Fig. 4).
1
4
3
2
1. Axle case
2. Axle cover assembly
Figure 4
3. Mounting screw
4. O-ring
4. Remove the axle case support mounting screws, the
axle case support, and the support shims (Fig. 5).
3
2
4
1
1. Axle case
2. Axle case support
4WD Rear Axle (Rev. G)
(Dae Dong Axle)
Page 10.1 – 6
Figure 5
3. Mounting screw
4. Support shim
Groundsmaster 328–D
5. Remove the knuckle pin mounting screws and the
knuckle pin. Remove the gasket and any remaining gasket material from either mating surface (Fig. 6).
6. While holding the bevel gear case, lightly tap the upper end of the bevel gear shaft out of the upper bearing
and upper bevel gear.
17 to 20 ft–lb
(23 to 27 N–m)
1
Threadlocking
Compound
3
5
4
7. Pull the bevel gear case from the axle case and remove the upper bevel gear, collar, spacer, and thrust
washer from the gear case.
7
9
8. Remove the axle case cover screws, cover, and the
O-ring from the axle case.
2
13
8
10
9. Remove the plug and sealing washer from the center
of the axle case cover. While holding the axle case cover, lightly tap the lower end of the bevel gear shaft out of
the lower bearing and lower bevel gear.
6
15
10.Remove and discard bevel gear shaft seals from
bevel gear case and axle case (Fig. 6).
11
12
14
17 to 20 ft–lb
(23 to 27 N–m)
Figure 6
1.
2.
3.
4.
5.
6.
7.
8.
Knuckle pin
Shaft seals
O–ring
Bevel gear case
Upper bearing
Bevel gear shaft
Collar
Spacer
9.
10.
11.
12.
13.
14.
15.
Upper bevel gear
Thrust washer
Lower bevel gear
Lower bearing
Axle case
Axle case cover
O-ring
Inspection
1. Measure the knuckle pin O.D. and the axle case support bushing I.D. to determine the bushing to pin clearance (Fig. 7). Replace components as necessary.
1
2
BUSHING TO PIN CLEARANCE:
0.002 to 0.016 in. (0.05 to 0.40 mm)
KNUCKLE PIN O.D. (Factory Spec.):
0.982 to 0.983 in. (24.95 to 24.98 mm)
AXLE CASE SUPPORT BUSHING I.D.
(Factory Spec.):
0.984 to 0.987 in. (25.00 to 25.08 mm)
2. Inspect all gears, shafts, bearings, cases, and covers for damage and wear. Replace components as necessary.
Groundsmaster 328–D
1. Knuckle pin
Page 10.1 – 7
Figure 7
2. Axle case support
4WD Rear Axle (Rev. G)
(Dae Dong Axle)
Installation
1. Coat new shaft seals with grease and install in axle
case and bevel gear case as shown (Fig. 8).
3
2
1
1. Axle case
2. Bevel gear case
2. Install the lower bevel gear, and bevel gear shaft in
the axle case cover. Coat a new O-ring with grease and
install the axle case cover (Fig. 9). Tighten cover screws
to 17 to 20 ft-lbs. (23 to 27 Nm).
3. Slide the bevel gear case over the bevel gear shaft
and install the thrust washer, spacer, bevel gear, and
collar. Make sure the bevel gear shaft is completely
seated in the upper and lower bearings (Fig. 9).
Figure 8
3. Shaft seal
17 to 20 ft–lbs.
(23 to 27 Nm)
Thread Locker
10
9
8
4. Install the knuckle pin. Use medium strength Loctite
thread locker and tighten the knuckle pin mounting
screws to 17 to 20 ft-lbs. (23 to 27 Nm).
7
6
5
3
2
1
4
1.
2.
3.
4.
5.
4WD Rear Axle (Rev. G)
(Dae Dong Axle)
Page 10.1 – 8
Axle case cover
Lower bevel gear
Bevel gear shaft
Lower bearing
Thrust washer
Figure 9
6.
7.
8.
9.
10.
17 to 20 ft–lbs.
(23 to 27 Nm)
Spacer
Upper bevel gear
Collar
Upper bearing
Knuckle pin
Groundsmaster 328–D
5. Determine necessary quantity of support shims.
B. Position support shims that were removed during
disassembly between axle case support and axle
case. Install mounting screws into axle case. Slowly
tighten screws while frequently checking for clearance (vertical endplay) between axle case support
and knuckle pin. If binding of components is noted
before screws are fully tightened, add additional support shims. Torque screws from 57 to 67 ft–lbs. (77 to
91 Nm).
C. Use dial indicator to measure vertical endplay of
axle case (Fig. 10).
AXLE CASE ASSEMBLY ENDPLAY:
0.001 to 0.008 in. (0.02 to 0.20 mm)
57 to 67 ft–lbs.
(77 to 91 Nm)
4
A. Lubricate the axle case support bushing with a
thin coat of grease and slide axle case support onto
knuckle pin.
1
VERTICAL
ENDPLAY
6
5
2
3
1. Axle case support
2. Axle case
3. Bevel gearcase
3
D. Adjust endplay by increasing or reducing number
of axle case support shims.
Figure 10
4. Dial indicator
5. Knuckle pin
6. Support shim location
2
1
NOTE: Axle case support shims are available in
0.004 in. (0.1 mm), 0.008 in. (0.2 mm), and 0.016 in.
(0.4 mm) thickness.
4
6. After correct support shims have been determined,
remove mounting screws, apply heavy strength Loctite
thread locker to screw threads, reinstall screws, and
torque from 57 to 67 ft–lbs. (77 to 91 Nm).
5
IMPORTANT: Correct engagement between bevel
gears is critical to axle performance and durability.
7. Temporarily install the bevel gear case/axle case assembly on the axle support. Position a dial indicator at
the tooths center. Prevent the axle from turning and
measure the upper bevel gear to differential shaft gear
backlash (Fig. 11).
Figure 11
1. Axle support
2. Upper bevel gear
3. Differential shaft gear
4. Dial indicator
5. Axle bearing shims
4
UPPER BEVEL GEAR BACKLASH:
0.004 to 0.016 in. (0.10 to 0.40 mm)
5
1
8. Adjust backlash by increasing or reducing axle bearing shim thickness (see Differential Shafts in this section
of this manual).
NOTE: Axle bearing shims are available in 0.004 in.
(0.1 mm), 0.008 in. (0.2 mm), and 0.020 in. (0.5 mm)
thickness.
2
3
Figure 12
1. Axle cover assembly
2. Lower bevel gear
3. Axle gear
Groundsmaster 328–D
Page 10.1 – 9
4. Dial indicator
5. Axle bearing shims
4WD Rear Axle (Rev. G)
(Dae Dong Axle)
9. Remove the bevel gear case/axle case assembly
from the axle support. Coat a new O-ring with grease
and temporarily install the axle cover assembly. Position
a dial indicator at the tooths center. Prevent the axle
from turning and measure the lower bevel gear to axle
gear backlash (Fig. 12).
LOWER BEVEL GEAR BACKLASH:
0.004 to 0.016 in. (0.10 to 0.40 mm)
10.Adjust backlash by increasing or reducing axle bearing shim thickness (see Axle Shafts in this section of this
manual).
NOTE: Axle bearing shims are available in 0.008 in.
(0.2 mm), 0.012 in. (0.3 mm), and 0.020 in. (0.5 mm)
thickness.
11. Tighten axle cover screws from 17 to 20 ft-lbs. (23 to
27 Nm).
12.Coat a new O-ring with grease and install the bevel
gear case/axle case assembly on the axle support.
Tighten mounting screws and nuts from 35 to 41 ft-lbs.
(47 to 56 Nm) (Fig. 13).
Differential Shafts
The following procedures assume the rear axle assembly has been removed from the machine.
35 to 41 ft–lbs.
(47 to 56 Nm)
1
Removal
6
IMPORTANT: Do not interchange right and left differential shafts assemblies.
5
4
1. Remove the mounting screws, nuts, and lock washers. Remove the bevel gear case/axle case assembly
and O-ring from the axle support (Fig. 13).
3
35 to 41 ft–lbs.
(47 to 56 Nm)
2. Mark and pull the differential shaft assembly from the
axle support.
3. Remove the retaining ring and bevel gear (Fig 14).
4. Drive the differential shaft out of the bearings. Remove the bearings and bearing shims.
2
Figure 13
1.
2.
3.
4.
Cap screw
Lock nut
Lock washer
Axle support
5. Bevel gear case/axle
case assembly
6. O-ring
5. Inspect all gears, shafts, bearings, and cases for
damage and wear. Replace components as necessary.
Installation
3
1. Press bearings onto differential shaft. Place correct
combination of bearing shims in axle support and drive
differential shaft and bearing assembly into axle support.
5
4
2
1
2. Install bevel gear and retaining ring.
3. Align differential shaft splines with differential gear
assembly and slide differential shaft assembly onto axle
support.
4. Coat new O-ring with grease. Install bevel gear case/
axle case assembly (see Bevel Gear Case/Axle Case
Assembly in this section of this manual).
4WD Rear Axle (Rev. G)
(Dae Dong Axle)
Figure 14
1. Retaining ring
2. Bevel gear
3. Differential shaft
Page 10.1 – 10
4. Bearing
5. Bearing shims
Groundsmaster 328–D
Axle Shafts
The following procedures assume the rear axle assembly has been removed from the machine.
17 to 20 ft–lbs.
(23 to 27 Nm)
Removal
1
4
1. Remove the axle cover mounting screws. Remove
the axle cover from the axle case as an assembly
(Fig. 15).
3
2. Use a bearing puller to remove the bearing and bevel
gear as shown (Fig. 16).
3. Remove the shims, spacer, and retaining ring. Drive
the axle out of the bearing and cover. Remove and discard the axle shaft seal.
4. Inspect all gears, shafts, bearings, spacers, and
cases for damage and wear. Replace components as
necessary.
2
Figure 15
1. Axle case
2. Axle cover assembly
3. Mounting screw
4. O-ring
Installation
1
1. Coat new axle shaft seal with grease and install in
axle cover as shown (Fig. 17).
2
2. Press the axle cover and bearing assembly onto the
axle shaft. Press only on the inner race of the cover
bearing (Fig. 17).
4
3
5
3. Install retaining ring, spacer, and correct combination of bearing shims. Install bevel gear and bearing.
4. Coat a new O-ring with grease and install the axle
cover assembly. Tighten axle cover screws to 17 to 20
ft-lbs. (23 to 27 Nm).
1. Bearing
2. Bevel gear
3. Shims
Figure 16
4. Spacer
5. Retaining ring
1
4
2
3
1. Axle shaft seal
2. Axle cover
Groundsmaster 328–D
Page 10.1 – 11
Figure 17
3. Bearing
4. Axle shaft
4WD Rear Axle (Rev. G)
(Dae Dong Axle)
Input Shaft/Pinion Gear
The following procedures assume the rear axle assembly has been removed from the machine.
Removal
1. Remove input shaft/pinion gear assembly from the
axle support. Remove the shims and bearing case Oring.
7
2. Release the stake washer and remove the locknut.
Remove and discard the stake washer (Fig. 18).
5
4
3. Drive the input shaft/pinion gear out from the outer
bearing cone and bearing case. Remove and discard
the oil seal and O-ring.
8
4. Inspect all gears, shafts, bearings, spacers, and
cases for damage and wear. Replace components as
necessary.
3
NOTE: Replacement input shaft/pinion gears are only
available in matched ring and pinion sets.
6
Installation
9
NOTE: When installing new bearing cones, press only
on the inner race of the bearing cone.
10
2. Place the shaft and bearing assembly in the bearing
case and install the outer bearing cone.
NOTE: The bearings must be completely seated.
There should be no input shaft/pinion gear end play.
11
2
1. If the inner bearing cone was removed, press a new
bearing cone all the way onto the input shaft/pinion gear.
1
1.
2.
3.
4.
5.
6.
Lock nut
Stake washer
Bearing case
Bearing case O-ring
Inner bearing
Outer bearing
Figure 18
7.
8.
9.
10.
11.
Input shaft/pinion gear
Bearing case shims
Seal collar
O-ring
Oil seal
3. Coat a new oil seal with grease and install as shown
(Fig. 19).
4. Coat a new O-ring with grease. Install O-ring in the
oil seal collar, and install the collar.
5. Install a new stake washer. Install the lock nut finger
tight.
0.040 in. (1.0 mm)
2
6. Set the bearing preload be securing the bearing case
in a vise. Thread a M12 x 1.5 hex head capscrew into the
splined end of the input shaft/pinion gear.
1
7. Slowly tighten the locknut until 4.0 to 6.0 in-lbs. (0.4
to 0.7 Nm) of force is required to rotate the input shaft/
pinion gear in the bearing case.
8. Secure the lock nut with the stake washer.
1. Oil seal
4WD Rear Axle (Rev. G)
(Dae Dong Axle)
Page 10.1 – 12
Figure 19
2. Bearing case
Groundsmaster 328–D
9. Use a depth gauge to measure the distance from the
end face of the input shaft/pinion gear to the mating surface of the bearing case. Subtract the “Design Cone
Center Distance” from this distance to determine initial
shim thickness (Fig. 20).
Design
Cone Center
Distance
1
DESIGN CONE CENTER DISTANCE
(distance from mating surface of axle support to end
face of pinion gear):
1.870 + 0.002 in. (47.5 + 0.05 mm)
2
NOTE: Bearing case shims are available in 0.004 in.
(0.1 mm) and 0.008 in. (0.2 mm) thickness.
10.Coat a new O-ring with grease. Place shims on the
bearing case and temporarily install input shaft/pinion
gear assembly into axle case. Tighten mounting screws
to 35 to 41 ft-lbs. (47 to 56 Nm).
Figure 20
1. Input shaft/pinion gear
2. Bearing case
11. Insert a screwdriver through the drain plug hole to
hold ring gear and measure the pinion gear to ring gear
backlash (Fig. 21).
1
PINION GEAR TO RING GEAR BACKLASH:
0.004 to 0.016 in. (0.10 to 0.40 mm)
12.Adjust backlash by increasing or reducing bearing
case shim thickness.
3
13.Check pinion gear to ring gear engagement (see Pinion Gear to Ring Gear Engagement in this section of this
manual.
14.Place the correct combination of shims on the bearing case. Tighten mounting screws to 35 to 41 ft-lbs. (47
to 56 Nm).
Groundsmaster 328–D
2
4
35 to 41 ft–lbs.
(47 to 56 Nm)
Figure 21
1. Axle case
2. Screwdriver
Page 10.1 – 13
3. Dial indicator
4. Input shaft/pinion gear
4WD Rear Axle (Rev. G)
(Dae Dong Axle)
Differential Gear
The following procedures assume the rear axle assembly has been removed from the machine.
35 to 41 ft–lbs.
(47 to 56 Nm)
5
Removal
1
7
1. Remove bevel gear case/axle case assemblies (see
Bevel Gear Case/Axle Case Assembly in this section of
this manual).
6
2
IMPORTANT: Do not interchange right and left differential shafts assemblies.
2. Mark and pull the differential shaft assemblies from
the axle support (see Differential Shafts in this section
of this manual).
3. Remove input shaft/pinion gear assembly, shims,
and O-ring from the axle support (Fig. 22).
4. Remove the axle support case screws. Separate the
axle support halves and remove the O-ring.
4
3
1.
2.
3.
4.
Pinion gear
O-ring
Axle support (right)
Axle support (left)
Figure 22
5. Case screws
6. Differential gear
7. O-ring
5. Remove the differential gear assembly, bearings,
and adjusting shims from the axle case.
2
1
6. Drive the spring pin from the differential case with a
punch and hammer. Discard the spring pin (Fig. 23).
NOTE: Mark and arrange all components so they can
be reassembled in their original position.
7. Remove the differential pinion shaft, pinion gears,
and pinion washers. Remove the differential side gears
and side gear shims. Remove the ring gear from the differential case only if the ring gear will be replaced (Fig.
24).
Figure 23
1. Differential case
2. Spring pin
NOTE: Replacement ring gears are only available in
matched ring and pinion sets.
1
3
2
5
4
5
4
2
3
7
6
22 to 25 ft–lbs.
(30 to 34 Nm)
Thread Locker
Figure 24
1.
2.
3.
4.
4WD Rear Axle (Rev. G)
(Dae Dong Axle)
Differential pinion shaft
Pinion gear
Pinion washer
Side gear
Page 10.1 – 14
5. Side gear shims
6. Ring gear
7. Differential case
Groundsmaster 328–D
Inspection
1. Measure the differential side gear O.D. and the differential case I.D. to determine the side gear to case
clearance (Fig. 25). Replace components as necessary.
SIDE GEAR TO CASE CLEARANCE:
0.002 to 0.012 in. (0.05 to 0.30 mm)
1
SIDE GEAR O.D. (Factory Spec.):
1.335 to 1.337 in. (33.91 to 33.95 mm)
DIFFERENTIAL CASE I.D. (Factory Spec.):
1.339 to 1.341 in. (34.00 to 34.06 mm)
2
2. Measure the differential pinion shaft O.D. and the
pinion gear I.D. to determine the pinion shaft to pinion
gear clearance (Fig. 26). Replace components as necessary.
