Service Manual

ManualsBrandsToro ManualsRiding ProductsGroundsmaster 455-D 4-Wheel Drive

Part No. 93804SL Rev. E

Service Manual

Groundsmaster

455-D

This publication provides the service technician with

information for troubleshooting, testing, and repair of

major systems and components o n th e

Groundsmaster 455-D

REFER TO THE GROUNDSMASTER 455-D OPERA-

OR’S MANUAL FOR OPERATING, MAINTENANCE

AND ADJUSTMENT INSTRUCTIONS. Space is pro-

vided at the end of Chapter 2 in this publication to insert

the Operator’s Manuals and Parts Catalogs for your

machine. Replacement Operator’s Manuals are avail-

able by sending complete Model and Serial Number of

traction unit and cutting unit to:

The Toro Company

8111 Lyndale Avenue South

Minneapolis, MN 55420

The Toro Company reserves the right to change product

speci

fications or this publication without notice.

This safety symbol means DANGER, WARN-

ING, or CAUTION, PERSONAL SAFETY IN-

STRUCTION. When you see this symbol,

carefully read the instructions that follow.

Failure to obey the instructions may result in

personal injury.

NOTE: A NOTE will give general information about the

correct operation, maintenance, service, testing or re-

pair of the machine.

IMPORTANT: The IMPORTANT notice will give im-

portant instructions which must be followed to pre-

vent damage to systems or components on the

machine.

The Toro Company - 1993, 1996, 1998, 2002, 2003

Summary of content (254 pages)