PINION SHAFT TO PINION GEAR CLEARANCE:
0.001 to 0.010 in. (0.03 to 0.25 mm)
PINION SHAFT O.D. (Factory Spec.):
0.550 to 0.551 in. (13.97 to 13.10 mm)
1. Side gear
PINION GEAR I.D. (Factory Spec.):
0.551 to 0.552 in. (13.10 to 14.02 mm)
Figure 25
2. Differential case
3. Inspect all gears, shafts, bearings, cases, and covers for damage and wear. Replace components as necessary.
1
2
Figure 26
1. Pinion shaft
Groundsmaster 328–D
Page 10.1 – 15
2. Pinion gear
4WD Rear Axle (Rev. G)
(Dae Dong Axle)
Installation
3
1. If the ring gear was removed from the differential
case, use medium strength Loctite thread locker and
tighten the mounting screws from 22 to 25 ft-lb (30 to
34 N–m).
2
1
2. Apply molybdenum disulfide lubricant (Three Bond
1901 or equivalent) to the splines and bearing surfaces
of the differential pinion gears, pinion washers and side
gears.
3. Install the side gear shims and side gears in their
original location in the differential case.
4. Place the differential pinion gears and pinion washers in their original location in the differential case. Temporarily install the differential pinion shaft.
Figure 27
1. Vise
2. Differential gear case
3. Dial indicator
More than 35% total tooth contact
5. Secure the differential case in a soft jawed vise. Position a dial indicator on a tooth of the differential pinion
gear. Press the pinion and side gear against the differential case and measure the pinion gear to side gear backlash (Fig. 27).
PINION GEAR TO SIDE GEAR BACKLASH:
0.004 to 0.016 in. (0.10 to 0.40 mm)
1/3 to 1/2 of entire width
from small end of tooth
Figure 28
6. Adjust backlash by increasing or reducing side gear
shim thickness.
NOTE: Side gear shims are available in 0.043 in. (1.10
mm), 0.047 in. (1.20 mm) and 0.051 in. (1.30 mm) thickness.
7. Apply gear marking compound, such as DyKemR
Steel Blue lightly over several gear teeth.
8. While applying a light load to either side gear, rotate
either pinion gear until the side gears have made one
complete revolution.
9. Ideal tooth contact should cover more than 35% of
each tooth surface. The contact area should be in the
center of each tooth and extend 1/3 to 1/2 way across
each tooth from the toe (small) end (Fig. 28).
10.Adjust side gear shims if necessary to correct tooth
contact. Recheck differential pinion gear to side gear
backlash if any changes are made.
12.Install differential gear assembly in right side axle
support half.
13.Coat a new o-ring with grease and install left side
axle support half. Tighten axle support case screws from
35 to 41 ft-lb (47 to 56 N–m).
14.Install input shaft/pinion gear assembly (see Input
Shaft/Pinion Gear in this section of this manual).
15.Coat new o-rings with grease, align differential shaft
splines with differential gear assembly and slide differential shaft assemblies onto axle support (see Differential Shafts in this section of this manual).
16.Install bevel gear case/axle case assemblies (see
Bevel Gear Case/Axle Case Assembly in this section of
this manual).
11. After backlash and tooth contact have been adjusted, align the hole in the differential pinion shaft with
the hole in the differential case and install a new spring
pin.
4WD Rear Axle (Rev. G)
(Dae Dong Axle)
Page 10.1 – 16
Groundsmaster 328–D
Pinion Gear to Ring Gear Engagement
The final position of the pinion gear is verified by using
the gear contact pattern method as described in the following procedure.
PROFILE
TOP LAND
GEAR TOOTH DEFINITIONS (Fig. 29):
Toe – the portion of the tooth surface at the end towards the center.
TOE
HEEL
Heel – the portion of the gear tooth at the outer end.
LENGTHWISE
BEARING
ARC
Top Land – top surface of tooth.
1. Paint the teeth of the ring gear, both drive and coast
side, with a gear marking compound, such as DyKemR
Steel Blue.
ROOT
Figure 29
2. Install the input shaft/pinion gear assembly into axle
case.
More than 35% total tooth contact
3. While applying a light load to the ring gear, rotate the
pinion gear in the direction of forward travel until the ring
gear has made one complete revolution.
Ideal tooth contact observed on the ring gear should
cover more than 35% of each tooth surface. The contact
area should be in the center of each tooth and extend 1/3
to 1/2 way across each tooth from the toe end (Fig. 30).
1/3 to 1/2 of entire width
from small end of tooth
Figure 30
Adjustments to the gear contact position are made by
moving the input shaft/pinion gear (bearing case shims)
or by moving the differential gear case (differential bearing shims) (Fig. 31).
4
3
NOTE: Bearing case shims are available in 0.004 in.
(0.10 mm) and 0.008 in. (0.20 mm) thickness.
NOTE: Differential bearing shims are available in
0.004 in. (0.10 mm), 0.008 in. (0.20 mm) and 0.016 in.
(0.40 mm) thickness.
Study the different contact patterns (Figs. 32 and 33)
and correct gear engagement as necessary.
2
NOTE: When making changes, note that two variables
are involved (see Gear Pattern Movement Summary in
this section of this manual).
Example: If the pinion gear to ring gear backlash is set
correctly to specifications and the bearing case shim is
changed to adjust tooth contact, it may be necessary to
readjust backlash to the correct specification before
checking the contact pattern.
Groundsmaster 328–D
1
Figure 31
1. Input shaft/pinion gear
2. Bearing case shims
3. Differential gear case
Page 10.1 – 17
4. Differential bearing
shims
4WD Rear Axle (Rev. G)
(Dae Dong Axle)
Gear Pattern Movement Summary
Heel Contact
Base Contact
Every gear has a characteristic pattern. The illustrations
show typical patterns only and explain how patterns shift
as gear location is changed.
1. If contact is toward the heel or base of the gear (Fig.
32):
A. Install thicker or additional bearing case shim(s)
to move pinion shaft toward ring gear.
Figure 32
B. Install thinner or remove differential bearing
shim(s) to move ring gear backward.
C. Repeat until proper tooth contact and pinion gear
to ring gear backlash are correct.
Toe Contact
Tip Contact
2. If contact is toward the toe or tip of the gear (Fig. 33):
A. Install thinner or remove bearing case shim(s) to
move pinion shaft away from ring gear.
B. Install thicker or additional differential bearing
shim(s) to move ring gear forward.
Figure 33
C. Repeat until proper tooth contact and pinion gear
to ring gear backlash are correct.
4WD Rear Axle (Rev. G)
(Dae Dong Axle)
Page 10.1 – 18
Groundsmaster 328–D
Bidirectional Clutch
RIGHT
FRONT
2
10
1
9
11
7
5
6
4
3
12
8
Loctite #242
Anti–seize
Lubricant
Figure 34
1.
2.
3.
4.
Clutch locator adapter
Cap screw (2 used)
Cap screw (2 used)
Bidirectional clutch
5.
6.
7.
8.
Spacer
Flat washer
Lock washer
Cap screw
9.
10.
11.
12.
Lock washer (6 used)
Socket head screw (6 used)
Drive shaft assembly
Rear axle assembly
Removal (Fig. 34)
Installation (Fig. 34)
1. Park machine on a level surface, lower cutting deck
(or implement), stop engine, engage parking brake and
remove key from the ignition switch.
1. Apply anti–seize lubricant to splines of rear axle input shaft.
2. Drain oil from bidirectional clutch (see Traction Unit
Operator’s Manual).
3. Remove six (6) socket head screws (item 10) and
lock washers (item 9) that secure driveshaft to bidirectional clutch on rear axle. Position end of driveshaft
away from clutch.
4. Remove cap screw (item 8), lock washer (item 7) and
flat washer (item 6) that secure clutch to rear axle. Locate and retrieve spacer (item 5).
5. Pull bidirectional clutch from rear axle input shaft.
Groundsmaster 328–D
2. Slide bidirectional clutch onto rear axle input shaft.
Align notches in clutch housing with cap screw heads on
axle clutch locator adapter.
3. Apply Loctite #242 (or equivalent) to threads of cap
screw (item 8) that secures clutch to rear axle shaft.
4. Secure clutch to axle shaft with cap screw, lock
washer (item 7), flat washer (item 6) and spacer (item 5).
5. Position end of driveshaft to bidirectional clutch on
rear axle. Secure driveshaft to clutch with six (6) socket
head screws (item 10) and lock washers (item 9).
6. Fill clutch with oil to the proper level (see Traction
Unit Operator’s Manual).
Page 10.1 – 19
4WD Rear Axle (Rev. G)
(Dae Dong Axle)
Bidirectional Clutch Service
Hylomar Jointing
Compound
1
DRIVE
SHAFT
4
6
10
3
12
REAR
AXLE
2
5
14
14 ft–lb
(19 N–m)
7
16
8
18
9
11
13
15
17
Figure 35
1.
2.
3.
4.
5.
6.
End plate
Socket head screw (6 used)
Oil seal
Snap ring
Bearing
Housing
7.
8.
9.
10.
11.
12.
Phillips head screw w/o–ring
Hub
Needle bearing
Thrust washer
Wave spring
Roller cage assembly
Disassembly (Fig. 35)
1. Thoroughly clean exterior of clutch before disassembly.
2. Disassemble clutch using Figure 35 as a guide.
Assembly (Fig. 35)
1. Lightly lubricate clutch components with clean Mobil
Fluid 424 before assembly.
13.
14.
15.
16.
17.
18.
Oil seal
Bearing Housing
Bearing
Snap ring
Retaining ring
Oil seal
3. When installing oil seals, make sure that seal lips are
facing in.
4. Apply Hylomar Jointing Compound (or equivalent) to
end plate (item 1) mating surface before installing end
plate.
5. Secure end plate with six (6) socket head cap
screws. Torque screws 14 ft–lb (19 N–m).
2. Assemble clutch using Figure 35 as a guide.
4WD Rear Axle (Rev. G)
(Dae Dong Axle)
Page 10.1 – 20
Groundsmaster 328–D
Chapter 11
72″ Cutting Units
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 3
Grass Deflector . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 4
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Height of Cut Adjustment . . . . . . . . . . . . . . . . . . 5
Mismatch Adjustments . . . . . . . . . . . . . . . . . . . . 6
Belt Tension Adjustment . . . . . . . . . . . . . . . . . . . 7
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Blade Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . 10
Groundsmaster® 300 Series
Page 11 - 1
Caster Arm Bushing Replacement . . . . . . . . . .
Rear Caster Wheel Bearing Service . . . . . . . . .
Front Caster Wheel Bearing Service . . . . . . . . .
Separating Cutting Unit From Traction Unit. . . .
Mounting Cutting Unit to Traction Unit. . . . . . . .
Push Arm and Torsion Spring Service . . . . . . . .
Gearbox Removal and Installation . . . . . . . . . .
Gearbox Service . . . . . . . . . . . . . . . . . . . . . . . .
Blade Spindle Service . . . . . . . . . . . . . . . . . . . .
11
12
13
14
16
18
21
23
26
Table of Contents
Specifications
ITEM
SPECIFICATION
__________________________________________________________________________________________
Cutting width
71.5 inch
________________________________________________________________________________________________________________________________________________________
Height of cut range
1 to 4 inch
________________________________________________________________________________________________________________________________________________________
Height of cut adjustment
0.5 inch increments
________________________________________________________________________________________________________________________________________________________
Blade bolt torque
75 to 100 ft-lb (left-hand thread)
________________________________________________________________________________________________________________________________________________________
Spindle nut torque
140 - 160 ft-lb.
________________________________________________________________________________________________________________________________________________________
Spindle end play
.006 inch max.
________________________________________________________________________________________________________________________________________________________
Spindle rolling torque
10 in-lb max.
________________________________________________________________________________________________________________________________________________________
Gearbox lubricant
SAE 80W90, API GL-5 gear lube
Figure 1
1. Filler plug
2. Check plug
Specifications
Page 11 - 2
Groundsmaster® 300 Series
General Information
Grass Deflector
WARNING
The grass deflector (Fig. 2) is a safety device
that diverts grass and other foreign objects
being discharged downward. WE STRONGLY
RECOMMEND THAT THE DEFLECTOR BE IN ITS
NORMAL OPERATING POSITION WHENEVER THE
CUTTING UNIT IS ENGAGED. NEVER OPERATE
CUTTING UNIT WITH THE DEFLECTOR REMOVED
FROM THE CUTTING UNIT OR TIED/BLOCKED IN
A RAISED POSITION, SINCE THE BLADES COULD
THEN THROW DEBRIS A CONSIDERABLE DISTANCE WITH SUFFICIENT FORCE TO CAUSE PERSONAL INJURY OR DAMAGE TO PROPERTY. If
Figure 2
1. Deflector in lowest position
the grass deflector is damaged, repair or re­
place the affected part(s).
NOTE: The deflector is spring loaded into its
downward normal operating position, but the
operator can temporarily swing it out of the
way to facilitate loading in a trailer or when
otherwise necessary.
Groundsmaster® 300 Series
Page 11 - 3
General Information
Troubleshooting
Troubleshooting
Page 11 - 4
Groundsmaster® 300 Series
Adjustments
Height of Cut Adjustment (Fig. 3, 4)
The height of cut is adjustable from 1 to 4 inches in
1/2 inch increments, by adding or removing an equal
number of spacers on the front and rear caster forks.
The height of cut chart below gives the combinations of
spacers to use for all height of cut settings.
NOTE: 1/4 inch spacers are available and can be ordered from your Toro distributor by Toro Part No.
27-1040. (Quantity - 8).
Height of Cut
Spacers Below Caster Arms
inches
mm
Front
Rear
1
1-1/2
2
2-1/2
3
3-1/2
4
25
38
51
64
76
89
102
0
1
2
3
4
5
6
0
1
2
3
4
5
6
NOTE: A more optimum cutting appearance of the turf
can be achieved in the lower heights of cut by lowering
the rear of the cutting unit. Accomplish this by relocating
the rear caster wheel axles in the upper hole of the
caster forks. Replace the axles into the lower caster fork
holes for higher height of cut settings where optimum
cutting appearance is not required.
Figure 3
1. Lynch pin
2. Spacers
3. Thrust washer
4. Large (front)
4. caster spindle
IMPORTANT: Do not attempt to cut off more than
one inch of the grass blades in the one (1) inch
height of cut setting with the rear of the cutting unit
lowered, as this may cause the engine to labor
excessively.
1. Start the engine and raise cutting unit so front caster
height of cut can be changed. Stop engine after cutting
unit is raised. Rear caster height of cut can be changed
with cutting unit lowered.
Figure 4
2. Squeeze back of wire and rotate wire on lynch pin.
Pull pin out of caster spindle. Slide spacers onto the
caster spindle to get desired height of cut. Then slide
washer onto spindle.
1. Lynch pin
2. Small (rear) caster
3. Spacers
4. Washer
5. For 1 in. H.O.C. only
3. Push caster spindle through caster arm. Slide any
remaining spacers onto spindle. Install lynch pin to
retain parts in place.
NOTE: When cutting unit is used in 1 inch or 1-1/2 inch
height of cut setting, front and rear rollers must be
positioned in the upper bracket holes.
Groundsmaster® 300 Series
Page 11 - 5
Adjustments
Checking and Correcting Mismatch of Blades (Fig. 5)
If there is mismatch between the blades, the grass will
appear streaked when it is cut. This problem can be
corrected by making sure the blades are straight and all
blades are cutting on the same plane.
1. Using a 3 foot long carpenters level, find a flat surface
on the shop floor.
2. Set rear caster wheels in the upper hole of caster
forks and adjust height of cut so all six height of cut
spacers are below the caster arm.
3. Lower cutting unit onto flat surface. Remove covers
from top of cutting unit. Loosen idler pulleys to release
tension against all three belts.
4. Rotate blades until the ends face forward and backward. Measure from floor to front tip of cutting edge and
remember this dimension. Then rotate same blade so
opposite end is forward and measure again. The difference between dimensions must not exceed 1/8 inch. If
difference exceeds 1/8 inch, replace the blade because
it is bent. Make sure to measure all three blades.
7. Remove cap screws, flat washers, lock washers and
nuts from outer spindle, in the area where shims must
be added. To raise or lower the blade, add a shim, Part
No. 3256-24, between spindle housing and bottom of
cutting unit. Continue to check alignment of blade and
add shims until tips of blades are within the required
dimension.
IMPORTANT: Do not use more than three shims at
any one hole location. Use decreasing numbers of
shims in adjacent holes if more than one shim is
added to any one hole location.
8. Tension idler pulleys against all three belts. Also
install covers to top of cutting unit.
9. Set rear caster wheels in lower holes in caster forks
if height of cut is above one (1) inch and adjust height
of cut.
10. Mount cutting unit to traction unit: refer to Mounting
Cutting Unit To Traction Unit
5. Compare measurements of outer blades with the
center blade. Center blade must not be more than 3/8
inch lower than outer blades. If center blade is more than
3/8 inch lower than outer blades, proceed to step 7 and
add shims between spindle housing and bottom of
cutting unit.
6. Rotate blades so tips line up with one another. Tips
of the adjacent blades must be within 1/8 inch of each
other. If tips are not within 1 /8 inch of each other,
proceed to step 7 and add shims between spindle
housing and bottom of cutting unit.
Adjustments
Page 11 - 6
1/8"
Figure 5
Groundsmaster® 300 Series
Belt Tension Adjustment (Fig. 6)
1. Lower the cutting unit to the floor and shut off the
engine. Engage the parking brake.
2. Remove the deck covers from the top of the cutting
unit.
3. Loosen the idler pulley for the belt being adjusted and
move idler into belt using a pry bar, until you get the
proper tension. Tighten the idler pulley flange nut.
Recommended tension is 3/8 inch deflection when
an eight (8) pound load is applied to the center of the
25 inch span between pulleys. Deflection is measured at the position on the belt where the load is
applied.
Groundsmaster® 300 Series
Page 11 - 7
Figure 6
1. Lower belt idler
2. Flange nut
Adjustments
Repairs
Blade Service (Fig. 7, 8, 9)
The blade must be replaced if a solid object is hit, the
blade is out of balance, worn or bent. Always use
genuine TORO replacement blades to ensure safety
and optimum performance. Never use blades made by
other manufacturers because they could be dangerous.