PAGE 1
Part No. 93804SL Rev. E Service Manual Groundsmaster 455-D ® This publication provides the service technician with information for troubleshooting, testing, and repair of major systems and components on the Groundsmaster 455-D REFER TO THE GROUNDSMASTER 455-D OPERATOR’S MANUAL FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. Space is pro vided at the end of Chapter 2 in this publication to insert the Operator’s Manuals and Parts Catalogs for your machine.
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Chapter 2 - Product Records and Manuals Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 Equivalents and Conversions . . . . . . . . . . . . . . . . 2 - 2 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . 2 - 3 Maintenance Interval Charts . . . . . . . . . . . . . . . . . 2 - 4 Equipment Operational and Service Historical Report Record Chapter 5 - Electrical System Wiring Schematics and Diagrams . . . . . . . . . . . . . 5 - 2 Special Tools . . . . . . . . . . . . .
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Safety Table of Contents While Doing Maintenance, Troubleshooting, Testing, Adjustments or Repairs . . . . . . . . . . . . . 3 SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . 1 Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . 1 While Operating. . . . . . . . . . . . . . . . . . . . . . . . . .
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long pants and a helmet is advisable and required by some local ordinances and insurance regulations. 8. Since diesel fuel is highly flammable, handle it carefully: 6. Assure interlock switches are adjusted correctly so engine cannot be started unless traction pedal is in NEUTRAL and cutting unit is DISENGAGED. A. Use an approved fuel container. B. Do not remove fuel tank cap while engine is hot or running. C. Do not smoke while handling fuel. D.
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A. Set parking brake. B. Move traction pedal to neutral and axle shift to Hi or LO position. C. Disengage cutting decks and wait for blades to stop. D. Stop engine and remove key from switch. E. Do not park on slopes unless wheels are chocked or blocked. 24. Use only a rigid tow bar if it becomes necessary to tow machine. Use trailer for normal transport. While Doing Maintenance, Troubleshooting, Testing, Adjustments or Repairs 25.
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Safety Instructions Page 1 - 4 Groundsmaster® 455-D
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Chapter 2 Table of Contents 1 2 2 2 3 3 3 MAINTENANCE CHARTS . . . . . . . . . . . . . . . . . . . . 4 2 Wheel Drive Quick Reference Aid . . . . . . . . . . 4 4 Wheel Drive Quick Reference Aid . . . . . . . . . . 6 EQUIPMENT OPERATION AND SERVICE HISTORY REPORT Record information about your Groundsmaster 455-D on the Equipment Operation and Service History Report Form. Use this information when referring to your ma chine.
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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.
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Torque Specifications The torque values listed below are for lubricated threads. Plated threads are considered to be lubricated. Capscrew Markings and Torque Values - U.S.
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Maintenance Schedules Maintenance Schedules Page 2 - 4 Rev.
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Product Records and Manuals Groundsmaster® 455-D Page 2 - 5 Rev.
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Maintenance Charts Page 2 - 6 Groundsmaster® 455-D
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EQUIPMENT OPERATION AND SERVICE HISTORY REPORT for GROUNDSMASTER® 455-D TORO Model and Serial Number:__________-__________ Engine Numbers: _____________________ Transaxle Numbers: _____________________ _____________________ Rotary Deck Numbers: __________-__________ Date Purchased: ____________________ Warranty Expires__________ Purchased From: ____________________ ____________________ ____________________ Contacts: Parts ____________________ Phone __________________ Service _________________
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GROUNDSMASTER® 455-D Maintenance Schedule Minimum Recommended Maintenance Intervals: Maintenance Procedure Inspect Air Filter, Dust Cup, and Baffle Lubricate All Grease Fittings Check Cutting Unit Gear Box Oil Level Maintenance Interval & Service Type: Every 50hrs A Level Service Every 100hrs Every 200hrs Every 400hrs Every 800hrs ‡ Change Engine Oil and Filter Check Battery Level and Connections Inspect Cooling System Hoses B Level Service Service Air Cleaner Filter Element † Inspect PTO and Cuttin
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GROUNDSMASTER® 455-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 Brake Operation Engine Oil Level Fuel Level Cooling System Fluid Level Drain Water/Fuel Separator Optional Air Filter Precleaner Radiator & Screen for Debris
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Replace Safety Switches Replace PTO/ Cutter Deck Belts _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ Inspect Cooling System Hoses A-Service required ______________________________ ______________________________ ______________________________ ______________________________ ______________________________ E -Service (every 800 hours) Inspect Engine Fan Belt Inspect Engine Timing Belt D
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Chapter 3 Engine INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 IDENTIFICATION AND SPECIFICATIONS . . . . . . . 3 General Specifications . . . . . . . . . . . . . . . . . . . . 3 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Cylinder Head Gasket . . . . . . . . . . . . . . . . . . . . . 4 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Valve Recess . . . . . . .
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Introduction The following pages give information about specifica tions, maintenance, troubleshooting, testing and repair of the diesel engine used in the Groundsmaster® 455-D mowers. Most repairs and adjustments require tools which are commonly available in many service shops. Special tools are described in the Special Tools section.
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Identification and Specifications General Specifications Item Specification ___________________________________________________________________________________________ Engine Type Peugeot XUD9AI, 4 cycle, water cooled, 4 cylinder, vertical in-line cylinders, single overhead cam, indirect injection, naturally aspirated. ________________________________________________________________________________________________________________________ ________________________________ Compression ratio 23.
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Cylinder Head Cylinder head height h is measured with the camshaft in place fitted with two bearing caps. h is measured on the oil seal lip contact diameter (the largest diameter). h nominal: 157.40 to 157.75 mm Maximum permissible bow on bottom of cylinder head: 0.07 mm (camshaft must turn freely). Maximum permissible gasket face machining: .14 mm in rela tion to the measured h nominal.
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Camshaft Camshafts with 0.5 mm oversize bearings* are iden tified by a yellow paint ring (d) between the cams of No. 1 cylinder. * NOTE: These camshafts are installed only on ex change engines, and can be obtained on special order. Engine Figure 4 Valves Units: mm Intake Min. Length l +0 Exhaust 112.2 8.005 7.985 øb ± 0.1 38.5 33 a 90° 90° øa – 0.015 Intake: Faces x and y can machined a maximum of 0.2 mm Exhaust: No machining is permissible.
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Valve Springs Units: mm Spring ød 29 P1: daN e1 18 42.4 Figure 7 Valve Guides Units: mm øf øg h j øk Tolerance 0 – 0.011 + 0.032 0 ± 0.25 ± 0.50 0 + 0.2 Production 14.02 14.13 13.981 14.051 Repair 1 14.29 14.211 52.00 36.50 8.02 Repair 2 14.59 14.511 øk is obtained by machining after fitting in the cylinder head Figure 8 Engine Page 3 - 6 Rev.
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Valve Seats Units: mm Intake øa øb c d Tolerance 0 – 0.025 ± 0.025 0 – 0.1 ± 0.15 Production 40.161 40.361 40 40.2 6.25 6.45 8.267 8.467 Repair 1 40.461 40.3 6.45 8.467 Repair 2 40.661 40.5 6.45 8.467 Engine Units: mm Exhaust øa øb c d Tolerance 0 – 0.025 ± 0.025 0 – 0.1 ± 0.15 Production 34.137 34.337 34 34.2 6.05 6.25 8.15 8.35 Repair 1 34.437 34.3 6.25 8.35 Repair 2 34.637 34.5 6.25 8.
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Cylinder / Piston Matching Units: mm Identification (x) CYLINDER øa Tolerance: + 0.018 – 0 PISTON øb Tolerance: ± 0.009 None 83 82.93 A1 83.03 82.96 Repair 1 R1 83.20 83.13 Repair 2 R2 83.50 83.43 Repair 3 R3 83.80 83.73 Production NOTE: The piston øb must be measured at dimension c. C 25.00 NOTE: The repair dimension (x) is stamped on the cylinder block and pistons. Figure 11 Piston Pin Units: mm ø external 24.994 to 25 ø internal 13.8 to 14.1 Engine Page 3 - 8 Rev.
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Crankshaft Units: mm Crank Pins and Journals øa b øc d Tolerance –0 – 0.016 ± 0.003 –0 – 0.019 ± 0.003 Production 50.00 1.827 60.00 1.842 Repair 1 49.70 1.977 59.70 1.992 NOTE: Repair 1 size connecting rod and main bearing shells can be identified by white paint (1) on the edge of the shell. Engine Units: mm End Float No. 2 Journal Half Shell Thickness e f Tolerance + 0.05 0 ± 0.025 Production 26.60 2.305 Repair 1 26.80 2.405 Repair 2 26.90 2.455 Repair 3 27.00 2.
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Tightening Torques Part Nm Kgm ft-lb __________________________________________________________________________________________ Connecting rod end caps 50 5 37 ________________________________________________________________________________________________________________________ ________________________________ Camshaft bearing caps 17.5 1.
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Special Tools NOTE: Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Some tools may be l isted in the Groundsmaster 455-D Parts Catalog. Some tools may also be available from a local supplier. TOR4033 Overhaul Tool Set This tool kit includes tools required for overhauling the engine. TOR4035 Tune-Up Set will also be required if overhauling the engine. Engine TOR80504A1 Extension (Fig. 24) TOR80110H Indicator Holder (Fig.
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TOR2437T Dial Indicator This dial indicator may be used with TOR80110H, TOR80117AM and TOR80504A2 to accomplish any of the following tasks: for checking the protrusion of the swirl chambers, valve recess and measurement for cylinder head gasket selection, adjusting the timing of the injection pump and for checking the crankshaft and float. Figure 16 TOR4024T Valve Spring Compressor This tool is used to compress valves for removal.
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TOR70153C Rear Main Seal Installer Used with a small hammer to install new rear main oil seal. Figure 20 TOR70153D Front Cover Seal Installer Engine Used with a small hammer to install new front crankshaft seal. Figure 21 TOR70153N Flywheel T.D.C. Locator Pin Used to set injection pump timing. Figure 22 TOR80110DZ 2mm Shim Cut Off Gauge With Cut Off Shim Used to gage and gut off new side seals to 2mm height. Figure 23 Groundsmaster 455-D Page 3 - 13 Rev.
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TOR80110GY Extension Rod and Adapter Used with TOR 80504A1 and TOR80504A2 to check crankshaft end float. Figure 24 TOR80110H Indicator Holder Block used to hold dial indicator to check protrusion of swirl chambers, valve recess and measurement for cylinder head gasket selection. Figure 25 TOR80117AM Timing Tool Kit For Roto Diesel DPC Pump Used with dial indicator to adjust timing of injection pump.
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TOR80149 Injector Socket Used to remove and install fuel injectors. Figure 28 TOR80504A1 Extension Engine Used with TOR 80110GY and TOR 80504A2 to check crankshaft end float. Figure 29 TOR 80504A2 Indicator Holder Used with TOR80110GY and TOR 80504A1 to check crankshaft end float. Figure 30 TOR976697 Camshaft Seal Installer Used to install camshaft seal. Figure 31 Groundsmaster 455-D Page 3 - 15 Rev.
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.0149 - Cylinder Head Separating Levers (Make Locally) Used to remove cylinder head (qty. 2 required). Units: mm Figure 32 TOR70153H Injector Pump Gear Puller Loosen the nut on the injector pump gear, then use this tool to loosen the pulley from the tapered shaft on the injector pump. TOR70153H Figure 33 Engine Page 3 - 16 Rev.
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Adjustments Valve Clearance Adjustment (See Valve Clearance Adjustment in the Engine Over haul Section.) Engine Speed Adjustments Engine Maximum fuel flow and speed adjustments are sealed and should only be unsealed by a CAV Lucas ROTODIESEL service dealer. Throttle Cable Adjustments The throttle control lever at the operator’s station must not touch the end of the slot during full range of motion from idle (SLOW) to full engine RPM (FAST).
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Troubleshooting Alternator Problem Possible Causes Alternator is not charging. Alternator belt loose. Charging circuit defective. Energizing circuit defective. Brushes worn or seized. Rotor winding defective. Stator winding defective. Regulator defective. Output low or irregular. Alternator belt loose. Charging circuit defective. Energizing circuit defective. Brushes worn or seized. Rotor winding defective. Stator winding defective. Regulator defective. Rotor partially short-circuited.
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Problem Possible Cause Correction Bad spray pattern Carbon deposit around the orifice Clean Scored nozzle seat Replace injector Needle damaged Replace injector Foreign matter jammed between nozzle seat and needle Clean Nozzle seat out-of-true Replace injector Water in fuel Drain water and flush fuel feed system (1) Copper gasket not replaced Replace gasket at each repair Injector nut too tight on injector body Tighten injector nut (1) Leaking injector Needle seized or showing seizing ma
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Fuel Injection Pump Problem Possible Cause Correction Engine has no power Defective fuel supply Check filter cartridge and pipes Incorrect pump timing Correct timing Incorrect spray, or injector pressure out of adjustment Check, clean and adjust injectors Air intake restriction Check hoses and air cleaner Insufficient automatic advance Have pump repaired Discharge rates too low Have pump repaired Idling stop out of adjustment Adjust stop and fast idling control Throttle cable out of adjust
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Problem Possible Cause Correction Engine will not start No preheating Check glow plugs and relay No fuel supply Make sure tank is not empty Check filter element and pipes Irregular engine speed Noisy engine Engine stalls at idling Vibrating engine Engine will not stop Groundsmaster 455-D Defective solenoid valve Check electric stop solenoid Seized pump plunger Have pump repaired Discharge valve blocked in “stop” position Have pump repaired Seized feed pump Drain water from tank, pipes a
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Low Power Problem Possible Causes Engine does not give full power Injection pump timing Seized piston rings Defective injector(s) Air intake restricted Valve leaks Clogged fuel filter Injection pipe restriction due to excessive tightening of unions Defective injection pump Irregular idling Defective injection pump Air getting into fuel system Idling stop out of adjustment Leaky injection pipe unions Speed fall-Off Clogged fuel filter Defective injection pump Engine speed rises to maximum Defective
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Noisy Engine Problem Possible Causes Knocking Loose main bearings Broken part Leakage return collector clogged Lifters out of adjustment Foreign matter in a cylinder Seized injector Engine Injection pump timing Sheared glow plug Timing out of adjustment Whistling, blowing Leaking cylinder head gasket Leaky glow plug Valve seats Leaky injector Groundsmaster 455-D Page 3 - 23 Rev.
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Pre-heating Problem Possible Causes Glow plug does not glow red hot Faulty glow plug Faulty glow plug relay Damaged wiring or connector All four glow plugs burnt out / ends melted – injection pump timing out of adjustment (engine overheating) See Chapter 5 - Electrical System Engine Page 3 - 24 Rev.
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Smoke During Operation Problem Possible Causes Black Defective injector Injection pump out of adjustment Injection pump timing Air intake restricted Inlet chambers clogged Not enough advance Defective injector Engine Grey Injection pump timing Air intake restricted Not enough advance Blue-Grey Defective injector Injection pump timing Too much oil Blue Too much oil Wear White Injection pump timing Cylinder head gasket Cold engine Groundsmaster 455-D Page 3 - 25 Rev.
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Starting Problems Problem Possible Causes Engine will not start and emits black smoke Air intake obstructed Defective injectors Lack of compression (seized rings, damaged or worn valve seats, or general wear) Injection pump timing Engine will not start and emits white smoke Leaking cylinder head gasket Engine will not start and does not emit any smoke Frozen fuel Injection pump does not work Leaking injection pipe unions Injection valve blocked No preheating Empty fuel tank Feed pipe obstructed Air g
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Testing and Inspection Injection Pump Timing (See Timing of Injection Pump in the Engine Overhaul section.) Glow Plug Test CAUTION Engine Be careful while handling or testing glow plugs. Glow plugs become extremely hot. Ac cidental contact with the heated plug tip could cause personal injury. 1. Disconnect the wire lead(s) to the glow plug. 2. Remove the glow plug. 3. Inspect the glow plug for signs of a burnt glow plug end tube.
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Compression Test Minimum cylinder compression is 20 bar (290 psi) at 200 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 four cylinders. 2. Insert a compression gauge adapter into the glow plug hole. 3.
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Injector Tests There are several tests to examine the condition of the injection nozzles. These tests require the use of a nozzle tester and nozzle tester adapter. defective, damaged or adjusted incorrectly, starting failures, low power output, or engine knocking can occur. 1. Securely fasten the nozzle to the adapter. CAUTION 2. Pump the handle several times to purge air from the nozzle mechanism. The nozzle tester forces fuel from the nozzle under extremely high pressure.
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Nozzle Leakage Test A nozzle that leaks fuel from the nozzle orifice must be replaced. 1. Securely fasten the nozzle to the adapter. 2. Wipe all fuel from the nozzle. 3. Operate the pump until the pressure is approximately 20 bar or kg/cm2 (280 psi) below opening pressure. Maintain this pressure to the nozzle. Good 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.
PAGE 49
Injection Pump Testing It is possible to determine if the fuel injection pump requires service through a process of elimination using other fuel system tests. The following test procedure will help isolate fuel system difficulties. 1. Make sure that fuel is being supplied to the injector pump. 2. Check the operating condition of the injection nozzles to make sure that the injection pressure is correct. 3.
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Thermostat Test If the engine overheats or runs too cool, and a faulty thermostat is suspected, the thermostat should be tested. 1. Remove the thermostat. 2. Put the thermostat in a container of water with a thermometer and heat the water. Starts to open at: 81o C (178o F) 7 mm (0.28 in.) full open at 88o C (190o F) 3. If the thermostat fails to open, only partially opens, or sticks, it should be replaced. Figure 37 Engine Page 3 - 32 Rev.
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Fuel System Service Priming Fuel System 1. Stop the engine. Unlatch and raise the hood 2. Fill the fuel tank. 3. Install a 3/16" hose over bleed screw. Put other end of hose into a container to catch fuel (Fig. 38). 5.Loosen bleed screw a few turns. Pump priming plunger until a steady stream of fuel comes out of hole in bleed screw. When fuel stops foaming, tighten bleed screw during down stroke of priming plunger. Wipe up any spilled fuel.
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Injector Service NOTE: If injectors need to be inspected or repaired it is recommended that it be done by an authorized CAV Lucas ROTO DIESEL service dealer - especially during the warranty period. Repairs by non-authorized dealers WILL void the warranty on the injectors. 1 Removal 8 2 1. Clean top of cylinder head and injection pipes. 2. Remove injection pipes (Fig. 57, Item 12). 3 3. Disconnect injector leakage pipe. 4 4. Remove the injectors (Fig.
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Assembly 1. Check all parts for condition and cleanliness. Oil parts before reassembly. 2. Secure the injector body in a “V” type injector holder. 3. Install the adjusting shims, spring, push rod, spacer and injector (Fig. 40, Items 2, 3, 4, 5, 6). 4. Install the injector holder nut (Fig. 28, Item 7) and tighten by hand. 5. Tighten injector nut to a torque of 10 Nm. Tighten the nut an additional 22° of rotation. NOTE: Each time an injector is removed from the en gine, new washers must be installed.
PAGE 54
Timing Belt Replacement Timing Belt Removal IMPORTANT: Never install a used belt. When the timing belt is removed a NEW timing belt must be installed. SPECIAL TOOLS REQUIRED: Tune-Up Tool Set TOR 4035 1 ea. M8 x 125 x 40 Metric Bolt 2 ea. M8 x 125 x 35 Metric Bolt TOR 70153N 1. Slowly turn the crankshaft in the operating direction (clockwise as viewed from the timing belt end) until the TDC Lock Pin tool (TOR 70153N) goes into the hole in the flywheel (Fig. 42). Figure 42 2.
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7. Loosen the nut (Fig. 45, Item 8) and the bolt (Item 9), securing the roller tensioner bracket (Item 10). 8. Rotate the roller tensioner bracket square (Item A) to compress the spring (Item 11). A 9. Re-tighten the bolt (Item 9). Engine 10. Remove the timing belt. Figure 45 Groundsmaster 455-D Page 3 - 37 Rev.
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Timing Belt Installation IMPORTANT: Never install a used belt. When the timing belt is removed a NEW timing belt must be installed. C A 1. Install the new timing belt, with the runs taut, in the following order (Fig. 46): Crankshaft gear (Item 13) Fixed roller (Item 11) Injection pump gear (Item B) Camshaft gear (Item C) Tensioner roller (Item 17) Coolant pump gear (Item 10). B Figure 46 A 2. Loosen the bolt (Fig. 47, Item 18) and nut (Item 19) to release the tensioner roller.
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4. Remove the three gear locking bolts and TDC Lock Pin tool. A 5. Turn the crankshaft two revolutions (clockwise). 6. Re-install the TDC Lock Pin tool TOR 70153 N and the three gear locking bolts. IMPORTANT: If you can not install any one of the locking devices, repeat the Timing Belt Installation procedures from the beginning. 7. Loosen the bolt (Fig. 48, Item 18) and nut (Item 19) to release the tensioner roller. Figure 48 Engine 8.
PAGE 58
Injection Pump Timing Timing of Injection Pump (Pump Mounted on Engine) b The adjustment position for start of injection varies on each pump (manufacturing tolerances). The adjustment position is given by measurement “X.XX” in one of three places on the pump (Fig. 51): a a. Tag on pump lever. b. Bar code label c. Inspection cap NOTE: “PMH” in French = “TDC” in English. 1. Remove the cover attachment nut, cover clips and timing belt covers. Figure 51 2.
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6. Clean the area around the pump timing plug (Fig. 54, Item d). Remove the pump timing plug. d b a 7. Use Timing Tool Assembly TOR 80117 AM. Lubricate the timing rod (Fig. 55, Item 1) with Diesel fuel, then install the timing rod in the pump timing hole (Item d). Check to see that the rod moves freely in the bore. 8. Install the dial indicator (metric) on the indicator bracket (Item 2). 9. Install the indicator bracket with dial indicator on the plug boss. Set the dial indicator to “0.00 mm”.
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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. IMPORTANT: Do not spray water on a hot engine.
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Engine Removal and Installation 2. Open the hood. Disconnect hood stop cable from engine. Lower the hood. Remove left and right hinge plates. Lift hood off chassis. 3. Disconnect positive (+) and negative (–) battery ca bles from battery. Loosen battery securing bolt and remove battery. 4. Open the radiator cap. Open radiator drain valve or remove lower radiator hose and allow coolant to drain into a pan. 8.
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Installing the Engine 1. To install the engine, perform steps 2- 14 of Removing the Engine in reverse order. 2. After disassembling or overhauling the engine, install a new oil filter. Replace this filter after the first 20 to 50 hours of operation. 3. Fill the engine with the correct oil. Fill the cooling system with a 50/50 solution of ethylene glycol anti freeze, and clean, soft water. Check for oil and coolant leaks and repair as necessary. Peugeot recommended Coolant/Antifreeze is available in 1 U.S.
PAGE 63
Engine Overhaul Disassembly of External Components 1. Remove TDC sensor and clutch housing center ing pin. 2. Mount the engine on a stand. 3. Lock the flywheel with TOR FD86 tool. 4. Remove exhaust manifold and inlet manifold. 5. Remove the coolant manifold. Engine 6. Remove the alternator and belt. 7. Remove the oil filter (Fig. 57, Item 10). 8. Remove the injector pipes (Item 12). 9. Remove the glow plug leads. 10. Remove the crankcase breather pipes/oil filter/filter pipe assembly (Item 13). 11.