Do not try to straighten a blade that is bent,
and never weld a broken or cracked blade.
Always use a new TORO blade to assure
continued safety certification of the product.
1 . Raise cutting unit to highest position, shut the engine
off and engage parking brake. Block cutting unit to
prevent it from falling accidentally.
2. Grasp end of blade using a rag or thickly padded
glove. Remove special screw, belleville washer and
blade from spindle assembly.
NOTE: The special screw has left hand thread.
3. To install the blade, assemble parts in reverse order,
and make sure the blade sail is facing up. Tighten
special screw to 75 to 100 ft-lb.
Figure 7
Inspecting and Sharpening Blade
1. Raise cutting unit to highest position, shut the engine
off and engage parking brake. Block cutting unit to
prevent it from falling accidentally.
2. Examine cutting ends of the blade carefully, especially where the flat and curved parts of the blade meet.
Since sand and abrasive material can wear away the
metal that connects the flat and curved parts of the
blade, check the blade before using the machine. If any
wear is noticed, replace the blade: refer to Removing
Cutter Blade.
Figure 8
WARNING
If the blade is allowed to wear, a slot will form
between the sail and flat part of the blade.
Eventually, a piece of the blade may break off
and be thrown from under the housing, pos­
sibly resulting in serious injury to yourself or
bystander.
3. Examine cutting edges of all blades. Sharpen the
cutting edges if they are dull or nicked. Sharpen only the
top side of the cutting edge and maintain the original
cutting angle to assure sharpness. The blade will remain
balanced if same amount of metal is removed from both
cutting edges.
Figure 9
4. To check blade for being straight and parallel, lay
blade on level surface and check its ends. Ends of blade
must be slightly lower than the center, and cutting edge
must be lower than heel of the blade. This blade will
produce good quality of cut and require minimal power
from the engine. By contrast, a blade that is higher at
the ends than the center, or cutting edge higher than the
heel of the blade is warped or bent and must be replaced.
5. To install the blade, ,assemble parts in reverse order,
and make sure the blade sail is facing up. Tighten
special screw to 75 to 100 ft-lb.
Groundsmaster® 300 Series
Page 11 - 9
Repairs
Belt Replacement (Fig. 10)
1. Lower cutting unit to the shop floor, shut off the engine
and engage the parking brake. Remove covers on top
of cutting unit and set covers aside. Loosen idler pulleys
to release tension of belts.
2. Remove carriage bolts, lock washers and nuts holding gear box in place. Lift gear box off mounting plate
and lay it on top of cutting unit.
3. Remove belts from spindle pulleys.
4. Mount a belt on lower pulley groove of left spindle,
slide belt under belt idler mount plate and install around
center spindle pulley. Tension belt by levering idler
pulley against belt and tighten idler pulley flange nut.
Figure 10
1. Lower belt idler
2. Flange nut
5. Place the right spindle belt under the gear box mount
plate and the opposite end on top of the right spindle
pulley. Place the left spindle belt under the gear box
mount plate and the opposite end on top of the left
spindle pulley. Mount the gear box and loop the belts
around the gear box pulley.
6. Feed the right and left spindle belts over the pulleys
by rotating the cutter blades. Tighten the gear box
mounting fasteners.
7. Tension idler pulleys against both belts. Install covers
on top of cutting unit.
Repairs
Page 11 - 10
Groundsmaster® 300 Series
Caster Arm Bushing Service (Fig. 11)
The caster arms have bushings pressed into the top and
bottom portion of the tube and after many hours of
operation, the bushings will wear. To check the bushings, move caster fork back and forth and from side-toside. If caster spindle is loose inside the bushings,
bushings are worn and must be replaced.
1. Raise cutting unit and block it so it cannot fall accidentally.
2. Remove lynch pin and spacers from top of caster
spindle.
3. Pull caster spindle out of mounting tube. Allow
spacer(s) and thrust washer to remain on bottom of
spindle to assure same height of cut when caster spindle is reinstalled.
Figure 11
4. Insert pin punch into top or bottom of mounting tube
and drive bushing out of tube. Also drive other bushing
out of tube. Clean inside of tubes to remove dirt.
5. Apply grease to inside and outside of new bushings.
Using a hammer and flat plate, drive bushings into
mounting tube.
6. Inspect caster spindle for wear and replace it if
damaged.
7. Push caster spindle through bushings and mounting
tube. Slide spacers onto spindle. Install lynch pin
through caster spindle to retain all parts in place.
Groundsmaster® 300 Series
Page 11 - 11
Repairs
Rear Caster Wheel Bearing Service (Fig. 12)
The rear caster wheels rotate on high quality roller
bearings which are supported by spanner bushings.
Even after many hours of use, provided that the bearing
was kept well-lubricated, bearing wear will be minimal.
However, failure to keep bearings lubricated will cause
rapid wear. A wobbly caster wheel usually indicates a
worn bearing.
1. Remove capscrew and locknut holding caster wheel
and (2) washers between caster fork.
2. Pull spanner bushing out of wheel hub.
3. Remove bushing from wheel hub and allow bearing
to fall out. Remove bushing from opposite side of wheel
hub.
4. Check the bearing, spanner and inside of wheel hub
for wear. Replace defective parts.
Figure 12
5. To assemble the caster wheel, push bushing into
wheel hub. Slide bearing into wheel hub. Push other
bushing into open end of wheel hub to captivate the
bearing inside the wheel hub.
6. Carefully slide spanner through the bushings and
wheel hub.
7. Install caster wheel assembly and (2) washers between caster fork, and secure all parts in place with
capscrew and locknut.
8. Lubricate caster wheel bearing through grease fitting,
using No. 2 general purpose lithium grease.
Repairs
Page 11 - 12
Groundsmaster® 300 Series
Front Caster Wheel Bearing Service (Fig. 13)
The front caster wheels rotate on high-quality roller
bearings which are supported by spanner bushings.
Even after many hours of use, provided that the bearing
was kept well-lubricated, bearing wear will be minimal.
However, failure to keep bearings lubricated will cause
rapid wear. A wobbly caster wheel usually indicates a
worn bearing.
1. Remove capscrew and locknut holding caster wheel
and (2) washers between caster fork.
2. Pull spanner bushing out of wheel hub.
3. Remove bushing from wheel hub and allow bearing
to fall out. Remove bushing from opposite side of wheel
hub.
4. Check the bearing, spanner and inside of wheel hub
for wear. Replace defective parts.
Figure 13
5. To assemble the caster wheel, push bushing into
wheel hub. Slide bearing into wheel hub. Push other
bushing into open end of wheel hub to captivate the
bearing inside the wheel hub.
6. Carefully slide spanner through the bushings and
wheel hub.
7. Install caster wheel assembly and (2) washers between caster fork, and secure all parts in place with
capscrew and locknut.
8. Lubricate caster wheel bearing through grease fitting,
using No. 2 general purpose lithium grease.
Groundsmaster® 300 Series
Page 11 - 13
Repairs
Separating Cutting Unit From Traction Unit (Fig. 14, 15, 16, 17)
1. Position machine on level surface, lower cutting unit
to the shop floor, shut engine off and engage parking
brake.
2. Remove self-tapping screws securing shield to top of
cutting unit and set shield aside.
3. Drive roll pin out of yoke and input shaft of gear box.
Also, loosen cap screws and lock nuts. Slide yoke off
the input shaft. If traction unit will be used without the
cutting unit, drive roll pin out of yoke at PTO pivot shaft
and remove entire universal shaft from traction unit.
Figure 14
DANGER
Do not start the engine and engage the PTO
lever when PTO shaft is not connected to gear
box on cutting unit. If engine is started and
PTO shaft is allowed to rotate, serious injury
could result.
1. PTO yoke
2. Yokes in phase
3. Roll pin
4. Capscrews & locknuts
4. Disconnect spring from lift cylinder cotter pin. Remove cotter pins and clevis pins securing lift chains to
lift arm.
Figure 15
1. PTO shield
2. Self-tapping screws
3. Lift chain
Repairs
Page 11 - 14
4. Spring in 4th link
5. Spring in cotter pin
Groundsmaster® 300 Series
WARNING
Since the right hand push arm is spring­
loaded to about 100 pounds and left hand
push arm is spring-loaded to about 150
pounds, a helper is needed to release push
arms from cutting unit. Sudden release of the
push arms could cause injury.
5. Have a helper push down on the right push arm while
you remove the cap screws, flat washers, lock washers
and nuts securing ball joint mount to caster arm on
cutting unit. Now the helper can carefully allow push arm
to move upward, which will gradually release the 100
pounds of spring load.
6. Have a helper push down on the left push arm while
you remove the cap screws, flat washers, lock washers
and nuts securing ball joint mount to mount bracket on
cutting unit. Now the helper can carefully allow push arm
to move upward which will gradually release the 150
pounds of spring load.
Figure 16
1. R.H. push arm
2. Caster arm
3. Capscrews & flatwashers
4. Ball joint mount
5. Flange locknuts
6. Jam nut
7. Ball joint
7. Roll the cutting unit away from the traction unit.
Figure 17
1. L.H. push arm
2. Ball joint
3. Ball joint mount
4. Capscrews & locknuts
Groundsmaster® 300 Series
Page 11 - 15
5. Caster arm
6. Flange locknuts
7. Jam nuts
Repairs
Mounting Cutting Unit to Traction Unit (Fig. 18, 19, 20, 21)
1. Position machine on level surface and shut
engine off.
2. Move cutting unit into position in front of traction unit.
WARNING
Since the right hand push arm is spring­
loaded to about 100 pounds and left hand
push arm is spring-loaded to about 150
pounds, a helper is needed to push the push
arm down. Sudden release of the push arm
could cause injury.
Figure 18
3. Slide a large flat washer (1/2 I.D. x 1-1/4 in. O.D.) onto
both cap screws (7/16 - 14 x 3 in.).
4. Have a helper carefully push down on right hand push
arm until holes in ball joint mount line up with holes in
caster arm. Secure ball joint mount to caster arm with
two cap screws w/large flat washers, one flat washer
(15/32 I.D. x 59/64 in. O.D.), two lock washers and nuts
(7/16 - 14). Heads of cap screws and large flat washers
must be on outside of caster arm.
1. R.H. push arm
2. Caster arm
3. Capscrews & flatwashers
4. Ball joint mount
5. Flange locknuts
6. Jam nut
7. Ball joint
5. Slide flat washers (1 5/32 1. D. x 59/64 in. O.D.) onto
two cap screws (7/16 - 14 x 3 in.).
6. Have a helper carefully push down on left hand push
arm until holes in ball joint mount are in line with holes
in mount bracket on cutting unit. Immediately slide 4 x
4 in. block of wood between top of push arm and
underside of chassis.
Figure 19
1. L.H. push arm
2. Ball joint
3. Ball joint mount
4. Capscrews & locknuts
WARNING
5. Caster arm
6. Flange locknuts
7. Jam nuts
Make sure wooden block does not slip out
accidentally.
7. Secure ball joint mount to mount bracket with two cap
screws, flat washers, and flange lock nuts (7/16 -14).
Heads of cap screws and flat washers must contact ball
joint mount.
Repairs
Page 11 - 16
Groundsmaster® 300 Series
8. Line up holes in yoke and input shaft of gear box.
Slide yoke onto shaft and secure parts together with roll
pin (3/16 x 1-1/2 in.). Tighten (2) capscrews and
locknuts securing yoke to input shaft.
9. Mount PTO shield over input shaft and onto gear box
mounting plate with two self-tapping screws.
10. Attach lift chains to lift arm and cutting unit with six
(6) shackles, shackle pins (3/8 x 1-1/2 in.) and cotter
pins (1/8 x 3/4 in.). Adjust chain length so both become
tight at the same time when lifting lift arm.
11. Connect ends of tension spring between fourth link
of rear chain and eye of cotter pin that holds cylinder pin
in place. Adjust length of chain so rear caster wheels
are off the ground in transport position.
Figure 20
1. PTO yoke
2. Yokes in phase
3. Roll pin
4. Capscrews & locknuts
Figure 21
1. PTO shield
2. Self-tapping screws
3. Lift chain
Groundsmaster® 300 Series
Page 11 - 17
4. Spring in 4th link
5. Spring in cotter pin
Repairs
Push Arm and Torsion Spring Service (Fig. 22, 23, 24, 25, 26, 27, 28)
Removing Push Arms,
Torsion Springs and Bushings
1. Separate cutting unit from traction unit and roll cutting
unit away from traction unit.
2. Have a helper push down on the left push arm while
you put a 4" x 4" block of wood between the chassis and
the top of the push arm, and across the full width of the
machine.
3. Loosen the large jam nut on the left-hand ball joint at
the end of the push arm. Remove the ball joint (mount
attached) from the push arm.
4. Remove the self-tapping screws holding the floor
plate to the main frame. Raise the floor plate and set it
aside.
Figure 22
5. Disconnect the right-hand brake cable from the brake
strut. Remove the jam nut holding the brake cabled in
the mount on the frame and slide the cable through the
hole in the push arm bracket.
6. Remove the cotter pin from the end of the parking
brake rod. Slide the rod out of the latch.
Figure 23
Figure 24
Repairs
Page 11 - 18
Groundsmaster® 300 Series
7. Remove the cap screws, locknuts, carriage bolts, lock
washers and nuts holding the brake mount and pedal
assembly in place. Lay the brake mount and the pedal
assembly on the wheel.
8. Have a helper push down slightly on the left push arm
while you remove the block of wood between the push
arm and the chassis. Slowly and carefully allow the push
arm to move upward until all spring load is released.
9. Remove the cap screws, locknuts, support plate and
push arm bracket holding the left side of the push arm
and pivot shaft to the main frame.
10. Remove the cap screws, locknuts, reinforcement
and push arm bracket holding the right side of the push
arm and pivot shaft to the main frame. The entire push
arm and pivot shaft assembly should now be free of the
main frame.
Figure 25
11. Drive the roll pins out of the pivot shaft and slide the
push arm assemblies off of the shaft.
12. Drive the pushing out of both push arm pivot tubes.
Clean the inside of the pivot tubes to remove all dirt and
other material.
Figure 26
Figure 27
®
Groundsmaster 300 Series
Page 11 - 19
Repairs
Installing Push Arms,
Torsion Springs and Bushings
1. Apply grease to inside and outside of new bushings.
Using a hammer and flat plate, carefully drive the bushings into the push arm pivot tubes. The bushings must
be flush with the end of the tube.
2. Inspect the torsion springs. If the springs are damaged, use new springs when assembling the parts.
3. Slide the torsion springs onto the inside of the push
arm pivot tubes. Install the washers, push arms with
springs and push arm brackets onto the pivot shaft.
Install the roll pins to secure the parts in place.
Figure 28
4. Raise the push arm and pivot shaft assembly into
position and secure it in place with cap screws, support
plate, reinforcement support and locknuts. Make sure
the springs contact the retainer plate on the push arms
and the underside of the frame.
5. Have a helper push down on the left push arm while
you place a 3 ft. long block of wood between the chassis
and to top of the push arms, across the full width of the
machine.
NOTE: After the wood block is installed, there should be
enough clearance for installing the ball joint into the front
of the push arm.
6. Thread jam nut fully onto the left-hand ball joint.
Screw the ball joint into the left-hand push arm until the
center of the ball joint is 2-3/8 inches away from the front
of the push arm. Do not tighten the jam nut until the deck
is mounted.
7. Install the brake mount and pedal assembly with cap
screws, locknuts, carriage bolts, lock washer and nuts.
Route the right-hand brake cable through the hole in the
right-hand push arm bracket. Connect the cable to the
brake strut with the clevis pin and the tension spring.
Hook the opposite end of the tension spring into the hole
in the side of the chassis. Also install the cable into the
mount on the frame.
Repairs
Page 11 - 20
Groundsmaster® 300 Series
Gearbox Removal and Installation (Fig. 29, 30)
Removing Gearbox and Drive Pulley
1. Lower the cutting unit, shut engine off and engage the
parking brake.
2. Remove shroud covering universal drive shaft. Disconnect drive shaft from gearbox. Remove belt covers
from top of cutting unit.
DANGER
Do not start the engine and engage the P.T.O.
when the P.T.O. shaft is not connected to the
gearbox. If engine is started and the P.T.O.
shaft is allowed to rotate, serious injury could
result.
3. Loosen idler pulleys for cutting unit drive belts and
remove belts from gearbox pulley.
4. Disassemble fasteners securing gearbox to cutting
unit and remove gearbox.
5. Remove the set screws from the taper lock bushing.
Install one setscrew into the hole that is threaded on the
side of taper lock. Tighten the setscrew until the taper
lock is loose from the inside of the pulley hub.
Figure 29
1. Isolation mounts
2. Brackets
3. Capscrews & lockwashers
4. Gear box
5. Woodruff key
6. Pulley assembly
7. Metal straps
8. Carriage bolts
9. Flatwashers & nuts
10. Taper lock
NOTE: Only one setscrew is used to loosen the
taper lock.
6. Slide the gearbox pulley and taper lock off of the
gearbox output shaft. Account for the woodruff key that
positions the pulley on the shaft, and remove the setscrew from the side of the taper lock.
Groundsmaster® 300 Series
Page 11 - 21
Repairs
Installing Gearbox and Drive Pulley
1. Install four (4) isolation mounts into two (2) brackets.
Use water or lubricant to ease installation. Install
mounts from bottom of bracket.
2. Install bracket on each side of gearbox with capscrews and lockwashers. Tighten capscrews to a torque
of 20 - 26 ft-lb.