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12. Remove the thermostat housing cover (Fig. 58, Item 17). TOR 80149 13. Remove the thermostat housing (Item 18). 14. Remove the injectors (Item 19) and retrieve the copper washer (Item 20), and flame trap washer (Item 21). 15. Remove the glow plugs (Item 22). Figure 58 Injection Pump Removal 1. Remove the timing belt. 2. Use injector pump gear puller TOR70153H, remove injector pump gear (Fig. 58a, Item 5). to TOR70153H Figure 58a 3. Remove the injection pump (Fig. 58b, Item 19). 4.
PAGE 65
Cylinder Head Removal 1. Remove the cylinder head cover. 2. Use a Torx head T55 tool to loosen the cylinder head bolts, working in a spiral from the outside. Remove the cylinder head bolts. IMPORTANT: DO NOT pry at gasket surface to loosen cylinder head from block. 3. Use levers (0.0149) to release the cylinder head from the block. 4. Remove the cylinder head and gasket. Engine Figure 59 Oil Pump Removal 1.
PAGE 66
Crankshaft and Piston Removal 1. Remove flywheel locking tool. 2. Remove the connecting rod end caps (Fig. 62, Item 8), marking each cap for re-installation in the same location. NOTE: Connecting rods and end caps are not num bered. Once they are removed there is no way of knowing the correct location for installation unless you mark them for re-installation. 3. Remove the flywheel. 4. Remove the main bearing caps (Item 9) (marks are cast-in). Figure 62 5. Retrieve end float washers with No. 2 cap. 5.
PAGE 67
Cylinder Head Overhaul 1. Progressively slacken the camshaft bearing caps (Fig. 65, Item 1). 2. Remove the bearing caps (Item 1), oil seals (Item 2), camshaft (Item 3), tappets (Item 4) and adjustment shims (Item 5). Mark adjustment shims and tappets so they will be re-installed in the same location – #1 intake, #1 exhaust, #2 intake, #2 exhaust, etc. NOTE: The shims are small and can stick to the tappets. Engine Figure 65 3. Use a valve compressor to remove the eight valves (Fig. 66). 4.
PAGE 68
8. Check the protrusion of the swirl chambers (Fig. 68, A). Protrusion: 0 to 0.03 mm Achieve this dimension by machining faces (a) and (b). 9. Check the valve recess (B). Exhaust: 0.9 to 1.45 mm Inlet: 0.5 to 1.05 mm Achieve this dimension by machining the valve seats. Figure 68 10. Lap in the valves. 11. Re-install the valves. IMPORTANT: If the cyl ind er head has been machined, fit compensating washers under the valve springs. (See Identification and Specifications section.) 12.
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Crankshaft Installation 1. Put thread lock Loctite on the oil gallery plugs and install them in the cylinder block. 2. Install the grooved main bearing shells. (See Crankshaft in the Inspection and Specifications section for main bearing shell thickness.) Engine Figure 71 3. Install the crankshaft. 4. Install the no. 3, 4 and 5 main bearing caps. 5. Install the two end float half-washers (Fig. 72, Item 1), with the anti-friction faces towards the crankshaft. Figure 72 6. Install the no.
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7. Check crankshaft end float (Fig. 74): A . I n s t al l t he dia l i ndi c a t o r , usi ng to ols TOR 80110G1, TOR 80504 A1 and A2. TOR 80110G1 B. End float must be between 0.07 and 0.32 mm. NOTE: For choice of half-washer thickness see Crankshaft in the Identification and Specifications section. 8. Apply a thin coat of Formetanch or Permatex No. 2 sealant to surface of block where bearing cap will mate (Fig. 73, Item a). TOR 80504 A1-A2 Figure 74 9. Install the two new side seals (Fig.
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13. Tighten the bearing cap bolts to a torque of 70 Nm (52 ft-lb). 14. Using shim TOR 80110DZ, cut off the side seals so that they protrude 2 mm. 15. Check that the crankshaft rotates without tight spots. TOR 80110DZ Engine Figure 76 Pistons and Connecting Rod Assembly 1. Assemble the connecting rods and pistons with the bearing shell tab recess (Fig. 77, Item a) on the same side as the piston crown recess (Item b). 2.
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3. Oil the piston and tighten the piston ring clamp (Fig. 78, Item 4). 4. Remove the connecting rod end caps. 5. Install the pistons in the bores, matching the markings made when removed, and aligning the crown recess (Item a) on the oil filter side of the block. 6. Install the connecting rod end caps. Tighten the nuts to a torque of 50 Nm (37 ft-lb). NOTE: For choice of bearing shell thickness, see Crankcase in Identification and Specifications section. Figure 78 Oil Seal Installation 1.
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3. Install the special shoulder bolt (Fig. 81, Item 1) to center the pump in the proper location. 4. Install the other bolts and tighten the bolts (Item 1, 2, 3) to a torque of 20 Nm (15 ft-lb). 5. Install the seal carrier plate and a new gasket (Item 4) and tighten the bolts to a torque of 15 Nm (11 ft-lb). 6. Put a new oil seal on tool TOR 70153 D. 7. Install the seal by tapping it fully home with a mallet. TOR 70153D 8. Apply Formetanch or Permatex No. 2 sealant as shown (Item a). Engine 9.
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Cylinder Head Gasket Selection 1. Install the dial indicator on support TOR 80110 H and zero it on a surface plate. 2. Turn the crankshaft and measure the protrusion of each piston at TDC. 3. Note the maximum protrusion (Fig. 82, Item d). 4. Select a cylinder head gasket of suitable thickness. TOR 80110H Units: mm Piston protrusion (d) Thickness identification 0.56 to 0.71 2 notches 0.71 to 0.75 3 notches 0.75 to 0.79 4 notches 0.79 to 0.83 5 notches Figure 82 Cylinder Head Installation 1.
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Cylinder Head Tightening 1. Install new washers on the bolts. 2. Pre-tighten the bolts in the order shown (Fig. 84) to a torque of 30 Nm (22 ft-lb). 3. Tighten the bolts in the order shown to a torque of 70 Nm 52 ft-lb). 4. Tighten each bolt in the order shown an additional 120° ± 2°. NOTE: The special cylinder head bolts (Item B) do not require re-tightening. The bolts can be removed and re-installed 5 times before replacing with new bolts.
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3. Remove the camshaft gear (Fig. 86, Item 1). 4. Remove the camshaft bearing caps (Item 2). 5. Remove the camshaft (Item 3). 6. Remove the tappets (Item 4). 7. Remove the basic shims (Item 5). 8. Determine the shim thickness to be fitted for each valve. Example: Units: mm No. 1 Intake valve Specified clearance 0.15 Clearance measured 0.25 Difference Shim installed Figure 86 + 0.10 2.425 * Shim to be installed 2.50 Clearance obtained 0.175 * Basic shim 9.
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11. Apply a thin coat of Formetanch or Permatex No. 2 sealant to each end of the bearing housing at (Fig. 87, Item a). 12. Apply MOLYKOTE G RAPID to the bearing surfaces on the camshaft. 13. Install the camshaft (Item 3) with the DIST marking at the timing gear end. 14. Install the camshaft bearing caps (Item 2) as shown by cast-in markings. Engine 15. Progressively tighten the bearing caps to 17.5 Nm (13 ft-lb). Figure 87 TOR 976697 16.
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Assembly of External Components 1. Install new fire ring washers (Fig. 89, Item 1), convex surface facing up. 2. Install new copper washers (Item 2). 3. Install the injectors and tighten to a torque of 90 Nm (66 ft-lb). 4. Install the pre-heat plugs (Item 4) and tighten to a torque of 22 Nm (16 ft-lb). 5. Install the thermostat housing (Item 5) and cover (Item 6), fitted with a new thermostat and gasket. 6. Install the cylinder head cover (Item 7), and tighten to a torque of 10 Nm (7 ft-lb). Figure 89 7.
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Break-in Engine After Overhaul Engine After disassembling or overhauling the engine, install the a new oil filter. Replace this filter with a new filter after the first 20 to 50 hours of operation. Groundsmaster 455-D Page 3 - 61 Rev.
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Engine Page 3 - 62 Rev.
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Chapter 4 Hydraulic System Table of Contents Groundsmaster® 455-D TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test No. 1: Checking Traction Circuit Working Pressure or Relief Pressure. . . . . . . Test No. 2: Checking Counterbalance Pressure Test No. 3: Checking Wing Deck Counterbalance Pressure . . . . . . . . . . . . . . . Test No. 4: Checking Steering Circuit Working Pressure or Relief Pressure. . . . . . . Test No.
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Specifications Item Description __________________________________________________________________________________________ Traction Pump Traction relief pressure Charge pressure Variable axial piston pump 6000 ± 100 PSI at high idle 100 +25 / – 10 PSI at 3000 ± 50 RPM ________________________________________________________________________________________________________________________________________________________ Charge/Auxiliary Pump Steering pressure Gear pump with flow divider 1200 ± 100 PSI a
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General Information Hydraulic Hoses 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 stopping the en gine and opening the bypass valve.
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SAE Straight Thread O-Ring Port - Non-adjustable (Fig. 4) 1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material. 2. Always replace the O-ring seal when this type of fitting shows signs of leakage. 3. Lubricate the O-ring with a light coating of oil. O-Ring 4. Install the fitting into the port and tighten it down full length until finger tight. 5. Tighten the fitting to the correct flats from finger tight (F.F.F.T.). Size 4 (1/4 in.
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Groundsmaster 455--D Page 4 -- 5 TEST PORT 32.8/15.4 FRONT AXLE TEST PORT 3000/1600 RPM ENGINE FRONT MOTOR .913 IN3 /REV (15.0 CC/REV) Rev. C 110 PSI (7.6 BAR) 6000 PSI (408 BAR) 6000 PSI (408 BAR) 1.50 IN3 /REV (25.0 CC/REV) FORWARD 16.2 GPM MAX (61 LITERS/MIN MAX) O I 100 MESH STRAINER Hydraulic System 1200 PSI (83 BAR) 200--400 PSI (13.6--27.2 BAR) .039 ONE--WAY ORIFICE RIGHT UNIT LIFT CENTER UNIT LIFT .08 ORIFICE .020 ORIFICE .039 ONE--WAY ORIFICE LEFT UNIT LIFT .
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Hydraulic Schematics Page 4 -- 6 Rev. C REAR MOTOR 2.01 IN3 /REV (32.9 CC/REV) 100 PSI 1.5 GPM (6.9 BAR) (5.66 LITERS/MIN) 12.6:1 REAR AXLE TEST PORT OVER--RUNNING CLUTCH T B P A 32.8/15.4 FRONT AXLE TEST PORT 3000/1600 RPM ENGINE FRONT MOTOR .913 IN3 /REV (15.0 CC/REV) 110 PSI (7.6 BAR) 6000 PSI (408 BAR) 6000 PSI (408 BAR) 1.50 IN 3/REV (25.0 CC/REV) FORWARD 16.2 GPM MAX (61 LITERS/MIN MAX) O I 1200 PSI (83 BAR) 100 MESH STRAINER 200--400 PSI (13.6--27.2 BAR) TEST PORT .
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Groundsmaster® 455-D Wing Lift Cylinder Steering Orbitrol Wing Lift Cylinder Center Unit Lift Cylinder Check Valve Center Unit Lift Cylinder Page 4 - 7 Flow Suction Return Pressure Check Valve Traction Motor Reservoir Aux. Pump Hydraulic Flow Diagrams Traction Motor General Auxiliary Pump Flow Filter Oil Cooler Steer Cylinder With all controls in neutral and the engine running, oil is drawn from the reservoir by the auxiliary pump. This gear-type pump has a flow divider cover.
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Hydraulic Flow Diagrams Page 4 - 8 Groundsmaster® 455-D Flow Suction Return Pressure Traction Motor ENGINE Traction Circuit – Forward Filter Oil Cooler Traction Motor When the top of the traction pedal is pushed down, a variable displacement hydrostatic piston pump creates a flow of oil to a fixed displacement piston motor mounted on the two-speed axle to drive the machine forward. On two wheel drive units, this flow returns to the traction pump and continues to operate in a closed loop.
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Groundsmaster® 455-D Page 4 - 9 Hydraulic Flow Diagrams Wing Lift Cylinder Wing Lift Cylinder Center Unit Lift Cylinder Steering Orbitrol Check Valve Center Unit Lift Cylinder Flow Suction Return Pressure Check Valve Reservoir Aux. Pump ENGINE Filter Counter Balance Valve Oil Cooler Hydraulic System Oil from the secondary pressure port of the auxiliary gear type pump goes to the three-spool valve, then through the counterbalance valve, oil cooler, filter, and back to reservoir.
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Hydraulic Flow Diagrams Page 4 - 10 Groundsmaster® 455-D Steering Orbitrol Check Valve Flow Suction Return Pressure Check Valve Reservoir Aux. Pump Filter Steering Circuit – R.H. Turn Oil Cooler Oil flows from the priority pressure port of the gear type auxiliary pump to the power steering valve, then through the oil cooler, filter, and back to reservoir.
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Special Tools NOTE: Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Some tools may be listed in the Groundsmaster 455-D Parts Catalog. Some tools may also be available from a local supplier. Hydraulic Pressure Test Kit Hydraulic System Used to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings.
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Hydraulic Tester - With Pressure and Flow Capabilities Load Valve Low Pressure Gauge Outlet Hose Flow Meter Gauge Protector Valve High Pressure Gauge Inlet Hose Figure 8 You must have o-ring face seal (ORFS) adapter fittings for this tester to use it on the Groundsmaster 455-D. 1. INLET HOSE: Hose connected from the system circuit to the inlet side of the hydraulic tester. 2. LOAD VALVE: If required, upon turning the valve to restrict flow, a simulated working load is created in the circuit. 4.
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Troubleshooting The cause of an improperly functioning hydraulic sys tem is best diagnosed with the use of proper testing equipment and a thorough understanding of the com plete hydraulic system. A hydraulic system with an excessive increase in heat or noise is a potential failure. Should either of these conditions be noticed, immediately stop the machine, turn off the engine, locate the cause of the trouble, and correct it before allowing the machine to be used again.
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Traction Response Is Sluggish Cause Correction __________________________________________________________________________________________ Brakes dragging. Inspect brakes and adjust or repair if necessary. ________________________________________________________________________________________________________________________________________________________ Charge pressure low - TEST NO. 6. NOTE: Counterbalance pressure will also be affected. Inspect charge relief valve and adjust or repair if necessary.
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Four Wheel Drive Does Not Engage Cause Correction ___________________________________________________________________________________________ Front axle shift lever in “HI” (forward) position. Front axle shift lever must be in “LOW” (rear) position for four wheel drive to engage. ________________________________________________________________________________________________________________________________________________________ Electrical problem.
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Cutting Unit Does Not Lift or Lift Too Slowly Cause Correction __________________________________________________________________________________________ Hydraulic oil level too low. Fill to proper level. ________________________________________________________________________________________________________________________________________________________ Low engine RPM. Adjust engine RPM - use tachometer.
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Cutting Unit Will Not Drop or Follow Ground Contours Cause Correction ___________________________________________________________________________________________ Low engine RPM. Adjust engine RPM - use tachometer. ________________________________________________________________________________________________________________________________________________________ Lift arm or cylinder pivots binding. Lubricate bushings. Inspect for damage. Repair or replace damaged parts.
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Cutting Unit Lowers or Raises Too Quickly Cause Correction __________________________________________________________________________________________ Missing or improperly installed orifice in hydraulic line. Properly install orifice between left valve and hydraulic hose to hydraulic lift cylinder(s). NOTE: Orifice must be installed to avoid interference with adapter fitting.
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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.
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TEST NO. 1: Checking Traction Circuit Working Pressure or Relief Pressure WORKING Pressure Check: 1. Make sure hydraulic oil is at normal operating tem perature by operating machine for approximately 10 minutes. 1 2. Lower cutting units, engage parking brake and stop the engine. 3. Raise seat to get access to hydraulic test fittings. Remove access cover from in front of auxiliary pump. 4.
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TEST NO. 2: Checking Counterbalance Pressure 1. Make sure hydraulic oil is at normal operating tem perature by operating machine for approximately 10 minutes. 1 2. Lower cutting units, engage parking brake and stop the engine. 3. Raise and support seat to get access to hydraulic test fittings. 4. Install a 1000 PSI gauge into the counterbalance/lift circuit quick disconnect fitting. 5. Start the engine, move throttle to full speed (3000 RPM) and observe gauge.
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TEST NO. 3: Checking Wing Deck Counterbalance Pressure Wing Deck Counterbalance Pressure 1. Make sure hydraulic oil is at normal operating tem perature by operating machine for approximately 10 minutes. 1 2 2. Lower cutting units, engage parking brake and stop the engine. 3. Install a 1000 PSI gauge into the wing decks coun terbalance quick disconnect fitting. 4. Start the engine, move throttle to full speed (3000 RPM) and observe gauge.
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TEST NO. 4: Checking Steering Circuit Working Pressure or Relief Pressure WORKING Pressure Check: 1. Make sure hydraulic oil is at normal operating tem perature by operating machine for approximately 10 minutes. 2. Lower cutting units, engage parking brake and stop the engine. 1 3. Raise and support the seat to get access to hydraulic test fittings. 4. Install a 5000 PSI gauge onto steering circuit quick disconnect fitting. Figure 13 5. Operate machine while monitoring gauge. 1.
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TEST NO. 5: Checking Lift Circuit Working Pressure or Relief Pressure WORKING Pressure Check: 1. Make sure hydraulic oil is at normal operating tem perature by operating machine for approximately 10 minutes. 1 2. Lower cutting units, engage parking brake and stop the engine. 3. Raise and support seat to get access to hydraulic test fittings. Remove access cover from in front of auxiliary pump. 4. Install a 5000 PSI gauge onto lift circuit quick discon nect fitting.
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TEST NO. 6: Checking Charge Pressure 1. Make sure hydraulic oil is at normal operating tem perature by operating machine for approximately 10 minutes. 2. Lower cutting units, engage parking brake and stop the engine. 3. Install a 1,000 PSI gauge onto the charge pressure quick disconnect fitting. 4. Start the engine and position throttle at high idle (3000 RPM). 1 TESTER READING TO BE 100 +25/–10 PSI. 5. If pressure is low, inspect charge relief valve and valve seat. Figure 15 1.
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Adjustments Traction Pump Neutral Adjustment The machine must not “creep” when traction pedal is released. If it does creep, an adjustment is required. 1. Park machine on a level surface and shut engine off. Make sure transaxle is engaged in HI position. Depress only the left brake pedal and engage the parking brake. 2. Jack up right side of machine until front tire is off the shop floor. Support machine with jack stands to prevent it from falling accidentally. 1 3.
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Repairs Removing Hydraulic System Components 1. Thoroughly clean the machine before disconnecting, removing or disassembling any hydraulic components. Always keep in mind the need for cleanliness when working on hydraulic equipment. 2. Put caps or plugs on any hydraulic lines or fittings left open or exposed. 3. Put labels on disconnected hydraulic lines and hoses for proper installation after repairs are completed. After Repair or Replacement of Components 1.
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Traction Pump Shaft Seal Replacement (Fig. 17) Figure 17 1. Park machine on a level surface, lower cutting units, engage parking brake and stop the engine. 2. Remove pump assembly from machine. 3. Remove retaining ring (Item 32) from pump housing. NOTE: It may be necessary to hold inward pressure against shaft to compress cylinder block spring while removing retaining ring. 4. After removing retaining ring, seal carrier (Item 30) will move out approximately 1/4 in.
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Hydraulic System Traction Pump Trunnion Seal Replacement (Fig. 18) Figure 18 1. Park the machine on a level surface, lower cutting units, engage parking brake and stop the engine. 2. Remove control linkage from swashplate control shaft on transmission (see Transmission Control Removal). 3. Remove hex tapping screws (Item 16) retaining trun nion seal cover (Item 35) to transmission housing. 4. Remove trunnion seal cover with lip seal (Item 34) and o-ring (Item 18). 5.
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Traction Pump Check and High Pressure Relief Valves (Fig. 19) Forward Reverse Figure 19 1. Park the machine on a level surface, lower cutting units, engage parking brake and stop the engine. 2. Remove the check/high pressure relief valve hex plug (Item 2). 3. Remove the valve cartridge assembly (Item 7). In spect the valve and mating seat in the housing for damage or foreign material. It will be necessary to replace the center section if the seat is damaged.
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Hydraulic System Traction Pump Charge Pressure Relief Valve (Fig. 20) Figure 20 1. Park the machine on a level surface, lower cutting units, engage parking brake and stop the engine. the parts unless shims need to be added or removed to adjust the pressure setting. 2. Remove the charge relief valve hex plug (Item 12). 5. Inspect the poppet and mating seat in the end cap for damage or foreign material. 3. Remove the spring (Item 9) and poppet (Item 8) from the housing. 4.
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Disassembly of Traction Pump (Fig. 21) Figure 21 1. End cap 2. Plug 3. 4. O-ring 5. Conical spring 6. Retaining ring 7. Relief valve 8. Charge relief poppet 9. Spring 10. Shim 11. O-ring 12. Charge relief plug 13. Needle bearing 14. End cap gasket 15. Pin 16. Screw 17. Trunnion cover 18. O-ring 19. Trunnion spacer 20. Shim 21. Roller bearing 22. O-ring 23. O-ring 24. Washer 25. Capscrew 26. Pump shaft 27. Ball bearing 28. Retaining ring 29. Lip seal 30.
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4. Remove end cap (Item 1) from pump housing. IMPORTANT: The valve plate (Item 39) may stick to the end cap. Do not allow valve plate to fall from end cap. 5. Remove gasket (Item 14) and alignment pins (Item 15) from end cap. IMPORTANT: Be careful not to damage valve plate and end cap surfaces. an o-ring (Item 18), on the side opposite the control. Remove these parts from the housing. (See Trunnion Seal Replacement). 16.
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Assembly of Traction Pump (Fig. 22) Figure 22 1. End cap 2. Plug 3. 4. O-ring 5. Conical spring 6. Retaining ring 7. Relief valve 8. Charge relief poppet 9. Spring 10. Shim 11. O-ring 12. Charge relief plug 13. Needle bearing 14. End cap gasket 15. Pin 16. Screw 17. Trunnion cover 18. O-ring 19. Trunnion spacer 20. Shim 21. Roller bearing 22. O-ring 23. O-ring 24. Washer 25. Capscrew 26. Pump shaft 27. Ball bearing 28. Retaining ring 29. Lip seal 30. Seal carrier 1.
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5. Install trunnion seal cover (Item 35) with o-ring (Item 18), seal (Item 34) and trunnion bearing into hous ing and over swashplate trunnion (see Trunnion Seal Replacement). Wrap end of swashplate control shaft with thin plastic to prevent damage to seal lip during installation. 6. Install hex tapping screws (Item 16) and tighten to a torque of 6 to 9 ft-lb. 7. Using caution to not damage the sealing surface, press ball bearing (Item 27) onto drive shaft (Item 26).
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Auxiliary/Steering Pump No. 92-7761 (S/N 69999 and Below) (Fig. 23) Figure 23 1. Dowel pin 2. Idler gear assembly 3. Drive gear assembly 4. Capscrew 5. Shaft seal 6. Washer 7. Front plate assembly 8. Needle bearing 9. O-ring seal 10. O-ring seal (moulded) 11. Bearing seal 12. Backup gasket 13. Wear plate 14. Body assembly 15. O-ring seal 16. O-ring seal 17. Relief valve assembly 18. Plug assembly 19. O-ring 20. Disc 21. Spring 22. Back plate assembly 23. Spool assembly 24. Plug assembly 25. O-ring 27.
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10. Remove backup-up gasket (Item 12) from front plate. 5. If gear width is less than 0.636", the gear assembly should be replaced. 11. Remove bearing seal (Item 11) from front plate by prying with a sharp tool. 6. Be sure snap rings are in grooves on either side of drive and idler gears. 12. Remove molded o-ring (Item 10) from front plate by prying with a screwdriver. 7. If edge of gear teeth are sharp, break edge with emery cloth. 13.
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Figure 23 General Auxiliary/Steering Pump Information Assembly of Back Plate Parts It is important that the relationship of the back plate (Item 22), body (Item 14), wear plate (Item 13) and front plate (Item 7) is correct. You will note two half moon cavities in the body which must face away from the front plate. NOTE: The smaller half moon port cavity must be on the pressure side of the pump. Side of wear plate with mid section cut out must be on suction side of pump.
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Assembly of Auxiliary/Steering Pump 1. The wear plate (Item 13), bearing seal (Item 11), molded o-ring (Item 10), back-up gasket (Item 12), shaft seal (Item 5) and o-rings (Item 9) should be replaced as new parts. 6. Put wear plate (Item 13) on top of back-up gasket with bronze face up. The side with the mid section cut away must be on suction side of pump. 7. Dip gear assemblies (Item 2, 3) into oil and slip into front plate bushings. 2. Install o-ring (Item 9) in groove of front plate (Item 7). 8.