10. Mount gearbox with brackets onto top of cutting unit.
Insert four (4) carriage bolts up from bottom of cutting
unit and install flatwasher and nut on each bolt to secure
the gearbox. Tighten nuts to 20 - 26 ft-lb.
11. Install drive belts onto gear box pulley and adjust
idlers to tension belts.
12. Install cutting unit covers.
3. To install the pulley, slide the taper lock - small end
first - into the pulley hub.
13. Install drive shaft to gear box and secure with a new
roll pin.
4. Insert the woodruff key into the keyway in the gearbox
shaft. Slide the pulley with the taper lock onto the
gearbox shaft while aligning the key and keyway.
14. Remove the gear box fill plug and check plug. Add
SAE 80W90 API GL-5 gear lube until level is to the
bottom of the check plug hole. Install plugs in gear box.
NOTE: The large hub on the pulley must face away from
the gearbox, and like the taper lock, the pulley must
contact the shoulder on the gearbox shaft.
5. Rotate the pulley to get the non-threaded holes in the
taper lock to line up with the two threaded holes in the
hub of the gearbox pulley. Start threading the setscrews
into the two holes and tighten them alternately and
evenly until both setscrews are tight.
6. Using a brass drift pin or sleeve and a hammer, hit
the taper lock firmly. Now tighten the setscrews to 55
in-lb. Continue to hit the taper lock and tighten the set
screws until the 55 in-lb of torque will not turn the
setscrews.
7. Check the alignment of the gearbox with a spindle
pulley. Loosen and relocate the taper lock to adjust, if
necessary.
8. Fill the recessed socket head in each setscrew, and
the other taper lock holes, with grease to prevent dirt
from packing into the holes.
9. Align holes in thin metal strip with the two front
gearbox mounting holes on base plate.
Repairs
Page 11 - 22
Figure 30
1. Isolation mounts
2. Brackets
3. Capscrews & lockwashers
4. Gear box
5. Woodruff key
6. Pulley assembly
7. Metal straps
8. Carriage bolts
9. Flatwashers & nuts
10. Taper lock
Groundsmaster® 300 Series
Gear Box Repair (Fig. 31, 32, 33)
Figure 31
6. Remove bearing cups (Item 14) from cap by putting
a punch through the shaft bore and through the seal and
then tapping against the back of the bearing cup until
driven out of the cap.
Gear Box Disassembly
1. Drain lubricant from gear box.
2. Remove capscrews and lift out shaft and cap assemblies.
3. Remove cap assemblies and bearing cones (Item 12)
from shafts (Item 17, 19).
NOTE: Mark each gear (Item 10 and 18) so they are
installed on the proper shaft (Item 17 or 19) when
re-assembled.
4. Remove retaining rings (Item 7).
5. Press shafts (Item 17, 19) back through bearing
cones (Item 9). When bearing cone is free, gears (Item
10, 18), keys (Item 8) and shims (Item 11) may be
removed from the shaft.
Groundsmaster® 300 Series
7. If the oil seal (Item 13) is removed, it will be destroyed.
To remove the oil seal, cut it out of the bore with a screw
driver or chisel.
8. To remove the bearing cups (Item 3) from the housing
a slide hammer puller may be used, or if this is not
available, the bearing cups may be knocked out with a
punch by coming down through the opposite cap bore
and tapping against the back side of the bearing cup
until it comes out.
9. Remove the plugs (Item 2) from the housing.
Page 11 - 23
Repairs
17
12
14
4, 5, 6
16
9
3
1
10
11
19
13
2
7
18
8
Figure 32
cap with the open side toward the machined side of the
cap.
Gear Box Pre-Assembly
1. Start with one of the shafts (Item 17) and put one of
the gears (Item 10) over the shaft so the tooth side is
towards the turned end of the shaft. Align the keyway in
the gear with the keyway in the shaft and install one of
the keys (Item 8) in the keyway.
2. Install one set of shims (Item 11) onto the turned end
of the shaft. Press one of the bearing cones (Item 9)
over the turned end of the shaft. Be sure the bearing
cone is installed as shown in the illustration (Fig. 42B).
Install a retaining ring (Item 7) on the turned end of the
shaft.
3. Put one of the bearing cones (Item 12) over the other
end of the shaft and down against the hub side of the
gear. Be sure the bearing cone is installed as shown in
the illustration.
4. Repeat steps 1 - 3 with the other set of parts to
complete the assembly.
6. Install the bearing cup (Item 14) into the cap. Make
sure the bearing cup is installed as shown in the illustration.
7. Repeat steps 5 - 6 with the other set of parts to
complete the two cap assemblies.
8. Take one of the shaft and gear assemblies and wrap
the end of the shaft with a piece of shim stock to keep
from cutting the oil seal on the keyway or splines. Put
the cap assembly down over the shaft so the bearing
cone (Item 12) on the shaft mates with the bearing cone
(Item 14) in the cap. Remove the shim stock from the
shaft that was used to protect the seal.
9. Press the bearing cups (Item 3) into both bearing
bores in the housing (Item 1). Make sure the cups are
installed as shown in the illustration. Install the plugs
(Item 2) into the tapped holes in the housing.
5. Put one of the caps (Item 16) down, with the machined
surface facing up. Install a new seal (Item 13) into the
Repairs
Page 11 - 24
Groundsmaster® 300 Series
Gear Box Final Assembly
1. Bearing drag is adjusted by the amount of gaskets
(Item 4, 5, 6) used between the cap and housing machined surfaces.
2. Put two 0.015 in. gaskets on the machined surface of
the housing, then install the shaft and cap assembly in
the housing so the bearing cone (Item 9) on the shaft
assembly and bearing cup (Item 3) in the housing are
mating. Align the holes in the cap with the holes in the
gaskets and housing.
3. Install capscrews and tighten.
Groundsmaster® 300 Series
4. The shaft should have a very slight amount of bearing
drag. If the shaft turns hard, the cap must be removed
and gasket(s) need to be added. If the shaft has no
bearing drag, or has end play, the cap must be removed
and gasket(s) taken out. The cap must be adjusted to
where the shaft has no end play and only a slight amount
of bearing drag.
5. Repeat steps 1 - 4 with the other shaft and cap
assembly.
6. After installing the gear box on the cutting unit, fill it
with SAE 80W90 API GL-5 lubricant to the level of the
check plug (see Maintenance section in this chapter).
Page 11 - 25
Repairs
Blade Spindle Service (Fig. 34, 35, 36, 37, 38)
Removing Spindle and
Bearings From Spindle Housing
3. Remove belt from spindle to be serviced.
1. Lower the cutting unit, shut the engine off and engage
the parking brake.
2. Remove deck covers from top of cutting unit. Loosen
idler pulley(s) to release belt tension.
4. Start the engine and raise the cutting unit. Turn the
engine OFF and remove the key from the key switch.
Block up the cutting unit so it cannot fall accidentally.
5. Remove the bolts (Item 13) and flange nuts (Item 8)
securing spindle housing to deck. Slide spindle housing
assembly out the bottom of the cutting unit.
Figure 34
Repairs
Page 11 - 26
Groundsmaster® 300 Series
6. Remove the lock nut and flat washer retaining the
spindle pulley on the spindle shaft. Slide the pulley off of
the shaft.
4
NOTE: All three spindle housing assemblies are different from one another. A spacer is located beneath the
right--hand pulley (Fig. 35).
7. If the spindle shaft will be replaced, remove the blade
bolt (left hand thread), belleville washer and blade from
the spindle shaft. Otherwise, the blade may be left on the
spindle shaft.
3
5
8. Press the spindle shaft out of the spindle housing using an arbor press. The small bearing spacer should remain on the spindle shaft as the shaft is being removed.
9. The seals will be removed next; however, notice the
orientation of the seal lips. The lips of the lower seals
face outward. On spindle assemblies that have the
grease fitting on the housing (shown in Fig. 36), the lip
of the upper seal faces inward. On spindle assemblies
that have the grease fitting on the top of the spindle shaft
(shown in Fig. 34), the lip of the upper seal faces outward. After noting orientation of seals, remove seals
from the spindle housing.
2
1
Figure 35
1. Left hand spindle
2. Right hand spindle
3. Right hand pulley
4. Left hand pulleu
5. Spacer
LOCK NUT
FLAT WASHER
CENTER
SPINDLE
PULLEY
10. Allow the bearings and small thick spacer to fall out
of the spindle housing.
11. Using a punch and hammer, drive both of the bearing
cups out of the spindle housing. Also, drive the large
spacer out of the housing.
12. A large snap ring is still inside the spindle housing
and it should remain there because it cannot be easily
removed.
IMPORTANT: If new bearings will be installed into a
used spindle housing that has the original snap ring
installed, discard the large snap ring that came with
the bearings because it is not needed. However,
new bearings with their matched spacer set and
snap ring must always be installed when the spindle
housing is being replaced. Replacement bearings
are sold only with a matched snap ring and spacer
set. These parts cannot be purchased separately.
UPPER
OIL SEAL
BEARING
LARGE SPACER
SMALL SPACER
SMALL
SNAP RING
LARGE
SNAP RING
GREASE
FITTING
BEARING
LOWER
OIL SEAL
CENTER
SPINDLE
BELLEVILLE
WASHER
SPECIAL SCREW
(LEFT HAND THREAD)
Figure 36
Groundsmaster 300 Series
Page 11 -- 27
Rev. I
Repairs
Installing Spindle, Bearings and Seals Into Spindle
Housing
IMPORTANT: If a new spindle housing is being
used, new bearings and the matched snap ring set
must be installed; refer to step 1 below. Never use
the old bearings, spacer and snap ring with a new
spindle housing. By contrast, use only new bearings with cups and spacer -- not the large snap ring
because it is not required -- when installing bearings
into a used spindle housing that has the large snap
ring installed; refer to step 2 below.
1. Install the large snap ring into the groove in the bore
of the spindle housing. Assure the snap ring is seated in
the groove.
8. Push the pulley onto the splines of the spindle shaft
and retain the parts together with the large flat washer
and lock nut. Tighten the nut to 100 -- 120 ft--lb (136 -162 N--m). After tightening, rotate the spindle shaft to be
sure that the shaft rotates freely.
9. Slide the pulley end of the spindle assembly through
the hole in the cutting unit. Mount the spindle assembly
in place with the eight (8) hex flange head bolts and
flange nuts.
10. Install the belt and adjust idler to get proper belt tension.
11. Reinstall the belt covers.
2. Using an arbor press, push the large spacer into the
top of the spidle housing; tightly against the snap ring.
The spacer must contact the snap ring to be sure of the
correct assembly of the parts.
3. Thoroughly oil the bearing cups and using an arbor
press, push the bearing cups, smallest inside diameter
first , into the top and bottom of the spindle housing. The
top bearing cup must contact the spacer that was
installed in step 2, and the bottom bearing cup must contact the large snap ring to be sure of the correct assembly of parts. Insure that the assembly is correct be
supporting the first cup and pressing the second against
it.
ARBOR PRESS
LARGE SPACER
BEARING
CUP
LARGE
SNAP RING
SUPPORT
Figure 37
4. Install the lower bearing and the lower oil seals into
the bottom of the spindle housing. Remember, the bottom seals must have the lip facing outward, not toward
the inside of the spindle housing.
5. Check the spindle shaft to make sure it is free of burrs
and nicks that could possibly cut the seals. Thoroughly
lubricate the spindle shaft and seal lips.
6. Slide the small, thick spacer into the spindle housing.
Then, install the upper bearing and seal into the top of
the spindle housing. On spindle assemblies that have
the grease fitting on the housing (shown in Fig. 36), the
lip of the upper seal faces inward. On spindle assemblies that have the grease fitting on the top of the spindle
shaft (shown in Fig. 34), the lip of the upper seal faces
outward.
Figure 38
7. Slide the bearing spacer onto the spindle shaft. Carefully slide the spindle shaft up through the spindle housing. The bottom seal and bearing spacer should fit
together when the spindle is installed.
Repairs
Page 11 -- 28
Rev. I
Groundsmaster 300 Series
Chapter 12
Triflex® 88″ Cutting Unit
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 3
Grass Deflectors . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 4
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Mechanical Door . . . . . . . . . . . . . . . . . . . . . . . . . 5
Skid and Roller Adjustment . . . . . . . . . . . . . . . . . 5
Height of Cut Adjustment . . . . . . . . . . . . . . . . . . 6
Mismatch Adjustments . . . . . . . . . . . . . . . . . . . . 8
Belt Tension Adjustment . . . . . . . . . . . . . . . . . . . 9
Wing Pulley Section Brake . . . . . . . . . . . . . . . . . 11
Wing Shaft End Play . . . . . . . . . . . . . . . . . . . . . . 11
Wing Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . 12
Wing Stop Adjustment . . . . . . . . . . . . . . . . . . . . 12
Groundsmaster® 300 Series
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blade Service . . . . . . . . . . . . . . . . . . . . . . . . . .
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . .
Caster Arm Bushing Replacement . . . . . . . . . .
Rear Caster Wheel Bearing Service . . . . . . . . .
Front Caster Wheel Bearing Service . . . . . . . . .
Separating Cutting Unit From Traction Unit. . . .
Mounting Cutting Unit to Traction Unit. . . . . . . .
Push Arm and Torsion Spring Service . . . . . . . .
Gear Case Removal and Installation. . . . . . . . .
Gear Case Service . . . . . . . . . . . . . . . . . . . . . .
Blade Spindle Service . . . . . . . . . . . . . . . . . . . .
Page 12 - 1
13
13
15
17
18
19
20
21
23
26
28
31
Table of Contents
Specifications
ITEM
SPECIFICATION
__________________________________________________________________________________________
Cutting width
Center section only
With one wing disengaged
88 inches
54 inches
71 inches
________________________________________________________________________________________________________________________________________________________
Height of cut range
1 to 4 inches
________________________________________________________________________________________________________________________________________________________
Height of cut adjustment
0.5 inch increments
________________________________________________________________________________________________________________________________________________________
Blade bolt torque
85 to 110 ft-lb
________________________________________________________________________________________________________________________________________________________
Spindle nut torque
140 - 160 ft-lb.
________________________________________________________________________________________________________________________________________________________
Spindle end play
.006 inch max.
________________________________________________________________________________________________________________________________________________________
Spindle rolling torque
10 in-lb max.
________________________________________________________________________________________________________________________________________________________
Gear case lubricant
SAE 80W90, API GL-5 gear lube
Figure 1
1. Filler plug
2. Check plug
Specifications
Page 12 - 2
Groundsmaster® 300 Series
General Information
Grass Deflectors
WARNING
The grass deflectors (Fig. 2) are safety de­
vices that divert grass and other foreign ob­
jects being discharged downward. WE
STRONGLY RECOMMEND THAT THE DEFLECTORS BE IN THEIR NORMAL OPERATING POSITION WH ENEVER THE CUTTING UNIT IS
ENGAGED. NEVER OPERATE CUTTING UNIT
WITH THE DEFLECTORS REMOVED FROM THE
CUTTING UNIT OR TIED/BLOCKED IN A RAISED
POSITION, SINCE THE BLADES COULD THEN
THROW DEBRIS A CONSIDERABLE DISTANCE
WITH SUFFICIENT FORCE TO CAUSE PERSONAL
INJURY OR DAMAGE TO PROPERTY. If a grass
Figure 2
deflector is damaged, repair or replace the
affected part(s).
1. Grass deflector (2)
Groundsmaster® 300 Series
Page 12 - 3
General Information
Troubleshooting
Troubleshooting
Page 12 - 4
Groundsmaster® 300 Series
Adjustments
Mechanical Door (Fig. 3)
On each side of the deck center section is a mechanical
door that opens and closes as the wing sections are
lowered and raised. The doors open to provide overlap
of the cutter blades when the wing units are down. The
doors close to provide safety and protection when the
wing units are raised.
To adjust mechanical door, disconnect threaded rod
from the door by removing cotter pin. Loosen the jam
nut and turn the rod in or out so that the bottom of the
door is 1/4 inch up from the bottom of the deck side
panel when the wing is fully raised. Tighten jam nut and
install the cotter pin.
Figure 3
1. Threaded rod
2. Mechanical door
3. Cotter pin
4. Jam nut
5. 1/4" (6 mm) gap
Skid and Roller Adjustment (Fig. 4, 5)
When height of cut is set or changed, skids and antiscalp rollers should also be adjusted (adjust on a hard
level surface).
1 inch height of cut – skids all the way up.
1-1/2 inch height of cut – skids 3/8 inch to 1/2 inch
off the ground.
2-1/2 inch height of cut – skids all the way down.
Figure 3
1. Skid adjustment
2. Anti-scalp roller adjustment
When height of cut is set at 1 to 1-1/2 inches, the center
anti-scalp roller and the two ball rollers on the front of
the deck should be in the upper position. when the
height of cut is 2 to 4 inches the rollers should be in the
lower position.
Figure 3
1. Center anti-scalp roller
Groundsmaster® 300 Series
Page 12 - 5
2. Upper and lower holes
Adjustments
Height of Cut Adjustment (Fig. 6, 7, 8)
The height of cut is adjustable from 1 to 4 inches in
1/2 inch increments, by adding or removing an equal
number of spacers on the front and rear caster forks.
The height of cut chart below gives the combinations of
spacers to use for all height of cut settings.
Height of cut
Spacers Below Caster Arms
inches
mm
Front
Rear
1
1-1/2
2
2-1/2
3
3-1/2
4
25
38
51
64
76
89
102
0
1
2
3
4
5
6
0
1
2
3
4
5
6
NOTE: A more optimum cutting appearance in the 1 inch
height of cut setting can be achieved by lowering the
rear of the cutting unit. Do this by relocating the rear
caster wheel axles in the upper holes of the caster forks.
Install the axles into the lower caster fork holes for
settings above 1 inch.
IMPORTANT: The rear caster wheel mounting hole
in use must be towards the rear of the deck. This is
necessary to provide adequate clearance between
the caster wheel and the mechanical door. If neces­
sary, the caster fork assembly should be removed
from the square tube and turned around so that the
mounting hole with the axle through it is toward the
rear. The caster wheel grease fittings should always
face outward.
Figure 6
1. “U” spacers (6)
2. Spacer opening
3. Caster wheel axle holes
4. Mechanical door
IMPORTANT: Do not attempt to cut off more than
one inch of the grass blades in the one (1) inch
height of cut setting with the rear of the cutting unit
lowered, as this may cause the engine to labor
excessively.
1. Start the engine and raise cutting unit so height of cut
can be changed. Stop engine after cutting unit is raised.
2. Squeeze back of wire and rotate wire on lynch pin.
Pull pin out of caster spindle. Slide spacers onto the
caster spindle to get desired height of cut. Then slide
washer onto caster shaft (front only).
3. Push caster shaft through caster arm. Slide any
remaining spacers onto spindle. Install lynch pin to
retain parts in place. Always have the same number of
spacers on each caster when adjusting height of cut.
Adjustments
Page 12 - 6
Figure 7
1. Thrust washer
2. Lynch pin
3. Spacers (6)
4. Wire spring
Groundsmaster® 300 Series
IMPORTANT: All six “U” shaped spacers must be on
rear square caster shafts – if one is left off,
remaining spacers will not stay in position during
operation. Always install spacers on caster shafts
with the spacer opening facing forward or to the
rear. Never install with the spacer facing the side or
middle of the deck (the arrow on the spacer should
be in the same direction as the pin).
NOTE: On front caster shafts, insert lynch pin in front
side of shaft with caster wheels in position as if deck
were traveling in forward direction. When inserted from
the front, the wire loop is less likely to be flipped up
during operation, causing the pin to fall out.
IMPORTANT: The thrust washer – not the spacers –
must contact bottom of front carrier frame tube.
Figure 8
1. Rear caster spacers
Groundsmaster® 300 Series
Page 12 - 7
2. Hooked over plate
Adjustments
Checking and Correcting Mismatch of Blades (Fig. 9, 10)
If there is mismatch between the blades, the grass will
appear streaked when it is cut. This problem can be
corrected by making sure the blades are straight and all
blades are cutting on the same plane.
1. Put the deck into position on a flat 4 x 8 foot sheet of
plywood that is at least 3/4 inch thick.
IMPORTANT: If the rear caster wheel axle is in the
lower hole, put a 3/4 inch block under each front
caster wheel to level the deck. This is not necessary
if the rear caster wheel axle is in the upper hole.
2. Adjust height of cut so all six (6) height of cut spacers
are below the caster arm (highest height of cut).
3. Lower cutting unit onto flat surface.
4. Rotate blades until the ends face forward and backward. Measure from floor to front tip of cutting edge and
record this dimension. Then rotate same blade so opposite end is forward and measure again. The difference
between dimensions must not exceed 1/8 inch. If difference exceeds 1/8 inch, replace the blade because it is
bent. Make sure to measure all five (5) blades.
Center Section:
7. Remove locknuts from spindle, in the area where
shims must be added. To lower a blade, add a shim,
Part No. 3256-24, between spindle housing and bottom
of cutting unit. Continue to check alignment of blade and
add shims until tips of blades are within the required
dimension.
IMPORTANT: Do not use more than three (3) shims
at any one hole location. Use decreasing numbers
of shims in adjacent holes of more than one shim is
added to any one hole location.
Wing Sections:
8. Raise or lower hinge bushing brackets and/or adjust
front and rear stops to achieve proper blade match and
height of cut. Each wing section should rest against the
front and back stops. A 1/2 inch gap between the wing
section and the center section should be maintained.
Torque fasteners to 65 ft-lb. Adjust wing lift cylinders and
belt tension after making wing adjustments. Install covers on top of cutting unit.
5. Rotate blades until the ends face forward and backward. Measure and record the dimensions from floor to
tips of blades at the front and the rear. Rotate blades
until ends face side to side. Measure and record dimensions from floor to tips of blades at each end of blades.
Compare measurements of all five blades. the maximum difference between any two adjacent blades
should not exceed 1/4 inch. the maximum difference
between the highest and lowest blade should not exceed 3/8 inch. The three center section blades can be
adjusted with shims (see Step 7). The wing blades can
be adjusted by repositioning the hinge bushing brackets
and/or the wing stops (see Step 8).
1/8"
Figure 9
6. Rotate blades so tips line up with on another. Tips of
adjacent blades must be within 1/8 inch of each other.
If tips are not within 1/8 inch of each other, proceed to
step 7 and add shims between spindle housing and
bottom of cutting unit or Step 8 to adjust wing sections.
Figure 10
1. Adjustable stop
Adjustments
Page 12 - 8
2. 1/2″ gap
Groundsmaster® 300 Series
Belt Tension Adjustment (Fig. 11, 12, 13)
NOTE: Check that belts are in good condition and
positioned correctly in the sheaves of the pulleys on the
center section and wing sections of the deck.
IMPORTANT: Check tension on new belts after 10
hours of use.
Wing Section:
NOTE: Block deck in raised position so that it cannot
accidentally lower while belts are being adjusted. Wings
should be in lowered position.
Loosen two (2) capscrews securing spring bracket (nuts
are located under the deck). Slide the spring bracket so
that the rubber bumper at one end just contacts the edge
of the idler arm and tighten the nuts under the deck to
secure the spring bracket. With the spring bracket in this
position the belt is properly tensioned.
Figure 11
1. Spring bracket retaining nuts
Figure 12
1. Rubber bumper
2. Spring bracket
Groundsmaster® 300 Series
Page 12 - 9
3. Idler pulley bolt
Adjustments
Center Section:
NOTE: Spring tension is only 10 to 15 lbs. on the wing
section, but is 80 to 90 lbs. on the center section,
requiring the use of a threaded rod for adjustments.
1. Loosen nuts securing the spring bracket to the deck.
Loosen the jam nut on the threaded rod.
2. Adjust the spring bracket so that the lip on the spring
bracket just contacts the rubber stop on the idler arm.
Use the threaded rod to make belt adjustments. Tighten
the capscrews and nuts securing the spring bracket in
position and tighten the jam nut on the threaded rod.
3. Be sure all belt guides are in the correct position and
secured to the deck before operating the cutting unit.
IMPORTANT: If there is a gap of more than 3/16 inch
between the rubber stop and the idler arm a belt
adjustment is necessary.
Figure 13
1. Threaded rod
2. Spring bracket nuts
3. Rubber stop
4. Tensioning nut
5. Jam nut
IMPORTANT: Too much tension on the belt will
cause early belt failure.
Adjustments
Page 12 - 10
Groundsmaster® 300 Series
Wing Pulley Brake (Fig. 14)
Raise wing to be adjusted, 15 degrees (use a magnetically mounted compass) and loosen brake pad capscrews with an Allen wrench. Push brake pad against
pulley with one hand and tighten capscrews with the
other hand.
NOTE: Idler arm assembly is shimmed to center the
brake pad (vertically) in the pulley groove. Add washers
under the idler arm pivot hub as necessary.
Figure 14
1. Brake pad capscrews (2) per wing 3. Allen wrench
2. Brake pad
4. 15° angle
Wing Shaft End Play (Fig. 15)
Slotted holes in the hinge bracket allow for adjustment
of wing shaft end play. End play should be no more than
1/16 inch.
Figure 15
1. Slotted wing shaft bracket holes
2. Slotted lift cylinder bracket holes
Groundsmaster® 300 Series
Page 12 - 11
Adjustments
Wing Lift Cylinders (Fig. 16, 17)
Slotted holes in the lift cylinder bracket allow for adjustment of the wing lift cylinders. With the cylinder fully
extended manually pull the pivot pin outward. The pivot
pin should rest up against the outer edge of the pivot
hole on each wing section.
Tighten the bolts to a torque of 65 ft-lb. Once the cylinder
is in the correct position, adjust the wing vertical stop on
the top of the deck.
NOTE: If the wings do not raise all the way (perpendicular to the deck), the wing lift cylinders may need adjustment. Adjust the wing stops after adjusting the wing lift
cylinders.
Figure 16
1. Slotted wing shaft bracket holes
2. Slotted lift cylinder bracket holes
Figure 17
1. Wing lift cylinder
2. Manually pull pin forward
3. Designed gap
Wing Stop Adjustment (Fig. 18)
1. Lower deck to floor, remove wing cover and raise
wings to 90° (perpendicular to deck). Block mechanical
door in fully raised position. Loosen jam nuts.
2. Pull up on mechanical door lift lever. Tighten the wing
bolt jam nuts by hand so that there is no gap between
the bolt head and the main deck surface.
3. Tighten jam nuts, lower wings and install covers.
Adjust mechanical door height if necessary.
Figure 18
1. Wing stop bolt
2. Mechanical door lift lever
Adjustments
Page 12 - 12
3. Jam nuts
4. Main deck surface
Groundsmaster® 300 Series
Repairs
Blade Service (Fig. 19, 20, 21)
The blade must be replaced if a solid object is hit, the
blade is out-of-balance, worn or bent. Always use genuine TORO replacement blades to ensure safety and
optimum performance. Never use blades made by other
manufacturers because they could be dangerous.
CAUTION
Do not try to straighten a blade that is bent,
and never weld a broken or cracked blade.
Always use a new TORO blade to assure
continued safety certification of the product.
1 . Raise cutting unit to highest position, shut the engine
off and engage parking brake. Block cutting unit to
prevent it from falling accidentally.
2. Grasp end of blade using a rag or thickly padded
glove. Remove special screw, washer, anti-scalp cup
and blade from spindle assembly.
Figure 19
1. Cutting blade
2. Mounting screw and washer
3. Anti-scalp cup
4. Flange bolts (6)
5. Spindle housing
3. To install the blade, assemble parts in reverse order,
and make sure the blade sail is facing up. Tighten
special screw to 85 to 110 ft-lb.
Groundsmaster® 300 Series
Page 12 - 13
Repairs
Inspecting and Sharpening Blade
1. Raise cutting unit to highest position, shut the engine
off and engage parking brake. Block cutting unit to
prevent it from falling accidentally.
2. Examine cutting ends of the blade carefully, especially where the flat and curved parts of the blade meet.
Since sand and abrasive material can wear away the
metal that connects the flat and curved parts of the
blade, check the blade before using the machine. If any
wear is noticed, replace the blade: refer to Removing
Cutter Blade.
Figure 20
WARNING
If the blade is allowed to wear, a slot will form
between the sail and flat part of the blade.
Eventually, a piece of the blade may break off
and be thrown from under the housing, pos­
sibly resulting in serious injury to yourself or
bystander.
3. Examine cutting edges of all blades. Sharpen the
cutting edges if they are dull or nicked. Sharpen only the
top side of the cutting edge and maintain the original
cutting angle to assure sharpness. The blade will remain
balanced if same amount of metal is removed from both
cutting edges.
Figure 21
4. To check blade for being straight and parallel, lay
blade on level surface and check its ends. Ends of blade
must be slightly lower than the center, and cutting edge
must be lower than heel of the blade. This blade will
produce good quality-of-cut and require minimal power
from the engine. By contrast, a blade that is higher at
the ends than the center, or cutting edge higher than the
heel of the blade is warped or bent and must be replaced.
5. To install the blade, assemble parts in reverse order,
and make sure the blade sail is facing up. Tighten
special screw to 85 to 110 ft-lb.
Repairs
Page 12 - 14
Groundsmaster® 300 Series
Belt Replacement (Fig. 22, 23, 24, 25)
Wing Sections:
1. Lower cutting unit to shop floor, turn off engine and
remove key. Remove belt covers.
NOTE: To remove center section belt, the wing section
belts have to be removed first.
2. With the wing unit raised, loosen nuts on capscrews
holding the spring bracket from under the deck.
NOTE: Block deck in raised position so that it cannot
accidentally lower while belts belt tension is being adjusted. Wings should be in lowered position.
3. With spring tension relaxed, lower the wings. Loosen
or remove the idler pulley bolt to allow the belt to pass
between the belt guide and the idler pulley.
4. Loosen or remove belt guides as necessary to allow
removal of belts from remaining pulleys.
Figure 22
1. Spring bracket retaining nuts
5. Put new belt into correct position in groove of pulley
on center section and wing section of deck, then tighten
idler pulley boot.
6. Replace or reposition all belt guides and adjust belt
tension.
7. Adjust wing pulley brake, then install covers.
IMPORTANT: Check new belt tension and brake
adjustment after initial 10 hours of operation.
Figure 23
1. Rubber bumper
2. Spring bracket
3. Idler pulley bolt
Figure 24
Groundsmaster® 300 Series
Page 12 - 15
Repairs
Center Section:
NOTE: Wing belts must be removed first.
1. Loosen capscrew nuts holding the spring bracket to
the deck. Loosen the threaded rod jam nut, then gradually loosen the tension nut to release the spring tension.
CAUTION
Loosen capscrew nuts holding the spring
bracket to the deck before loosening
threaded rod to avoid sudden movement of
the spring bracket.
2. With belt tension released, remove idler arm and belt
guides as necessary and remove the belt.
3. Position new belt correctly in the center section
pulleys. Replace and tighten the idler arm and guide.
Figure 25A
1. Threaded rod
2. Spring bracket nuts
3. Rubber stop
4. Tension nut
5. Jam nut
4. Be sure all belt guides are in the correct position and
secured to the deck and adjust belt tension by following
the procedure described above.
IMPORTANT: Check tension of new belts after initial
10 hours of operation.
IMPORTANT: If there is a gap of more than 3/16 inch
between the rubber stop and the idler arm a belt
adjustment is necessary.
IMPORTANT: Too much tension on the belt will
cause early belt failure.
Figure 25B
Repairs
Page 12 - 16
Groundsmaster® 300 Series
Caster Arm Bushing Service (Fig. 26)
The caster arms have bushings pressed into the top and
bottom portion of the tube and after many hours of
operation, the bushings will wear. To check the bushings, move caster fork back and forth and from side-toside. If caster spindle is loose inside the bushings,
bushings are worn and must be replaced.
1. Raise cutting unit and block it so it cannot fall accidentally.
2. Remove lynch pin and spacers from top of caster
spindle.
3. Pull caster spindle out of mounting tube. Allow
spacer(s) and thrust washer to remain on bottom of
spindle to assure same height of cut when caster spindle is reinstalled.
Figure 26
4. Insert pin punch into top or bottom of mounting tube
and drive bushing out of tube. Also drive other bushing
out of tube. Clean inside of tubes to remove dirt.
5. Apply grease to inside and outside of new bushings.
Using a hammer and flat plate, drive bushings into
mounting tube.
6. Inspect caster spindle for wear and replace it if
damaged.
7. Push caster spindle through bushings and mounting
tube. Slide spacers onto spindle. Install lynch pin
through caster spindle to retain all parts in place.
Groundsmaster® 300 Series
Page 12 - 17
Repairs
Rear Caster Wheel Bearing Service (Fig. 27)
The rear caster wheels rotate on high quality roller
bearings which are supported by spanner bushings.
Even after many hours of use, provided that the bearing
was kept well-lubricated, bearing wear will be minimal.
However, failure to keep bearings lubricated will cause
rapid wear. A wobbly caster wheel usually indicates a
worn bearing.
1. Remove capscrew and locknut holding caster wheel
and (2) washers between caster fork.
2. Pull spanner bushing out of wheel hub.
3. Remove bushing from wheel hub and allow bearing
to fall out. Remove bushing from opposite side of wheel
hub.
4. Check the bearing, spanner and inside of wheel hub
for wear. Replace defective parts.
Figure 27
5. To assemble the caster wheel, push bushing into
wheel hub. Slide bearing into wheel hub. Push other
bushing into open end of wheel hub to captivate the
bearing inside the wheel hub.
6. Carefully slide spanner through the bushings and
wheel hub.
7. Install caster wheel assembly and (2) washers between caster fork, and secure all parts in place with
capscrew and locknut.
8. Lubricate caster wheel bearing through grease fitting,
using No. 2 general purpose lithium grease.
Repairs
Page 12 - 18
Groundsmaster® 300 Series
Front Caster Wheel Bearing Service (Fig. 28)
The front caster wheels rotate on high-quality roller
bearings which are supported by spanner bushings.
Even after many hours of use, provided that the bearing
was kept well-lubricated, bearing wear will be minimal.
However, failure to keep bearings lubricated will cause
rapid wear. A wobbly caster wheel usually indicates a
worn bearing.
1. Remove capscrew and locknut holding caster wheel
and (2) washers between caster fork.
2. Pull spanner bushing out of wheel hub.
3. Remove bushing from wheel hub and allow bearing
to fall out. Remove bushing from opposite side of wheel
hub.
4. Check the bearing, spanner and inside of wheel hub
for wear. Replace defective parts.
Figure 28
5. To assemble the caster wheel, push bushing into
wheel hub. Slide bearing into wheel hub. Push other
bushing into open end of wheel hub to captivate the
bearing inside the wheel hub.
6. Carefully slide spanner through the bushings and
wheel hub.
7. Install caster wheel assembly and (2) washers between caster fork, and secure all parts in place with
capscrew and locknut.
8. Lubricate caster wheel bearing through grease fitting,
using No. 2 general purpose lithium grease.
Groundsmaster® 300 Series
Page 12 - 19
Repairs
Separating Cutting Unit From Traction Unit (Fig. 29)
1. Position machine on level surface, lower cutting unit
to the shop floor, shut engine off and engage parking
brake.