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Gear Pump No. 94--8297 (S/N 70001 & Up) (Fig. 23a) 8 9 7 1 6 10 5 4 11 3 12 2 1 13 15 14 16 1 1 6 5 4 21 17 2 18 19 13 20 Figure 23a 1. O--ring 2. Body asm. 3. Drive gear asm. 4. Wear plate 5. Backup gasket 6. Seal 7. Front plate Repairs 8. Washer 9. Cap screw 10. Shaft seal 11. Washer 12. Plug 13. Idler gear 14. Gear Page 4 -- 39.1 Rev. C 15. Key 16. Adaptor plate 17. O--ring 18. Washer 19. O--ring 20. Valve 21. Back plate asm.
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Repair Information Work in a clean area, cleanliness is extremely important when repairing hydraulic pumps. Before disconnecting the lines, clean port area of pump. Disconnect hydraulic lines, removing pump assembly from vehicle and plug ports. Thoroughly clean the outside of pump. After cleaning then remove port plugs and drain oil. Disassembly 1. Scribe a line, at an angle, across front plate (7), bo dies (2), adapter plate (16) and backplate (21). This will assure proper reassembly.
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Front Plate, Backplate and Adapter Plates Inspection 4. Place balance pressure seal (6) in groove in front plate (7) and adapter plate (16). 1. Oil groove in bushings in front plate, backplate and adapter plates should be in line with dowel pin holes and 180 degrees apart. This positions the oil grooves closest to respective dowel pin holes. 5. Apply a thin coat of petroleum jelly to both milled gear pockets of front body (2).
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Hydraulic System This page is blank. Groundsmaster 455--D Page 4 -- 39.4 Rev.
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Front Traction Motor Repairs (Fig. 24) Figure 24 1. Valve plate 2. Cylinder block kit 3. Shaft assembly 4. Plug 5. O-ring seal 6. Lip seal 7. Sleeve 8. Roller bearing 9. Housing 10. Thrust plate 11. Gasket 12. Bearing Shaft Seal Replacement The lip type shaft seal (Item 6) can be replaced without disassembly of the motor; however, replacement of the seal requires removal of the motor from the transaxle. 13. Straight 14. End cap assembly 15. Flat washer 16. Capscrew 17.
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Figure 25 When the four (4) cap screws (Item 16) are loosened, the internal spring loading will cause the end cap (Item 14) to separate slightly. Loosen these screws evenly to prevent distortion of parts. If separation does not occur as screws are loosened, tap end cap with soft hammer until parts separate. IMPORTANT: All surfaces exposed are critical and caution must be used to avoid damage. Note the orientation of housing (Item 9) to end cap (Item 14).
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Figure 26 Lift out the cylinder block assembly (Item 2). The pistons may come out of cylinder block bores. There is no special orientation of piston to bore that needs to be maintained. Do not attempt to disassemble the spring and other parts from the center bore of the cylinder block. The entire cylinder block assembly (Item 2) should be re placed if any of its components are damaged. Remove thrust plate (Item 10) from counter bore in motor housing (Item 9).
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Press shaft (Item 3) and bearing (Item 8) together, then press into housing (Item 9). Install retaining ring (Item 17) if used. Lubricate thrust plate (Item 10) and insert in counterbore of housing (Item 9). Assemble cylinder block parts if necessary and lubricate with clean hydraulic oil. There is no special orientation of piston to bore that needs to be maintained. Groundsmaster® 455-D Place the housing assembly in a horizontal position.
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Figure 28 Repairs Page 4 - 44 Groundsmaster® 455-D
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Properly orient the end cap (Item 14) and housing (Item 9). Refer to previously scribed lines for assembly guide. Press the bearing (Item 11) into end cap (Item 14) leaving 3/32 to 1/8 inch of bearing protruding beyond face. The valve plate (Item 1) pilots on this bearing. Insert locating pin (Item 13) into end cap. Lubricate the slotted side of the motor valve plate (Item 1) and slip it over the locating pin and protruding bearing.
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Rear Axle 4WD Motor Repairs (Fig. 30) Figure 30 1. Capscrew 2. Back plate 3. O-ring 4. Bearing 5. Cam plate insert 6. Housing 7. Bearing 8. Retaining ring 9. Thrust race 10. Thrust bearing Disassembly of Rear Axle 4WD Motor 11. Spacer 12. Drive shaft 13. Retaining ring 14. Rotating assembly DO NOT attempt to disassemble the spring and other parts from the center bore of the cylinder block. The entire rotating assembly (Item 14) should be replaced if any of its components are damaged. 1.
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Inspection of Rear Axle 4WD Motor Parts Assembly of Rear Axle 4WD Motor Parts 1. Wash all parts thoroughly in a suitable solvent. 1. Lubricate all moving parts with clean hydraulic oil before assembly. 2. Examine needle bearings (Item 4) and (Item 7) in housing and back plate. Make sure they are free of excessive play and remain in the bearing cage. If needle bearings are damaged, housing (Item 6) or back plate (Item 2) should be replaced (bearings are not available separately). 3.
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Lift Valve Repairs (Fig. 31) Figure 31 1. Plug 2. Disc 3. Spring 4. Detent plunger 5. O-ring seal 6. Plug 7. O-ring seal 8. Body 9. O-ring seal 10. Back-up washer 11. Plug 12. O-ring Seal 13. Spool 14. Lock nut 15. Washer 16. Plug 17. O-ring seal 18. Washer 19. Washer 20. Washer 21. Spring 22. Poppet 23. Seat 24. Wiper seal 25. Bushing 26. Washer Disassembly of Lift Valve 27. Spring 28. Spacer 29. Retaining ring 30. Cap 31. Plunger 32. Plug 33. Spring 34. Poppet 35. Seat 36. O-ring seal 37. Plunger 4.
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2. Install new o-rings (Item 12) in proper grooves in spool bores. 8. Remove plugs (Item 1), disks (Item 2), springs (Item 3) and detent plungers (Item 4). 9. Remove locknut (Item 14), washer (Item 15), plug (Item 16), washers (Item 18, 19, 20), spring (Item 21) and poppet (Item 22). IMPORTANT: Do not remove seat (Item 23). Seat has been set to a predetermined depth and locked in place. 10. Remove all o-rings and back-up rings from all plugs and seats. 3.
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Steering Control Unit Repair (Fig. 32) Figure 32 1. Set screw 2. Dust seal 3. Retaining ring 4. Gland seal bushing 5. Seal 6. Quad ring seal 7. Bearing race 8. Thrust (needle) bearing 9. Housing 10. Control sleeve 11. Centering springs 12. Control spool 13. Seal 14. Spacer plate 15. Drive 16. Gerotor 17. Spacer 18. End cap 20. Centering pin 21. Check ball retainer 22. Check ball 23. Seal 24. Check ball seat 25. Seal Disassembly Cleanliness is extremely important when repairing a steering control unit.
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Meter (Gerotor) End Disassembly 1. Clamp unit in vise, meter end up. Clamp lightly on edges of mounting area. Use protective material on vise jaws. Housing distortion could result if jaws are over tightened. Figure 33 2. Remove 5/16" cap screws. 3. Remove end cap. Hydraulic System 4. Remove seal from end cap. Figure 34 5. Remove meter. Be careful not to drop star. 6. Remove seal from meter.
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7. Remove drive. 8. Remove spacer plate. 9. Remove seal from housing. Figure 36 Control End Disassembly 10. Remove housing from vise. Place housing on a clean soft cloth to protect surface finish. Use a thin blade screwdriver to pry retaining ring from housing. Figure 37 11. Rotate spool and sleeve until pin is horizontal. Push spool and sleeve assembly forward with your thumbs just far enough to free gland bushing from housing. Remove bushing.
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12. Remove quad-ring seal from seal gland bushing. 13. Use a thin blade screwdriver to pry dust seal from seal gland bushing. Do not damage bushing. Figure 39 Hydraulic System 14. Remove 2 bearing races and the needle thrust bearing from spool and sleeve assembly. Figure 40 15. Remove spool and sleeve assembly from 14 hole end of housing. IMPORTANT: Do not bind spool and sleeve in hous ing. Rotate spool and sleeve assembly slowly when removing from housing. 16. Push pin from spool and sleeve assembly.
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17. Push spool partially from control end of sleeve, then remove six (6) centering springs from spool carefully by hand 18. Push spool back through and out of sleeve. Rotate spool slowly when removing from sleeve. Figure 42 19. Remove seal from housing. 20. Remove set screw from housing. 21. Screw a #10-24 machine screw into end of check ball seat. Then by pulling on screw, with a pliers, lift seat out of housing. 22. Remove two (2) seals from check valve seat. 23.
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Reassembly Check all mating surfaces. Replace any parts that have scratches or burrs that could cause leakage. Clean all metal parts in clean solvent. Blow dry with air. Do not wipe dry with cloth or paper towel because lint or other matter can get into the hydraulic system and cause damage. Do not use a coarse grit or try to file or grind these parts. NOTE: Lubricate all seals with clean petroleum jelly such as Vaseline. Do not use excessive lubricant on seals for meter section.
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7. Bring spring slots of both parts in line and stand parts on end of bench. Insert spring installation tool through spring slots of both parts. Tool is available from a Eaton Hydraulics supplier as Eaton part no. 600057. Position three (3) pairs of centering springs (or 2 sets of 3 each) on bench so that extended edge is down and arched center section is together. In this position, insert one end of entire spring set into spring installation tool with spring notches facing sleeve. 8.
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14. Install 1-1/4" diameter dust seal in seal gland bush ing, flat or smooth side of dust seal must face down towards bushing. 15. Install the quad-ring seal in seal gland bushing. Smooth seal in place with your finger. Do not use any seal that falls freely into pocket of bushing, see Fig. 60. 16. Install seal gland bushing over the spool end with a twisting motion. Tap the bushing in place with a rubber hammer. Make sure the bushing is flush against the bearing race. Figure 49 Hydraulic System 17.
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18. Clamp housing in vise, as shown. Clamp lightly on edges of mounting area. Do not over tighten jaws. NOTE: Check to insure that the spool and sleeve are flush or slightly below the 14 hole surface of the housing. IMPORTANT: Clean the upper surface of the hous ing by wiping with the palm of clean hand. Clean each of the flat surfaces of the meter section parts in a similar way when ready for reassembly. Do not use cloth or paper to clean surfaces. Figure 51 19. Install 3" diameter seal in housing. 20.
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21. Rotate spool and sleeve assembly until pin is paral lel with port face. Install drive, make sure you engage drive with pin, To assure proper alignment, mark drive as shown (ref. B). Note relationship between slotted end of drive to splined end of drive when marking. Figure 53 Hydraulic System 22. Install 3" diameter seal in meter. Figure 54 23. With seal side of meter toward spacer plate, align star valleys (ref. A) on drive (ref. B).
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24. Install 3" diameter seal in end cap. 25. Install end cap on gerotor, align holes. Figure 56 26. Install seven (7) DRY cap screws with new seal washers in end cap. Pre-tighten screws to 150 inch pounds, then torque screws to 275 inch pounds in sequence shown.
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Chapter 5 Electrical System Table of Contents Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injection Pump (ETR) Solenoid . . . . . . . . . . . . . Gauges and Indicator Lights . . . . . . . . . . . . . . . High Temperature Shut-Down Switch . . . . . . . . Temperature Gauge Sender . . . . . . . . . . . . . . . Engine Oil Pressure Switch . . . . . . . . . . . . . . . . Fuel Gauge Sender . . . . . . . . . . . . . . . . . . . . . . 4WD Solenoid . . . . . . . . . . . . . . . . . . . .
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Wiring Schematics RED B S Page 5 -- 1.1 Rev. C TERMINAL S TERMINAL I TERMINAL B TERMINAL A TERMINAL Y DETAIL A VIO RED ALTERNATOR F B AGC 30 AMP FUSE HOLDER BLUE RED BATTERY STARTER BK BK OR BK 2 3 6 4 5 1 PLUGS RELAY STARTER OR 30 GREY 87 TERMINAL X GLOW GLOW RED 85 86 87A LINK FUSIBLE BROWN RELAY GLOW PINK RED GREY WHITE WHITE WHITE B I X PINK Y E.T.R. SOLENOID S WHITE CAP. SEAT SW. A 30 ’C’ TRACTION SW.
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Groundsmaster 455--D Page 5 -- 1.2 Rev. C Wiring Schematics RED B S TERMINAL I TERMINAL S TERMINAL B TERMINAL Y TERMINAL A ALTERNATOR F B RED 85 86 GREY TERMINAL X GLOW GLOW BK 87A GREY OR BK PLUGS STARTER RELAY 87 OR 30 FUSIBLE LINK FUSE HOLDER AGC 30 AMP DETAIL A VIO RED BLUE RED BATTERY STARTER BK PINK GLOW RELAY 2 3 6 4 5 1 RED 87A 85 (NC) 86 S PINK A B I SEAT SWITCH WATER IN FUEL Y X 2 ’SWITCHED’ FUSES ’ACC’ 3 ’N.O.
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Wiring Schematics Page 5 -- 1.3 Rev. C Groundsmaster 455--D + VIO F TERMINAL I TERMINAL S TERMINAL B TERMINAL Y TERMINAL A OR 85 GLOW BK 30 RELAY STARTER BK 6 4 (--) IGINITION SWITCH W B I Y X YEL 2 VIO/R Y W W ’C’ ’D’ 3 C.U.
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Groundsmaster 455--D Page 5 -- 1.4 Rev.
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Wiring Schematics + ALTERNATOR F B STARTER B S Page 5 - 2 Rev. C DETAIL A OR OR BK TERMINAL X TERMINAL I START RUN 3 2 CIRCUIT B+I+S B+I+A W W (+) W BK BK IGNITION SWITCH A PINK S SEAT SWITCH X+Y NONE "MAKE" I B 30 RED 87A X Y W Y VIO/R 30 87 (NO) 85 W 'N.C.
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Groundsmaster® 455-D + ALTERNATOR F B STARTER B S Page 5 - 3 Rev. C DETAIL A OR OR BK TERMINAL X TERMINAL I START RUN 3 2 B+I+S B+I+A NONE W W (+) W BK BK IGNITION SWITCH S PINK A SEAT SWITCH X+Y NONE "MAKE" Wiring Schematics 87A X Y W Y VIO/R 30 87 (NO) W 'N.C.
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Wiring Schematics + ALTERNATOR F B STARTER B S Page 5 - 4 Rev. C DETAIL A OR OR BK TERMINAL X TERMINAL I START RUN 3 2 B+I+S B+I+A NONE W W (+) W BK BK IGNITION SWITCH S PINK A SEAT SWITCH X+Y NONE "MAKE" B I 87A X Y W Y W 'N.C.
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Special Tools NOTE: Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Some tools may be available from a local supplier. Continuity Tester Battery powered test lamp which is helpful in testing for continuity of circuits and electrical components when the current is off. Figure 1 Electrical System Volt - Ohm - Amp Meter The meter can test electrical components and circuits for current, resistance, or voltage draw.
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Skin-Over Grease Special non-conductive grease which forms a light protective skin to help waterproof electrical switches and contacts.
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Troubleshooting Study the operating characteristics preceding the elec trical failure to help identify the area of difficulty. Try to isolate the failure to a specific functional system; then check that area, repairing one component at a time. Attempting to repair more than one system at one time will lead to confusion. CAUTION Remove all jewelry, especially rings and watches, before doing any electrical trou bleshooting or testing.
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Starting Problems (continued) Condition Possible Cause Correction __________________________________________________________________________________________ Nothing happens when start attempt is made. Troubleshooting 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. “Run” fuse open. Check fuse and replace if fuse is open.
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Starting Problems (continued) Condition Possible Cause Correction ___________________________________________________________________________________________ Engine cranks, but does not start (if engine cranks, cause of problem is not in interlock system). Injection pump ETR solenoid wiring loose or corroded. Clean and tighten or repair as necessary. Injection pump ETR solenoid faulty. Test solenoid. Replace if faulty. Glow relay faulty. Test glow relay. Replace if faulty.
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General Run and Transport 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.
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General Run and Transport Problems (continued) Condition Possible Cause Correction ___________________________________________________________________________________________ 4WD does not engage. Axle in HI range. Axle must be in Low range for 4WD to engage. Axle HI/LOW switch or plunger faulty. Test HI/LOW switch. Check for proper installation and operation of plunger assembly. Replace switch or repair plunger if faulty. Axle HI/LOW switch wiring loose, corroded or damaged. Repair wiring.
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Cutting Unit Operation Problems Condition Possible Cause Correction __________________________________________________________________________________________ Engine continues to run (but should not) when PTO switch 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.
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Cutting Unit Operation Problems (continued) Condition Possible Cause Correction No cutting units Operate. Groundsmaster® 455-D Axle in HI range. Axle must be in Low range for cutting units to operate. “Deck” fuse open. Check fuse and replace if fuse is open. If fuse burns out often, find and correct cause. “Relay” fuse open. Check fuse and replace if fuse is open. If fuse burns out often, find and correct cause. PTO clutch air gap out of adjustment. Check air gap and adjust if necessary.
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Cutting Unit Operation Problems (continued) Condition Possible Cause Correction __________________________________________________________________________________________ One wing cutting unit does not operate. Wing switch faulty. Test switch. Replace if faulty. Wing switch wiring loose, corroded or damaged. Repair wiring. Wing clutch air gap out of adjustment. Check air gap and adjust if necessary. Wing clutch faulty. Test clutch. Repair or replace if faulty.
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Verify Interlock System Operation The purpose of the interlock system is to prevent the engine from cranking or starting unless the traction pedal is in NEUTRAL and the cutting unit engagement switch is DISENGAGED. In addition, the engine will stop when the cutting unit engagement switch is engaged or traction pedal is depressed with operator off the seat. 5. Raise off the seat and depress the traction pedal while engine is running and the cutting unit engagement switch is DISENGAGED.
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Testing This section will define components, and the tests that can be performed on those components, when those parts are disconnected from the electrical system. CAUTION For accurate resistance and/or continuity checks, elec trically disconnect the component being tested from the circuit (e.g. unplug the seat switch connector before doing a continuity check).
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Seat Switch, Relay and Time Delay Capacitor The seat switch is a normally open (N.O.) switch that closes when the operator is on the seat. With no opera tor on the seat, there is an open circuit to the time delay capacitor and relay coil. If the PTO switch or traction switch is open and the operator raises off the seat, the engine will stop after a delay of 1 to 2 seconds. Seat Switch Test 3 2 1 1. Raise the seat to get access to the seat switch wiring connector. 2.
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Traction (Neutral) Switch The traction switch is a normally closed and opens when traction pedal is depressed in either direction. IMPORTANT: The traction switch has three (3) terminals. Make sure the wires are connected to the “COMMON” and “N.O.” terminals. Test the switch by disconnecting the wires from the switch terminals and connecting a continuity tester across the COMMON and N.O. terminals.
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Axle Hi/Low Switch The axle hi/low switch is normally open (N.O.) when the transaxle is in neutral or hi range. This prevents the cutting units or 4WD from engaging while the transaxle is neutral or hi range. The switch closes when the axle shift rod is moved to low range, which pushes the switch button in. 1 1. Disconnect the switch wire connector and install a continuity tester or ohm meter between the two leads of the switch. 2.
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PTO Switch To test the PTO switch independent of wiring harness, disconnect wire connector from the switch terminals. When the switch is ON, there should be continuity between terminals A – B only. When the switch is OFF, terminals C – D and B – E should show continuity. 1 Figure 13 1. PTO switch Figure 14 1.
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Start, Cutting Unit, Time Delay and High Temp. Relays To test the relay, disconnect the relay wire connector and install a continuity tester between the relay termi nals (terminals 30 and 87). The relay should make and break continuity at terminals 30 and 87 as 12 V.D.C. is connected and disconnected to terminal 85 with termi nal 86 connected to ground. 1 Figure 15 1. Start relay 2 3 Electrical System 1 Figure 16 1. Cutting unit relay 2. High temp. relay 3.
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Glow Relay and Glow Plugs 1. Attach an amp meter to glow plug circuit. Turn ignition switch to ON. Meter may have an initial reading as high as 100 amps. A. If amp meter shows a reading for 5 to 12 seconds, the glow relay is operating. If there is no reading, go to step 2. B. Turn ignition switch OFF, then ON again. A read ing of 48 amps should be observed. Go to step 3. 1 2. To test the circuit: A. Check with a test light at buss bar connection for glow plugs at cylinder head.
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Battery Use a hydrometer to test the battery. Charge the battery if necessary (see Battery Service). Electrolyte specific gravity 1 Fully charged: 1.250 - 1.280 Discharged: less than 1.240 Figure 20 Injection Pump (ETR) Solenoid The Groundsmaster® 455-D has an energize-to-run (ETR) fuel stop solenoid. The solenoid will stop injector pump fuel delivery with any electrical failure in the RUN circuit. 1. Disconnect the wire from the solenoid. 1 Electrical System 2.
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Gauges and Indicator Lights Oil Pressure Light Test the lamp by disconnecting the wires and applying 12 V.D.C. between the lamp wiring terminals. Oil pressure lamp should come on when the ignition key switch is in the RUN position with the engine not running or if the oil pressure switch closes during operation - oil pressure below 7 psi (0.5 kg/cm2). Test the lamp by disconnecting the wire from oil pres sure switch and grounding it against the engine.
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High Temperature Shut-Down Switch 1. Lower the coolant level in the engine and remove the high temperature shut-down switch. 2. Put the switch in a container of oil with a thermometer and heat the oil. 1 3. The switch is normally open (N.O.) and should close at approximately 221o F (105o C). 2 CAUTION Handle hot oil with special care to prevent personal injury or fire. Figure 22 Electrical System 1. High temperature shut-down switch 2. Temperature gauge sender Figure 23 Temperature Gauge Sender 1.
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Engine Oil Pressure Switch The switch is normally closed (NC) and opens with pressure. The switch opens at approximately 8 psi. 1. Turn ignition key switch ON. Oil pressure lamp should be on. If lamp is not on: 1 1. Disconnect wire from switch and touch wire to a good ground, such as the engine block. 2. If lamp comes on, replace switch. 3. If lamp does not come on check wiring between lamp and switch for continuity. Figure 25 1. Engine oil pressure switch If lamp is on with engine running: 1.
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4WD Solenoid 1. Disconnect the wire connector. 2. Connect a 12 volt battery so the positive (+) battery terminal is connected to colored solenoid lead. Connect the negative (–) battery terminal to black lead. The valve spool should retract completely as 12 V.D.C is applied between leads. 1 2 3. If valve spool does not operate properly check for binding or damage to valve. 4. If valve moves smoothly, but does not engage when 12 V.D.C is applied to solenoid leads, replace solenoid coil. 5.
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P.T.O. Clutch and Wing Clutch 1. Park machine on a level surface, engage parking brake, lower the cutting units and turn engine OFF. 1 2. Disconnect electrical connector from affected clutch. Continuity Test Connect a continuity tester or ohmmeter to the two (2) terminals of the electrical connector on the clutch. If continuity is not present, replace the clutch or electro magnet part of the clutch (see Chapter 7 - P.T.O System or Chapter 8 - Cutting Unit).
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Repairs IMPORTANT: Before welding on the machine, dis connect both battery cables from the battery and disconnect the terminal connector from the alter nator to prevent damage to the electrical system. Battery Service IMPORTANT: To prevent damage to electrical com ponents, do not operate the engine with the battery cables disconnected. Electrolyte Specific Gravity Keep the terminals and entire battery case clean. To clean the battery, wash the entire case with a solution of baking soda and water.