2. Disconnect three (3) hydraulic lines at mounting
bracket, located next to traction pedal, using quick
disconnects. Immediately put attached rubber plugs in
disconnects on both the traction unit and deck hoses.
3. Remove PTO shield from top of cutting unit and set
shield aside.
4. Drive roll pin out of yoke and input shaft of gear case.
Loosen capscrews and nuts securing yoke to shaft.
Slide yoke off the input shaft. If traction unit will be used
without the cutting unit, drive roll pin out of yoke at PTO
pivot shaft and remove entire universal shaft from traction unit.
6. Have another person help push down on the right
push arm while you remove the capscrews, flat washers
and nuts securing ball joint mount to caster arm on
cutting unit. Now the person helping can carefully allow
push arm to move upward, which gradually releases the
100 pounds of spring load.
7. Have another person help push down on the left push
arm while you remove the capscrews, flat washers and
nuts securing ball joint mount to carrier frame on cutting
unit. Now the person helping can carefully allow push
arm to move upward which will gradually release the
150 pounds of spring load.
8. Roll the cutting unit away from the traction unit.
DANGER
Do not start the engine and engage the PTO
lever when PTO shaft is not connected to gear
case on cutting unit. If engine is started and
PTO shaft is allowed to rotate, serious injury
could result.
5. Disconnect spring from lift cylinder cotter pin. Remove cotter pins and clevis pins securing lift chains to
lift arm.
WARNING
Since the right hand push arm is spring­
loaded to approximately 100 pounds and left
hand push arm is spring-loaded to approxi­
mately 150 pounds, another person is needed
to help release push arms from cutting unit.
Sudden release of the push arm could cause
injury.
Repairs
Page 12 - 20
Figure 29
1. Hose plugs
2. Quick disconnects
3. Yoke
4. Roll pin
Groundsmaster® 300 Series
Mounting Cutting Unit to Traction Unit (Fig. 30, 31, 32, 33)
1. Position machine on level surface and shut
engine off.
2. Move cutting unit into position in front of traction unit.
WARNING
Since the right hand push arm is spring­
loaded to about 100 pounds and left hand
push arm is spring-loaded to about 150
pounds, another person is needed to help
push the push arm down. Sudden release of
the push arm could cause injury.
3. To assure correct alignment, measure from the end
of each push arm to the center line of the ball joint. Adjust
to 2-3/8 inches. If adjustment is required, leave the lock
nut loose.
Figure 30
1. Lock nut
2. Ball joint
3. Push arm
4. Have a helper carefully push down on left hand push
arm until holes in bracket line up with holes in caster
arm. Immediately slide a 4 x 4 inch block of wood
between top of push arm and under side of chassis.
5. Secure mounting bracket to caster arm with mounting
hardware. Tighten bolts to a torque of 45 ft-lbs. Tighten
lock nut where ball joint connects to lift arm.
WARNING
Figure 31
Make sure wooden block does not slip out
accidentally.
1. Mounting bracket holes
2. Carrier frame holes
3. Mounting hardware
6. Have a helper carefully push down on right hand push
arm until holes in bracket line up with holes in caster
arm. Immediately slide a 4 x 4 inch block of wood
between top of push arm and under side of chassis.
7. Secure mounting bracket to caster arm with mounting
hardware. Bolts should be tighten to 45 ft-lbs. Tighten
lock nut where ball joint connects to lift arm.
Figure 32
1. Right push arm ball joint
2. Mounting bracket
Groundsmaster® 300 Series
Page 12 - 21
3. Mounting hardware
Repairs
IMPORTANT: The PTO shaft yokes must be exactly
in line with each other when outer PTO is installed
on splined shaft. Remove sleeve and change yoke
position if alignment is not correct. Misalignment of
the two yokes will shorten life of PTO shaft assem­
bly and cause unnecessary vibration when cutting
unit is operated.
8. Line up holes in yoke and input shaft of gear case.
Slide yoke onto shaft and secure parts together with roll
pin, capscrews and nuts.
9. Mount PTO shield over input shaft and onto gear case
mounting plate with two self tapping screws.
10. Attach three (3) lift chains to lift arm and cutting unit
with six (6) shackles, shackle pins and cotter pins.
Adjust chain length so that the front of the deck raises
level (side to side). When main lift cylinder is fully
extended the left push arm should be just below the
frame stop (1/16 to 3/8 inch). Half chain link adjustments
can be made by switching mounting holes in push arm
brackets. Tie up extra chain links if additional length may
be needed in the future.
Figure 33
1. PTO shaft yokes in phase
2. Roll pin
3. Gear case input shaft
4. Tension spring
5. Rear lift chain
6. Front lift chains
7. Right push arm
8. Carrier frame
9. Left push arm
IMPORTANT: Improper chain adjustment could re­
sult in main deck lift arm damage if deck contacts
traction unit.
NOTE: As starting points use the following settings:
Right front chain – 10 links, lower bracket hole.
Left front chain – 14 links, lower hole
Rear chain – 10 links, upper and front holes
11. Adjust length of rear chain so rear caster wheels are
as far as possible from the ground but carrier frame does
not contact right push arm when deck is lifted.
CAUTION
Improper chain adjustment may result in the
deck contacting the traction pedal and forc­
ing it into reverse.
12. To check adjustment, stay in the driver’s seat, raise
the deck all the way and turn the key OFF. Set the
parking brake and then walk to the front of the traction
unit to see if the deck is contacting the linkage.
13. Connect ends of tension spring between fourth link
of rear chain and eye of cotter pin that holds cylinder pin
in place.
Repairs
Page 12 - 22
Groundsmaster® 300 Series
Push Arm and Torsion Spring Service (Fig. 34, 35, 36, 37, 38, 39, 40)
Removing Push Arms,
Torsion Springs and Bushings
1. Separate cutting unit from traction unit and roll cutting
unit away from traction unit.
2. Have a helper push down on the left push arm while
you put a 4" x 4" block of wood between the chassis and
the top of the push arm, and across the full width of the
machine.
3. Loosen the large jam nut on the left-hand ball joint at
the end of the push arm. Remove the ball joint (mount
attached) from the push arm.
4. Remove the self-tapping screws holding the floor
plate to the main frame. Raise the floor plate and set it
aside.
Figure 34
5. Disconnect the right-hand brake cable from the brake
strut. Remove the jam nut holding the brake cabled in
the mount on the frame and slide the cable through the
hole in the push arm bracket.
6. Remove the cotter pin from the end of the parking
brake rod. Slide the rod out of the latch.
Figure 35
Figure 36
Groundsmaster® 300 Series
Page 12 - 23
Repairs
7. Remove the cap screws locknuts, carriage bolts, lock
washers and nuts holding the brake mount and pedal
assembly in place. Lay the brake mount and the pedal
assembly on the wheel.
8. Have a helper push down slightly on the left push arm
while you remove the block of wood between the push
arm and the chassis. Slowly and carefully allow the push
arm to move upward until all spring load is released.
9. Remove the cap screws, locknuts, support plate and
push arm bracket holding the left side of the push arm
and pivot shaft to the main frame.
10. Remove the cap screws, locknuts, reinforcement
and push arm bracket holding the right side of the push
arm and pivot shaft to the main frame. The entire push
arm and pivot shaft assembly should now be free of the
main frame.
Figure 37
11. Drive the roll pins out of the pivot shaft and slide the
push arm assemblies off of the shaft.
12. Drive the pushing out of both push arm pivot tubes.
Clean the inside of the pivot tubes to remove all dirt and
other material.
Figure 38
Figure 39
Repairs
Page 12 - 24
Groundsmaster® 300 Series
Installing Push Arms,
Torsion Springs and Bushings
1. Apply grease to inside and outside of new bushings.
Using a hammer and flat plate, carefully drive the bushings into the push arm pivot tubes. The bushings must
be flush with the end of the tube.
2. Inspect the torsion springs. If the springs are damaged, use new springs when assembling the parts.
3. Slide the torsion springs onto the inside of the push
arm pivot tubes. Install the washers, push arms with
springs and push arm brackets onto the pivot shaft.
Install the roll pins to secure the parts in place.
4. Raise the push arm and pivot shaft assembly into
position and secure it in place with cap screws, support
plate, reinforcement support and locknuts. Make sure
the springs contact the retainer plate on the push arms
and the underside of the frame.
Figure 40
1. Lock nut
2. Ball joint
3. Push arm
5. Have a helper push down on the left push arm while
you place a 3 ft. long block of wood between the chassis
and to top of the push arms, across the full width of the
machine.
NOTE: After the wood block is installed, there should be
enough clearance for installing the ball joint into the front
of the push arm.
6. Thread jam nut fully onto the left-hand ball joint.
Screw the ball joint into the left-hand push arm until the
center of the ball joint is 2-3/8 inches away from the front
of the push arm. Do not tighten the jam nut until the deck
is mounted.
7. Install the brake mount and pedal assembly with cap
screws, locknuts, carriage bolts, lock washer and nuts.
Route the right-hand brake cable through the hole in the
right-hand push arm bracket. Connect the cable to the
brake strut with the clevis pin and the tension spring.
Hook the opposite end of the tension spring into the hole
in the side of the chassis. Also install the cable into the
mount on the frame.
Groundsmaster® 300 Series
Page 12 - 25
Repairs
Gear Case Removal and Installation (Fig. 41, 42)
Removing Gear Case and Drive Pulley
1. Lower the cutting unit, shut engine off and engage the
parking brake.
2. Remove shroud (Item 20) covering universal drive
shaft. Disconnect drive shaft from gear case. Remove
belt covers from top of cutting unit.
4. Remove flange nuts and carriage bolts securing gear
case mount plate (Item 22) to cutting unit and remove
plate and gear case.
5. Remove the set screws (Item 28) from the taper lock
bushing (Item 27). Install one setscrew into the hole that
is threaded on the side of taper lock. Tighten the setscrew until the taper lock is loose from the inside of the
pulley hub.
NOTE: Only one setscrew is used to loosen the
taper lock.
DANGER
Do not start the engine and engage the P.T.O.
when the P.T.O. shaft is not connected to the
gear case. If engine is started and the P.T.O.
shaft is allowed to rotate, serious injury could
result.
6. Slide the gear case pulley (Item 26) and taper lock
(Item 27) off of the gear case output shaft. Account for
the woodruff key (Item 24) that positions the pulley on
the shaft, and remove the setscrew from the side of the
taper lock.
3. Loosen belt tension and remove belt from gear case
pulley.
7. Remove gear case from mount plate and remove
brackets (Item 18) from gear case.
Figure 41
Repairs
Page 12 - 26
Groundsmaster® 300 Series
Installing Gear Case and Drive Pulley
1. Install bracket (Item 18) on each side of gear case
with capscrews and lockwashers. Tighten capscrews to
a torque of 20 - 26 ft-lb. Install gear case and bracket
assembly to mount plate (Item 22) with carriage bolts
and flange nuts.
2. To install pulley (Item 26) and slide taper lock
(Item 27), small end first, into pulley hub.
3. Insert woodruff key (Item 24) into keyway in gear case
shaft. Slide pulley with taper lock onto gear case shaft
while aligning key and keyway.
NOTE: Large hub on pulley must face away from gear
case, and like the taper lock, the pulley must contact the
shoulder on the gear case shaft.
4. Rotate pulley to get non-threaded holes in taper lock
to line up with the two threaded holes in hub of gear case
pulley. Start threading setscrews (Item 28) into the two
holes and tighten setscrews alternately and evenly until
both setscrews are tight.
5. Using a brass drift pin or a sleeve and hammer, hit
taper lock firmly. Now tighten setscrews to 55 in-lb.
Continue to hit taper lock and tighten set screws until
55 in-lb of torque will not turn the setscrews.
6. Check alignment of gear case with a spindle pulley.
Loosen and relocate taper lock to adjust, if necessary.
7. Fill recessed socket head in each setscrew, and the
other taper lock holes, with grease to prevent dirt from
packing into the holes.
8. Mount gear case with brackets onto top of gear case
mount plate (Item 22) with carriage bolts and
flange nuts.
9. Mount gear case mount plate to cutting unit with
carriage bolts and flange nuts.
10. Install drive belt onto gear case pulley and adjust
belt tension.
11. Install belt covers.
12. Install drive shaft to gear box and secure with a new
roll pin.
13. Remove gear case fill plug and check plug. Add SAE
80W90 API GL-5 gear lube until level is to the bottom of
check plug hole. Install plugs in gear case.
Figure 42
Groundsmaster® 300 Series
Page 12 - 27
Repairs
Gear Case Repair (Fig. 43, 44)
Figure 43
Gear Case Disassembly
1. Drain lubricant from gear case.
2. Remove capscrews and lift out shaft and cap
assemblies.
3. Remove cap assemblies and bearing cones (Item 12)
from shafts (Item 17, 19).
NOTE: Mark each gear (Item 10 and 18) so they are
installed on the proper shaft (Item 17 or 19) when
re-assembled.
4. Remove retaining rings (Item 7).
5. Press shafts (Item 17, 19) back through bearing
cones (Item 9). When bearing cone is free, gears (Item
10, 18), keys (Item 8) and shims (Item 11) may be
removed from the shaft.
Repairs
6. Remove bearing cups (Item 14) from cap by putting
a punch through the shaft bore and through the seal and
then tapping against the back of the bearing cup until
driven out of the cap.
7. If the oil seal (Item 13) is removed, it will be destroyed.
To remove the oil seal, cut it out of the bore with a screw
driver or chisel.
8. To remove the bearing cups (Item 3) from the housing
a slide hammer puller may be used, or if this is not
available, the bearing cups may be knocked out with a
punch by coming down through the opposite cap bore
and tapping against the back side of the bearing cup
until it comes out.
9. Remove the plugs (Item 2) from the housing.
Page 12 - 28
Groundsmaster® 300 Series
17
12
14
4, 5, 6
16
9
3
1
10
11
19
13
2
7
18
8
Figure 44
Gear Case Pre-Assembly
1. Start with one of the shafts (Item 17) and put one of
the gears (Item 10) over the shaft so the tooth side is
towards the turned end of the shaft. Align the keyway in
the gear with the keyway in the shaft and install one of
the keys (Item 8) in the keyway.
2. Install one set of shims (Item 11) onto the turned end
of the shaft. Press one of the bearing cones (Item 9)
over the turned end of the shaft. Be sure the bearing
cone is installed as shown in the illustration (Fig. 42B).
Install a retaining ring (Item 7) on the turned end of the
shaft.
3. Put one of the bearing cones (Item 12) over the other
end of the shaft and down against the hub side of the
gear. Be sure the bearing cone is installed as shown in
the illustration.
4. Repeat steps 1 - 3 with the other set of parts to
complete the assembly.
cap with the open side toward the machined side of the
cap.
6. Install the bearing cup (Item 14) into the cap. Make
sure the bearing cup is installed as shown in the illustration.
7. Repeat steps 5 - 6 with the other set of parts to
complete the two cap assemblies.
8. Take one of the shaft and gear assemblies and wrap
the end of the shaft with a piece of shim stock to keep
from cutting the oil seal on the keyway or splines. Put
the cap assembly down over the shaft so the bearing
cone (Item 12) on the shaft mates with the bearing cone
(Item 14) in the cap. Remove the shim stock from the
shaft that was used to protect the seal.
9. Press the bearing cups (Item 3) into both bearing
bores in the housing (Item 1). Make sure the cups are
installed as shown in the illustration. Install the plugs
(Item 2) into the tapped holes in the housing.
5. Put one of the caps (Item 16) down, with the machined
surface facing up. Install a new seal (Item 13) into the
Groundsmaster® 300 Series
Page 12 - 29
Repairs
Gear Case Final Assembly
1. Bearing drag is adjusted by the amount of gaskets
(Item 4, 5, 6) used between the cap and housing machined surfaces.
2. Put two 0.015 in. gaskets on the machined surface of
the housing, then install the shaft and cap assembly in
the housing so the bearing cone (Item 9) on the shaft
assembly and bearing cup (Item 3) in the housing are
mating. Align the holes in the cap with the holes in the
gaskets and housing.
3. Install capscrews and tighten.
Repairs
4. The shaft should have a very slight amount of bearing
drag. If the shaft turns hard, the cap must be removed
and gasket(s) need to be added. If the shaft has no
bearing drag, or has end play, the cap must be removed
and gasket(s) taken out. The cap must be adjusted to
where the shaft has no end play and only a slight amount
of bearing drag.
5. Repeat steps 1 - 4 with the other shaft and cap
assembly.
6. After installing the gear box on the cutting unit, fill it
with SAE 80W90 API GL-5 lubricant to the level of the
check plug.
Page 12 - 30
Groundsmaster® 300 Series
Blade Spindle Service (Fig. 45, 46, 47)
Removing Spindle Housing Assembly
1. Lower the cutting unit, shut the engine off and engage
the parking brake.
2. Remove deck covers from top of cutting unit. Release
belt tension. Remove belt from spindle to be serviced.
3. Start the engine and raise the cutting unit. Turn the
engine OFF and remove the key from the key switch.
Block up the cutting unit so it cannot fall accidentally.
4. Using a rag or thickly padded glove, grasp end of
blade. Remove blade bolt, flat washer, anti-scalp cup
and blade from spindle assembly.
5. Remove flange nuts and carriage bolts securing
spindle housing to deck. Slide spindle housing assembly out the bottom of the cutting unit.
Disassembly
1. Remove the nut and flat washer retaining the spindle
pulley on the spindle shaft. Slide pulley off of shaft.
2. Press the spindle shaft out of the spindle housing
using an arbor press. The bearing spacer remains on
the spindle shaft as the shaft is being removed.
3. Remove seals from spindle housing.
4. Allow the bearings and small thick spacer to fall out
of the spindle housing.
5. Using a punch and hammer, drive both of the bearing
cups out of the spindle housing. Also drive the large
spacer out of the housing.
6. A large snap ring is still inside the spindle housing and
it should remain there because it cannot be easily
removed.
Figure 45
1. Grease fitting
2. Jam nut
3. Washer
4. Wave seal
5. Carriage bolt
6. Flat washer
7. Spindle housing
8. Flange nut
9. Spindle shaft
10. Spindle spacer
11. Blade
12. Anti-scalp cup
13. Flat washer
14. Capscrew
15. Bearing assembly
16. Spacer – matched set
IMPORTANT: If new bearings will be installed into a
used spindle housing that has the original snap ring
installed, discard the large snap ring that came with
the bearings because it is not needed. However, new
bearings with their matched spacer and snap ring
must always be installed when the spindle housing
is being replaced. Replacement bearings are sold
only with a matched snap ring and spacer set. These
parts cannot be purchased separately.
Groundsmaster® 300 Series
Page 12 - 31
Repairs
Assembly and Installation of Spindle
IMPORTANT: If a new spindle housing is being used,
new bearings and matched snap ring set must be
installed; see step 1 below. Never use old bearings,
spacer, and snap ring with a new spindle housing.
If installing bearings into a used spindle housing
that still has a snap ring installed, use only new
bearings with cups and spacer – not the large snap
ring because it is not required; see step 2 below.
1. Install large snap ring into groove in bore of spindle
housing. Make sure snap ring is seated in groove.
2. Using an arbor press, push large spacer into top of
spindle housing; tightly against snap ring. The spacer
must contact the snap ring to be sure of the correct
assembly of the parts.
Figure 46
3. Thoroughly oil the bearing cups and using an arbor
press, push the bearing cups, smallest inside diameter
first, into the top and bottom of the spindle housing. The
top bearing cup must contact the spacer that was installed in step 2, and the bottom bearing cup must
contact the snap ring to be sure of the correct assembly
of parts. Insure that the assembly is correct by supporting the first cup and pressing the second against it.
4. Apply a film of grease on lips of both seals, then install
bearing and seal into bottom of spindle housing. Remember, the BOTTOM SEAL MUST HAVE THE LIP FACING
OUTWARD, not toward the inside of the spindle housing.
Figure 47
5. Check the spindle shaft to make sure it is free of burrs
and nicks that could possibly cut the seals and thoroughly lubricate both the shaft and seal lips.
6. Slide small, thick spacer into spindle housing, then
install bearing and seal into top of spindle housing. LIP
OF UPPER SEAL MUST FACE INWARD.
7. Slide bearing spacer onto spindle shaft. Carefully
slide spindle shaft through spindle housing. The bottom
seal and bearing spacer fit together when the spindle is
installed.
8. Push pulley onto splines of spindle shaft and retain
the parts together with the large flat washer and nut.
Tighten the nut to 100 - 120 ft-lb and rotate the spindle
shaft to be sure that the shaft rotates freely.
9. Slide pulley end of spindle assembly through hole in
cutting unit. Mount the spindle assembly in place with
the carriage bolts and flange nuts.
10. Install the belt and adjust belt tension.
11. Reinstall the belt covers.
Repairs
Page 12 - 32
Groundsmaster® 300 Series
Chapter 13
Guardian® 72″ Recycler® Cutting Unit
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Height of Cut Adjustment . . . . . . . . . . . . . . . . . .
Adjusting Skids . . . . . . . . . . . . . . . . . . . . . . . . . .
Mismatch Adjustments . . . . . . . . . . . . . . . . . . . .
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blade Service . . . . . . . . . . . . . . . . . . . . . . . . . . .
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . .
Groundsmaster® 300 Series
2
3
4
4
5
6
7
7
9
Page 13 - 1
Caster Arm Bushing Replacement . . . . . . . . . .
Caster Wheel Bearing Service . . . . . . . . . . . . .
Separating Cutting Unit From Traction Unit. . . .
Mounting Cutting Unit to Traction Unit. . . . . . . .
Push Arm and Torsion Spring Service . . . . . . . .
Gearbox Removal and Installation . . . . . . . . . .
Gearbox Service . . . . . . . . . . . . . . . . . . . . . . . .
Blade Spindle Service . . . . . . . . . . . . . . . . . . . .
10
11
12
13
14
17
19
22
Table of Contents
Specifications
ITEM
SPECIFICATION
__________________________________________________________________________________________
Cutting width
72 inches
________________________________________________________________________________________________________________________________________________________
Height of cut range
2 to 5 inches
________________________________________________________________________________________________________________________________________________________
Height of cut adjustment
0.5 inch increments
________________________________________________________________________________________________________________________________________________________
Blade bolt torque
85 to 110 ft-lb
Spindle nut torque
140 - 160 ft-lb.
Gearbox lubricant
SAE 80W90, API GL-5 gear lube
________________________________________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________________________________________
Figure 1
1. Filler plug
2. Check plug
3. Drain plug
Specifications
Page 13 - 2
Groundsmaster® 300 Series
Troubleshooting
Groundsmaster® 300 Series
Page 13 - 3
Troubleshooting
Adjustments
Height of Cut Adjustment (Fig. 2, 3)
The height of cut is adjustable from 2 to 5 inches in 1/2
inch increments, by adding or removing an equal number of spacers on the front and rear caster forks. The
height of cut chart below gives the combinations of
spacers to use for all height of cut settings.
Height of Cut
Spacers Below Caster Arms
inches
mm
Front
Rear
2
2-1/2
3
3-1/2
4
4-1/2
5
50
64
76
89
102
114
127
0
1
2
3
4
5
6
0
1
2
3
4
5
6
1. Start the engine and raise cutting unit so height of cut
can be changed. Stop engine after cutting unit is raised.
Figure 2
1. Front caster wheel
2. Lynch pin
Front Caster Wheels
3. Spacers
4. Thrust washer
1. Squeeze back of wire and rotate wire on lynch pin.
Pull pin out of caster spindle and slide spindle out of
front caster arm. Slide spacers onto the caster spindle
to get desired height of cut. Then slide washer onto
spindle.
2. Push caster spindle through caster arm. Install other
thrust washer and remaining spacers onto spindle. Install lynch pin to retain parts in place.
Rear Caster Wheels
1. Squeeze back of wire and rotate wire on lynch pin.
Pull pin out caster spindle.
NOTE: Rear caster fork assembly does not need to be
removed from caster arm to change height of cut.
2. Remove or add “C” shaped spacers at narrow part of
spindle shaft, below caster arm, to get desired height of
cut. Make sure thrust washers, not spacers, contact top
and bottom of caster arm.
Figure 3
1. Rear caster wheel
2. Lynch pin
3. Spacers
4. Thrust washer
3. Install lynch pin to secure caster wheel assembly.
4. Make sure all four caster wheels are set at same
height of cut.
Adjustments
Page 13 - 4
Groundsmaster® 300 Series
Adjusting Skids (Fig. 4)
1. Adjust each skid by loosening the three (3) flange nuts
and moving the skid to the desired position. Tighten the
flange nuts to secure the skid in position.
Figure 4
1. Skid
Groundsmaster® 300 Series
Page 13 - 5
2. Flange nuts
Adjustments
Checking and Correcting Mismatch of Blades (Fig. 5)
If there is mismatch between the blades, the grass will
appear streaked when it is cut. This problem can be
corrected by making sure the blades are straight and all
blades are cutting on the same plane.
1. Using a 3 foot long carpenters level, find a flat surface
on the shop floor.
2. Adjust height of cut so all six height of cut spacers are
below the caster arm.
3. Lower cutting unit onto flat surface. Remove covers
from top of cutting unit. Release belt tension.
4. Rotate blades until the ends face forward and backward. Measure from floor to front tip of cutting edge and
remember this dimension. Then rotate same blade so
opposite end is forward and measure again. The difference between dimensions must not exceed 1/8 inch. If
difference exceeds 1/8 inch, replace the blade because
it is bent. Make sure to measure all three blades.
proceed to step 7 and add shims between spindle
housing and bottom of cutting unit.
7. Remove cap screws, flat washers, lock washers and
nuts from outer spindle, in the area where shims must
be added. To raise or lower the blade, add a shim, Part
No. 3256-24, between spindle housing and bottom of
cutting unit. Continue to check alignment of blade and
add shims until tips of blades are within the required
dimension.
IMPORTANT: Do not use more than three shims at
any one hole location. Use decreasing numbers of
shims in adjacent holes if more than one shim is
added to any one hole location.
8. Adjust belt tension and install covers.
5. Compare measurements of outer blades with the
center blade. Center blade must not be more than 3/8
inch lower than outer blades. If center blade is more than
3/8 inch lower than outer blades, proceed to step 7 and
add shims between spindle housing and bottom of
cutting unit.
6. Rotate blades so tips line up with one another. Tips
of the adjacent blades must be within 1/8 inch of each
other. If tips are not within 1/8 inch of each other,
Adjustments
Page 13 - 6
1/8"
Figure 5
Groundsmaster® 300 Series
Repairs
Blade Service (Fig. 6, 7, 8)
The blade must be replaced if a solid object is hit, or if
the blade is out-of-balance, worn or bent. Always use
genuine TORO replacement blades to ensure safety
and optimum performance. Never use blades made by
other manufacturers because they could be dangerous.
CAUTION
Do not try to straighten a blade that is bent,
and never weld a broken or cracked blade.
Always use a new TORO blade to assure
continued safety certification of the product.
1 . Raise cutting unit to highest position, shut the engine
off and engage parking brake. Block cutting unit to
prevent it from falling accidentally.
Figure 6
1. Blade bolt
2. Lockwasher
3. Anti-scalp cup
2. Grasp end of blade using a rag or thickly padded
glove. Remove blade bolt, lockwasher, anti-scalp cup
and blade from spindle shaft.
3. Install the blade, anti-scalp cup, lockwasher and
blade bolt. Make sure blade sail is facing up toward
cutting unit. Tighten blade bolt to a torque of 85 to
110 ft-lb.
Groundsmaster® 300 Series
Page 13 - 7
Repairs
Inspecting and Sharpening Blade
1. Raise cutting unit to highest position, shut the engine
off and engage parking brake. Block cutting unit to
prevent it from falling accidentally.
2. Examine cutting ends of the blade carefully, especially where the flat and curved parts of the blade meet.
Since sand and abrasive material can wear away the
metal that connects the flat and curved parts of the
blade, check the blade before using the machine. If any
wear is noticed, replace the blade: refer to Removing
Cutter Blade.
Figure 7
WARNING
If the blade is allowed to wear, a slot will form
between the sail and flat part of the blade.
Eventually, a piece of the blade may break off
and be thrown from under the housing, pos­
sibly resulting in serious injury to yourself or
bystander.
3. Examine cutting edges of all blades. Sharpen the
cutting edges if they are dull or nicked. Sharpen only the
top side of the cutting edge and maintain the original
cutting angle to assure sharpness. The blade will remain
balanced if same amount of metal is removed from both
cutting edges.
Figure 8
4. To check blade for being straight and parallel, lay
blade on level surface and check its ends. Ends of blade
must be slightly lower than the center, and cutting edge
must be lower than heel of the blade. This blade will
produce good quality-of-cut and require minimal power
from the engine. By contrast, a blade that is higher at
the ends than the center, or cutting edge higher than the
heel of the blade is warped or bent and must be replaced.
5. To install the blade, ,assemble parts in reverse order,
and make sure the blade sail is facing up. Tighten blade
bolt to a torque of 85 to 110 ft-lb.
Repairs
Page 13 - 8
Groundsmaster® 300 Series
Belt Replacement (Fig. 9, 10, 11)
Signs of a worn belt are: squealing when belt is rotating,
blades slipping when cutting grass, frayed belt edges,
burn marks and cracks. Replace the belt if any of these
conditions are evident.
The blade drive belt is held under tension by a spring
loaded idler.
1. Lower cutting unit to shop floor, stop the engine and
engage the parking brake. Remove belt covers from top
of cutting unit.
2. Disconnect spring from idler arm bracket to release
belt tension. Remove cotter pin and clevis pin securing
idler arm bracket to idler arm.
3. Remove capscrews and nuts securing gear box plate
to deck channels. Lift gear box plate and gear box off
deck channels and lay it on top of deck.
4. Remove belt from around spindle pulleys and through
idler pulley assembly.
Figure 9
1. Spring
2. Idler arm
3. Idler arm bracket
5. Install belt around spindle pulleys and through idler
pulley assembly.
6. Install gear box plate on deck channels while routing
belt around gear box pulley. Mount gear box plate to
deck channels with capscrews and nuts.
7. Install idler arm bracket to idler arm with cotter pin
and clevis pin. Hook spring onto idler arm bracket. To
make sure there is proper belt tension on drive belt,
spring should be extended to a length of approximately
7.00 inches. If spring is not extended to this length,
move spring rod to other mounting holes further away
from belt.
Figure 10
8. Install belt covers.
1. Gear box plate
2. Capscrews and nuts
Figure 11
Groundsmaster® 300 Series
Page 13 - 9
Repairs
Caster Arm Bushing Service (Fig. 12)
The caster arms have bushings pressed into the top and
bottom portion of the tube and after many hours of
operation, the bushings will wear. To check the bushings, move caster fork back and forth and from side-toside. If caster spindle is loose inside the bushings,
bushings are worn and must be replaced.
1. Raise cutting unit and block it so it cannot fall accidentally.
2. Remove lynch pin and spacers from top of caster
spindle.
3. Pull caster spindle out of mounting tube. Allow
spacer(s) and thrust washer to remain on bottom of
spindle to assure same height of cut when caster spindle is reinstalled.
Figure 12
4. Insert pin punch into top or bottom of mounting tube
and drive bushing out of tube. Also drive other bushing
out of tube. Clean inside of tubes to remove dirt.
5. Apply grease to inside and outside of new bushings.
Using a hammer and flat plate, drive bushings into
mounting tube.
6. Inspect caster spindle for wear and replace it if
damaged.
7. Push caster spindle through bushings and mounting
tube. Slide spacers onto spindle. Install lynch pin
through caster spindle to retain all parts in place.
Repairs
Page 13 - 10
Groundsmaster® 300 Series
Caster Wheel Bearing Service (Fig. 13)
The rear caster wheels rotate on high quality roller
bearings which are supported by spanner bushings.
Even after many hours of use, provided that the bearing
was kept well-lubricated, bearing wear will be minimal.
However, failure to keep bearings lubricated will cause
rapid wear. A wobbly caster wheel usually indicates a
worn bearing.
1. Remove capscrew and locknut holding caster wheel
between caster fork.
2. Pull spanner bushing out of wheel hub.
3. Remove bushing from wheel hub and allow bearing
to fall out. Remove bushing from opposite side of wheel
hub.
4. Check the bearing, spanner and inside of wheel hub
for wear. Replace defective parts.
5. To assemble the caster wheel, push bushing into
wheel hub. Slide bearing into wheel hub. Push other
bushing into open end of wheel hub to captivate the
bearing inside the wheel hub.
Figure 13
1. Caster wheel
2. Capscrew and locknut
3. Bushing (2)
4. Spanner bushing
5. Roller bearing
6. Carefully slide spanner through the bushings and
wheel hub.
7. Install caster wheel assembly between caster fork,
and secure all parts in place with capscrew and locknut.
8. Lubricate caster wheel bearing through grease fitting,
using No. 2 general purpose lithium grease.
Groundsmaster® 300 Series
Page 13 - 11
Repairs
Separating Cutting Unit From Traction Unit (Fig. 14, 15, 16)
1. Position machine on level surface, lower cutting unit
to the shop floor, shut engine off and engage parking
brake.
2. Remove self-tapping screws securing shield to top of
cutting unit and set shield aside.
3. Drive roll pin out of yoke and input shaft of gear box.
Also, loosen cap screws and lock nuts. Slide yoke off
the input shaft. If traction unit will be used without the
cutting unit, drive roll pin out of yoke at PTO pivot shaft
and remove entire universal shaft from traction unit.
Figure 14
DANGER
Do not start the engine and engage the PTO
lever when PTO shaft is not connected to gear
box on cutting unit. If engine is started and
PTO shaft is allowed to rotate, serious injury
could result.
1. Drive shaft yokes
2. Yokes in phase
3. Roll pin
4. Capscrews
4. Disconnect cotter pins and clevis pins securing lift
chains to lift arms.
WARNING
Since the right hand push arm is springloaded to about 100 pounds and left hand
push arm is spring-loaded to about 150
pounds, a helper is needed to release push
arms from cutting unit. Sudden release of the
push arms could cause injury.
5. Have a helper push down on the right push arm while
you remove the cap screws, flat washers, lock washers
and nuts securing ball joint mount to caster arm on
cutting unit. Now the helper can carefully allow push arm
to move upward, which will gradually release the 100
pounds of spring load.
Figure 15
1. R.H. push arm
2. Caster arm
3. Ball joint mount
4. Capscrews and washers
5. Ball joint
6. Jam nut
6. Have a helper push down on the left push arm while
you remove the cap screws, flat washers, lock washers
and nuts securing ball joint mount to mount bracket on
cutting unit. Now the helper can carefully allow push arm
to move upward which will gradually release the 150
pounds of spring load.
7. Roll the cutting unit away from the traction unit.
Figure 16
1. L.H. push arm
2. Caster arm
3. Ball joint mount
4. Chain mount
Repairs
Page 13 - 12
5. Capscrews and washers
6. Ball joint
7. Jam nut
Groundsmaster® 300 Series
Mounting Cutting Unit to Traction Unit (Fig. 14, 15, 16, 17)
1. Position machine on level surface and shut
engine off.
2. Move cutting unit into position in front of traction unit.
8. Line up holes in yoke and input shaft of gear box.
Slide yoke onto shaft and secure parts together with roll
pin. Tighten (2) capscrews and locknuts securing yoke
to input shaft.
9. Mount PTO shield over input shaft and onto gear box
mounting plate with two self-tapping screws.
WARNING
Since the right hand push arm is spring­
loaded to about 100 pounds and left hand
push arm is spring-loaded to about 150
pounds, a helper is needed to push the push
arm down. Sudden release of the push arm
could cause injury.
3. Have a helper carefully push down on right hand push
arm until holes in ball joint mount line up with holes in
caster arm.
10. Connect lift chains to lift arm and cutting unit chain
brackets with (6) shackles, shackle pins and cotter pins.
To make sure cutting unit lifts properly, secure chains to
the following links when connecting:
Front left – 11th link�
Front right – 8th link�
Rear – 7th link�
11. Check operation to make sure chains lift deck tight
against stops when lift arm is raised.
4. Secure ball joint mount to caster arm with capscrews,
flat washers and flange nuts. Flat washers must be
installed to outside of caster arm.
5. Have a helper carefully push down on left hand push
arm until holes in ball joint mount are in line with holes
in mount bracket on cutting unit. Immediately slide 4 x 4
in. block of wood between top of push arm and underside of chassis.
WARNING
Make sure wooden block does not slip out
accidentally.
6. Secure ball joint mount and chain bracket to caster
arm with capscrews, flat washers and flange nuts. Flat
washers must be installed to outside of caster arm.
Chain bracket must be installed using forward set of
holes.
Figure 17
1. Front left lift chain
2. Front right lift chain
3. Rear lift chain
7. Carefully remove wood block holding push arm down.
Groundsmaster® 300 Series
Page 13 - 13
Repairs
Push Arm and Torsion Spring Service (Fig. 18, 19, 20, 21, 22, 23, 24)
Removing Push Arms,
Torsion Springs and Bushings
1. Separate cutting unit from traction unit and roll cutting
unit away from traction unit.
2. Have a helper push down on the left push arm while
you put a 4" x 4" block of wood between the chassis and
the top of the push arm, and across the full width of the
machine.
3. Loosen the large jam nut on the left-hand ball joint at
the end of the push arm. Remove the ball joint (mount
attached) from the push arm.
4. Remove the self-tapping screws holding the floor
plate to the main frame. Raise the floor plate and set it
aside.
Figure 18
5. Disconnect the right-hand brake cable from the brake
strut. Remove the jam nut holding the brake cabled in
the mount on the frame and slide the cable through the
hole in the push arm bracket.
6. Remove the cotter pin from the end of the parking
brake rod. Slide the rod out of the latch.
Figure 19
Figure 20
Repairs
Page 13 - 14
Groundsmaster® 300 Series
7. Remove the cap screws, locknuts, carriage bolts, lock
washers and nuts holding the brake mount and pedal
assembly in place. Lay the brake mount and the pedal
assembly on the wheel.
8. Have a helper push down slightly on the left push arm
while you remove the block of wood between the push
arm and the chassis. Slowly and carefully allow the push
arm to move upward until all spring load is released.
9. Remove the cap screws, locknuts, support plate and
push arm bracket holding the left side of the push arm
and pivot shaft to the main frame.
10. Remove the cap screws, locknuts, reinforcement
and push arm bracket holding the right side of the push
arm and pivot shaft to the main frame. The entire push
arm and pivot shaft assembly should now be free of the
main frame.
Figure 21
11. Drive the roll pins out of the pivot shaft and slide the
push arm assemblies off of the shaft.
12. Drive the pushing out of both push arm pivot tubes.
Clean the inside of the pivot tubes to remove all dirt and
other material.
Figure 22
Figure 23
®
Groundsmaster 300 Series
Page 13 - 15
Repairs
Installing Push Arms,
Torsion Springs and Bushings
1. Apply grease to inside and outside of new bushings.
Using a hammer and flat plate, carefully drive the bushings into the push arm pivot tubes. The bushings must
be flush with the end of the tube.
2. Inspect the torsion springs. If the springs are damaged, use new springs when assembling the parts.
3. Slide the torsion springs onto the inside of the push
arm pivot tubes. Install the washers, push arms with
springs and push arm brackets onto the pivot shaft.
Install the roll pins to secure the parts in place.
4. Raise the push arm and pivot shaft assembly into
position and secure it in place with cap screws, support
plate, reinforcement support and locknuts. Make sure
the springs contact the retainer plate on the push arms
and the underside of the frame.
Figure 24
1. L.H. push arm
2. Caster arm
3. Ball joint mount
4. Chain mount
5. Capscrews and washers
6. Ball joint
7. Jam nut
5. Have a helper push down on the left push arm while
you place a 3 ft. long block of wood between the chassis
and to top of the push arms, across the full width of the
machine.
NOTE: After the wood block is installed, there should be
enough clearance for installing the ball joint into the front
of the push arm.
6. Thread jam nut fully onto the left-hand ball joint.
Screw the ball joint into the left-hand push arm until the
center of the ball joint is 2.25 inches away from the front
of the push arm. Do not tighten the jam nut until the deck
is mounted.
7. Install the brake mount and pedal assembly with cap
screws, locknuts, carriage bolts, lock washer and nuts.
Route the right-hand brake cable through the hole in the
right-hand push arm bracket. Connect the cable to the
brake strut with the clevis pin and the tension spring.
Hook the opposite end of the tension spring into the hole
in the side of the chassis. Also install the cable into the
mount on the frame.
Repairs
Page 13 - 16
Groundsmaster® 300 Series
Gearbox Removal and Installation (Fig. 25, 26)
Removing Gearbox and Drive Pulley
1. Lower cutting unit to shop floor, stop the engine and
engage the parking brake. Remove belt covers from top
of cutting unit.
2. Remove shroud (Item 9) covering universal drive
shaft. Disconnect drive shaft from gearbox.
4. Remove capscrews and nuts securing gear box plate
(Item 10) to deck channels.
5. Remove the set screws (Item 19) from the taper lock
bushing (Item 18). Install one setscrew into the hole that
is threaded on the side of taper lock. Tighten the setscrew until the taper lock is loose from the inside of the
pulley hub.
NOTE: Only one setscrew is used to loosen the
taper lock.
DANGER
6. Slide the gearbox pulley (Item 17) and taper lock off
of the gearbox output shaft. Account for the woodruff key
that positions the pulley on the shaft, and remove the
setscrew from the side of the taper lock.
Do not start the engine and engage the P.T.O.
when the P.T.O. shaft is not connected to the
gearbox. If engine is started and the P.T.O.
shaft is allowed to rotate, serious injury could
result.
3. Disconnect spring from idler arm bracket to release
belt tension. Remove cotter pin and clevis pin securing
idler arm bracket to idler arm.
7. Disassemble fasteners securing gear box to gear box
mount plate and remove gearbox. Remove brackets
(Items 6, 13) from gear box.
Figure 25
Groundsmaster® 300 Series
Page 13 - 17
Repairs
Installing Gearbox and Drive Pulley
1. Install isolation mounts (Item 3) into brackets (Item 7,
13). Use water or lubricant to ease installation. Install
mounts from bottom of bracket.
2. Install bracket on each side of gearbox with capscrews and lockwashers. Tighten capscrews to a torque
of 20 - 26 ft-lb.
3. Install gearbox with brackets to gear box mount plate
(Item 10).
4. To install pulley (Item 17), slide taper lock (Item 18),
small end first, into pulley hub.
5. Insert woodruff key into keyway in gearbox shaft.
Slide pulley with taper lock onto gearbox shaft while
aligning key and keyway.
NOTE: Large hub on pulley must face away from gearbox, and like the taper lock, the pulley must contact
shoulder on the gearbox shaft.
6. Rotate pulley to get non-threaded holes in taper lock
to line up with the two threaded holes in hub of gearbox
pulley. Start threading set screws (Item 19) into the two
holes and tighten them alternately and evenly until both
set screws are tight.
7. Using a brass drift pin or sleeve and a hammer, hit
taper lock firmly. Now tighten set screws to 55 in-lb.
Continue to hit taper lock and tighten set screws until
55 in-lb of torque will not turn the set screws.
8. Check alignment of gearbox with a spindle pulley.
Loosen and relocate taper lock to adjust, if necessary.
9. Fill recessed socket head in each setscrew, and other
taper lock holes, with grease to prevent dirt from packing
into holes.
10. Install gear box plate on deck channels while routing
belt around gear box pulley. Mount gear box plate to
deck channels with capscrews and nuts.
11. Install idler arm bracket to idler arm with cotter pin
and clevis pin. Hook spring onto idler arm bracket. To
make sure there is proper belt tension on drive belt,
spring should be extended to a length of approximately
7.00 inches. If spring is not extended to this length,
move spring rod to other mounting holes further away
from belt.
12. Install belt covers. Install drive shaft to gear box and
secure with a new roll pin.
13. Remove gear box fill plug and check plug. Add SAE
80W90 API GL-5 gear lube until level is to bottom of
check plug hole. Install plugs in gear box.
Figure 26
Repairs
Page 13 - 18
Groundsmaster® 300 Series
Gear Box Repair (Fig. 27, 28)
Figure 27
Gear Box Disassembly
1. Drain lubricant from gear box.
2. Remove capscrews and lift out shaft and cap assemblies.
3. Remove cap assemblies and bearing cones (Item 12)
from shafts (Item 17, 19).
NOTE: Mark each gear (Item 10 and 18) so they are
installed on the proper shaft (Item 17 or 19) when
re-assembled.
4. Remove retaining rings (Item 7).
5. Press shafts (Item 17, 19) back through bearing
cones (Item 9). When bearing cone is free, gears (Item
10, 18), keys (Item 8) and shims (Item 11) may be
removed from the shaft.
Groundsmaster® 300 Series
6. Remove bearing cups (Item 14) from cap by putting
a punch through the shaft bore and through the seal and
then tapping against the back of the bearing cup until
driven out of the cap.
7. If the oil seal (Item 13) is removed, it will be destroyed.
To remove the oil seal, cut it out of the bore with a screw
driver or chisel.
8. To remove the bearing cups (Item 3) from the housing
a slide hammer puller may be used, or if this is not
available, the bearing cups may be knocked out with a
punch by coming down through the opposite cap bore
and tapping against the back side of the bearing cup
until it comes out.
9. Remove the plugs (Item 2) from the housing.
Page 13 - 19
Repairs
17
12
14
4, 5, 6
16
9
3
1
10
11
19
13
2
7
18
8
Figure 28
Gear Box Pre-Assembly
1. Start with one of the shafts (Item 17) and put one of
the gears (Item 10) over the shaft so the tooth side is
towards the turned end of the shaft. Align the keyway in
the gear with the keyway in the shaft and install one of
the keys (Item 8) in the keyway.
2. Install one set of shims (Item 11) onto the turned end
of the shaft. Press one of the bearing cones (Item 9)
over the turned end of the shaft. Be sure the bearing
cone is installed as shown in the illustration (Fig. 42B).
Install a retaining ring (Item 7) on the turned end of the
shaft.
3. Put one of the bearing cones (Item 12) over the other
end of the shaft and down against the hub side of the
gear. Be sure the bearing cone is installed as shown in
the illustration.
4. Repeat steps 1 - 3 with the other set of parts to
complete the assembly.
cap with the open side toward the machined side of the
cap.
6. Install the bearing cup (Item 14) into the cap. Make
sure the bearing cup is installed as shown in the illustration.
7. Repeat steps 5 - 6 with the other set of parts to
complete the two cap assemblies.
8. Take one of the shaft and gear assemblies and wrap
the end of the shaft with a piece of shim stock to keep
from cutting the oil seal on the keyway or splines. Put
the cap assembly down over the shaft so the bearing
cone (Item 12) on the shaft mates with the bearing cone
(Item 14) in the cap. Remove the shim stock from the
shaft that was used to protect the seal.
9. Press the bearing cups (Item 3) into both bearing
bores in the housing (Item 1). Make sure the cups are
installed as shown in the illustration. Install the plugs
(Item 2) into the tapped holes in the housing.
5. Put one of the caps (Item 16) down, with the machined
surface facing up. Install a new seal (Item 13) into the
Repairs
Page 13 - 20
Groundsmaster® 300 Series
Gear Box Final Assembly
1. Bearing drag is adjusted by the amount of gaskets
(Item 4, 5, 6) used between the cap and housing machined surfaces.
2. Put two 0.015 in. gaskets on the machined surface of
the housing, then install the shaft and cap assembly in
the housing so the bearing cone (Item 9) on the shaft
assembly and bearing cup (Item 3) in the housing are
mating. Align the holes in the cap with the holes in the
gaskets and housing.
3. Install capscrews and tighten.
Groundsmaster® 300 Series
4. The shaft should have a very slight amount of bearing
drag. If the shaft turns hard, the cap must be removed
and gasket(s) need to be added. If the shaft has no
bearing drag, or has end play, the cap must be removed
and gasket(s) taken out. The cap must be adjusted to
where the shaft has no end play and only a slight amount
of bearing drag.
5. Repeat steps 1 - 4 with the other shaft and cap
assembly.
6. After installing the gear box on the cutting unit, fill it
with SAE 80W90 API GL-5 lubricant to the level of the
check plug (see Maintenance section in this chapter).
Page 13 - 21
Repairs
Blade Spindle Service (Fig. 29, 30, 31)
Removing Spindle Housing Assembly
1. Lower the cutting unit, shut the engine off and engage
the parking brake.
2. Remove deck covers from top of cutting unit. Release
belt tension. Remove belt from spindle to be serviced.
3. Start the engine and raise the cutting unit. Turn the
engine OFF and remove the key from the key switch.
Block up the cutting unit so it cannot fall accidentally.
4. Using a rag or thickly padded glove, grasp end of
blade. Remove blade screw, flat washer, anti-scalp cup
and blade from spindle assembly.
5. Remove flange nuts and carriage bolts securing
spindle housing to deck. Slide spindle housing assembly out the bottom of the cutting unit.
Disassembly
1. Remove lock nut retaining the spindle pulley on
spindle shaft. Slide pulley off of shaft.
2. Press the spindle shaft out of the spindle housing
using an arbor press. The bearing spacer remains on
the spindle shaft as the shaft is being removed.
3. Remove seals from spindle housing.
4. Allow the bearings and small thick spacer to fall out
of the spindle housing.
5. Using a punch and hammer, drive both of the bearing
cups out of the spindle housing. Also drive the large
spacer out of the housing.
Figure 29
1. Grease fitting
2. Lock nut
3. Spindle pulley
4. Wave seal
5. Bearing assembly
6 Carriage bolt
7. Flat washer
8. Spindle housing
9. Flange nut
10. Spindle shaft
11. Spindle shaft spacer
12. Blade
13. Anti-scalp cup
14. Lock washer
15. Blade screw
6. A large snap ring is still inside the spindle housing and
it should remain there because it cannot be easily
removed.
IMPORTANT: If new bearings will be installed into a
used spindle housing that has the original snap ring
installed, discard the large snap ring that came with
the bearings because it is not needed. However, new
bearings with their matched spacer and snap ring
must always be installed when the spindle housing
is being replaced. Replacement bearings are sold
only with a matched snap ring and spacer set. These
parts cannot be purchased separately.
Repairs
Page 13 - 22
Groundsmaster® 300 Series
Installing Spindle, Bearings
and Seals Into Spindle Housing
IMPORTANT: If a new spindle housing is being used,
new bearings and matched snap ring set must be
installed; see step 1 below. Never use old bearings,
spacer, and snap ring with a new spindle housing.
If installing bearings into a used spindle housing
that still has a snap ring installed, use only new
bearings with cups and spacer – not the large snap
ring because it is not required; see step 2 below.
1. Install large snap ring into groove in bore of spindle
housing. Make sure snap ring is seated in groove.
2. Using an arbor press, push large spacer into top of
spindle housing; tightly against snap ring. The spacer
must contact the snap ring to be sure of the correct
assembly of the parts.
Figure 30
3. Thoroughly oil the bearing cups and using an arbor
press, push the bearing cups, smallest inside diameter
first, into the top and bottom of the spindle housing. The
top bearing cup must contact the spacer that was installed in step 2, and the bottom bearing cup must
contact the snap ring to be sure of the correct assembly
of parts. Insure that the assembly is correct by supporting the first cup and pressing the second against it.
4. Apply a film of grease on lips of both seals, then install
bearing and seal into bottom of spindle housing. Remember, the BOTTOM SEAL MUST HAVE THE LIP FACING
OUTWARD, not toward the inside of the spindle housing.
Figure 31
5. Check the spindle shaft to make sure it is free of burrs
and nicks that could possibly cut the seals and thoroughly lubricate both the shaft and seal lips.
6. Slide small, thick spacer into spindle housing, then
install bearing and seal into top of spindle housing. LIP
OF UPPER SEAL MUST FACE INWARD.
7. Slide bearing spacer onto spindle shaft. Carefully
slide spindle shaft through spindle housing. The bottom
seal and bearing spacer fit together when the spindle is
installed.
8. Push pulley onto splines of spindle shaft and retain
the parts together with the large flat washer and nut.
Tighten the nut to 100 - 120 ft-lb and rotate the spindle
shaft to be sure that the shaft rotates freely.
9. Slide pulley end of spindle assembly through hole in
cutting unit. Mount the spindle assembly in place with
the carriage bolts and flange nuts.
10. Install the belt and adjust belt tension.
11. Reinstall the belt covers.
Groundsmaster® 300 Series
Page 13 - 23
Repairs
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Commercial Products
© The Toro Company
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