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Fuses The electrical system is protected by twelve (4) fuses located under the control panel to the operator’s right. NOTE: It is not always possible to see if a fuse is faulty. It is recommended that you check for faulty fuses with a continuity tester, not visually. 4 2 3 1 The starter circuit is also protected by a 30A in-line fuse between the start relay and starter solenoid (S/N 59999 and below). The alternator charging circuit is protected by a 80A in-line fuse (S/N 60001 and up). Figure 34 1.
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Traction (Neutral) Switch Replacement 1. Remove the two wires that are connected to the traction switch. 2. Have a helper push the traction pedal down into either the FORWARD or REVERSE position; this will take the switch arm tension off of the switch. Loosen two (2) screws and remove the switch. 3. Install new switch. DO NOT over-tighten screws as the switch case could break. NOTE: Have a helper hold the traction pedal down while installing the switch. 4. Reconnect the two wires to the new switch.
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4WD Solenoid Coil Replacement 1. Park machine on a level surface, engage parking brake, lower the cutting units and turn engine OFF. 2. Disconnect solenoid electrical connector. 1 3. Remove coil nut. 4. Remove coil assembly. 5. Install new coil assembly and secure with coil nut. Apply “Locktite 242" or equivalent to threads on end of stem tube before installing nut. Tighten nut to a torque of 15 in-lb. Over-tightening may damage coil nut or cause solenoid valve to malfunction. Figure 36 6.
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Wing Switch Replacement 1. Park machine on a level surface, engage parking brake, lower the cutting units and turn engine OFF. 2. Remove deck covers. 3. Disconnect wing switch electrical connector. 4. Remove boot, spring, nut and washer, then remove the wing switch. Disconnect wiring assembly from switch terminals. 1 5. Install wire assembly on new wing switch. Make sure that one wire is connected to the “COMMON” terminal, and one wire is connected to the “NORMALLY OPEN” (N.O.) terminal.
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Repairs Page 5 - 34 Groundsmaster® 455-D
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Chapter 6 Axles and Brakes Table of Contents 2 3 3 4 6 6 6 7 REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Wheel Bearing Service . . . . . . . . . . . . . . . . . . . . 8 Front Axle Removal and Disassembly. . . . . . . . 10 Transaxle Service . . . . . . . . . . . . . . . . . . . . . . . 12 Rear 4WD Axle Service . . . . . . . . . . . . . . . . . . . 14 Axles and Brakes SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION . . . . . . . . . .
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Specifications Item Specification __________________________________________________________________________________________ Tire pressure 20 PSI front and rear ________________________________________________________________________________________________________________________________________________________ Wheel bolt torque 85 - 100 ft-lb rear, 45 - 55 ft-lb front ______________________________________________________________________________________________________________________________________
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General Information TM Four-Matic 4WD Over-Running Clutch Operation Th ere are two hydraulic drive motors on the Groundsmaster 455-D, 4WD; one for the front axle and one for the rear axle. The drive for the rear axle incor porates an OVER-RUNNING (ROLLER) CLUTCH THAT 49 RPM Unlocked Locked 50 RPM TRANSMITS POWER ONLY IN THE FORWARD DIRECTION 49 RPM (Fig. 3).
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Special Tools Order special tools from the TORO SPECIALS TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Rear 4WD Axle Tools TOR4030 – Differential Case Gauge Used to determine the number of shims required between the 4WD rear axle differential housing. Figure 5 TOR4039 – Pilot Bushing Driver Used to install the pilot bushing into ends of 4WD rear axle. Figure 6 TOR4040 – Pinion Nut Tool Used to remove or install the pinion (sleeve) nut on the 4WD rear axle.
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TOR4041 – Bevel Gear Remover Used to separate the bevel gears from their shafts in the ends of the 4WD rear axle. Figure 5 TOR4042 – Pinion Gauge Used to determine the number of shims required to properly position the 4WD rear axle pinion. Figure 6 TOR4043 – Oil Seal Installation Tool Used to install the oil seals in the ends of the 4WD rear axle.
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Adjustments Brake Adjustment Adjust service brakes when there is more than 1.5 in. “free travel” of brake pedal, or when brakes do not work effectively. Free travel is the distance the brake pedal moves before braking resistance is felt. To reduce free travel of brake pedals, tighten nut on brake rod adjuster, 1/2 turn at a time, until you get desired “free travel” in pedal. 1 1 Figure 11 1. Brake rod adjuster Rear Axle Toe-in Adjustment 1.
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Transaxle Shift Linkage Adjustment 1. Remove steering tower cover. Measure from end of shaft to edge of transaxle. 2. Move axle shift lever forward to transport (high speed) position. Measure shaft dimension from side of transaxle case to end of shaft (Fig. 13). Adjust upper linkage length at top eye rod if necessary to get proper dimension (Fig. 14). Low position 1.2 - 1.3 in. (30 - 33 mm) 3. Move axle shift lever rearward to mow (low speed) position.
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Repairs Wheel Bearing Service (2WD Rear Axle) 7. Use No. 2 general purpose lithium base grease containing E.P. additive. Pack both bearings with grease. Install one bearing into the cup on inboard side of wheel hub. Lubricate the inside of the new lip seal and press it into the wheel hub. 1. Jack up rear of machine until tire is off the floor. Support machine with jack stands or blocks to prevent it from falling. 2. Remove dust cap from end of wheel spindle.
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Adjusting Rear Wheel Bearings 1. Remove dust cap from end of wheel spindle. Remove cotter pin retaining slotted nut in place. 2. Rotate the wheel by hand and tighten the slotted nut until the bearing binds SLIGHTLY. Then, loosen the nut until the nearest slot and hole in the spindle line up. Reinstall the cotter pin to retain the slotted nut in place. NOTE: The correct end play of the adjusted assembly is 0.002 - 0.005 inches. 1 3. Remove jack stands or blocks and lower machine to floor. Figure 16 1.
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Front Axle Removal and Disassembly Figure 17 Install belleville washers (Item 28) as shown Figure 18 Repairs Page 6 - 10 Groundsmaster® 455-D
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Front Axle Removal 5. Remove brake disks (Item 4) and brake actuator (Item 5). 1. Drain oil from transaxle. 2. Jack up front of machine and support chassis frame with jack stands. 3. Remove front wheels. Remove nuts (Fig. 18, Item 19). Use a puller to pull each wheel hub (Item 13) off of shafts. Remove belleville washers (Item 28). 4. Remove roll pin (Fig. 17, Item 42). Remove cap screws (Item 43, 44) securing shift rod support (Item 10) to transaxle.
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Transaxle Service NOTE: This illustration shows a differ ent hydrostatic drive mounting surface and differential than what is used on the Toro Groundsmaster 455-D.
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Transaxle Disassembly Transaxle Assembly 1. Clean all exterior surfaces of transaxle. Reverse steps 1 - 8 under Transaxle Disassembly, watching out for the following: 2. Put the transaxle on a work bench with cover side up. Remove screws. Lift cover (Fig. 20, Item 16) off and discard gasket (Item 4). 1. After shift rod is in position, install ball, then spring and bolt. Turn bolt in until head of bolt contacts case. 3. Remove differential assembly and thrust washers (Item 8A and 9). 2.
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Rear 4WD Axle Service Axle Housing (A) Axle Housing (B) Figure 23 Figure 24 Repairs Page 6 - 14 Groundsmaster® 455-D
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Disassembly The two gear cases, right and left can be removed from the housing without requiring the entire axle to be dis assembled. 3 1. Remove tie rod by disconnecting rod end ball joint on each end. Disconnect hydraulic cylinder rod end from drag link arm. 2. Remove bolts (Fig. 23, Item 23 and 21) securing gear case to axle housing and pull gear case complete with final drive case.
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Install seal so garter spring faces hydraulic motor Figure 29 Disassembling Axle Housing 4. Pull out differential shaft (Fig. 23, Item 14) from housing (B). 1. Remove axle from machine before disassembling: A. Jack up rear of machine and support from frame with jack stands. B. Remove wheels from axle. C. Remove hydraulic motor. Do not disconnect hy draulic lines from motor. D. Support axle with a jack, then remove axle pivot pin to separate axle from frame. E.
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Inspection Clean the disassembled parts by washing in cleaning solvent. Inspect gears and pinions to be sure their teeth are in good condition. Check to be sure that each bearing rotates smoothly. Examine housings for cracks. Reassembly Replace damaged or worn parts as necessary. Oil or grease the surfaces of rotating or sliding parts before assembling. Grease oil seals and o-rings before installing. Assembling Pinion Shaft 1.
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Adjusting Pinion Shaft Cone Center “Cone Center” is the distance from the mating face of axle housing to end face of pinion. This distance can be increased or decreased by installing removing shims. Cone center specification 43 ± 0.05mm (1.69 ± 0.002 in.) Shim stock for this adjustment is available in the follow ing thicknesses: Thickness Part No. Shim set 77-4010 0.1 mm (0.004 in.) 76-7410 0.2 mm (0.008 in.) 76-7420 0.4 mm (0.016 in.
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Adjusting Backlash Backlash specification 0.25 ∼ 0.35 mm (0.010 ∼ 0.014 in.) Adjust shim thickness (between bearing housing of axle housing (A) and bearing) to get specified backlash. Shim stock for this adjustment is available in these thicknesses: Thickness Part No. Shim set 77-4000 0.1 mm (0.004 in.) 76-7290 0.2 mm (0.008 in.) 76-7300 0.4 mm (0.016 in.
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Assembling Axle Housing 1. Coat mating faces of two housings (A) and (B) with sealant and attach selected shim to face of housing (B). Put the two housings together and fasten them by tightening bolts to following torque value: Torque specification 2.5 ∼ 3.0 kg-m (18 ∼ 22 ft-lb) 2. Fit ball bearings to out end of each differential shaft, then mount pinion (14T) and retain pinion by installing circlip. The ball bearings have a groove cut in the end faces of the inner and outer races.
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Installing Drag Link and Tie Rod Arm 1. Carefully insert bushing into arm. 2. Put arm into position over holder, fitting it to final case and secure to case with bolts. 3. Check thrust clearance. Proper thrust clearance is 0 to 0.2 mm (0.008in.). If necessary reduce clearance to specification by shimming. Shim stock for this adjust ment is available in the following thicknesses: Shim Part No. TIE ROD ARM Shim Part No. DRAG LINK ARM Shim set 77-4050 77-4040 0.8 mm (0.03 in.) 76-7820 76-7700 1.
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4. After obtaining proper pinion backlash, grease o-ring and fit it to mating face of axle housing. Secure gear case to housing by tightening bolts to the following torque value: Torque specification 5.0 ∼ 6.0 kg-m (36 ∼ 43 ft-lb) Reassembling Wheel Shaft 1. Grease oil seal and fit it to bearing holder. 2. Insert shaft into holder. Install ball bearing and retain bearing by installing circlip. Figure 40 3. Mount bevel gear (29T) on splined end of shaft. 4.
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Installing Axle on Machine 1. Support axle under machine with a jack. 2. Install axle pivot pin to secure axle to frame. Make sure to install thrust washers between axle pivot and frame. 3. Install hydraulic motor to adaptor housing. 4. Install wheels to axle. Tighten wheel bolts to a torque of 85 - 100 ft-lb. 5. Fill axle with SAE 80-90W EP gear lube. Lubricant capacity is approximately 80 oz. (2.5 U.S. qt.). 6. Check rear wheel toe-in and adjust if necessary. 0.25 in.
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Repairs Page 6 - 24 Groundsmaster® 455-D
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Chapter 7 PTO (Power Take-Off) System Table of Contents 2 2 3 3 4 5 5 7 PTO Drive Pulley and Bearing Service . . . . . . . . 7 PTO Clutch Removal and Installation . . . . . . . . . 8 Lower Pulley and Bearing Service . . . . . . . . . . 10 PTO Shaft and Bearing Service . . . . . . . . . . . . 11 Driveshaft Removal and Installation . . . . . . . . . 12 Driveshaft Universal Joint Replacement . . . . . . 13 PTO Clutch Service . . . . . . . . . . . . . . . . . . . . . . 14 PTO System SPECIFICATIONS . . . . .
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Specifications Item Specification ________________________________________________________________________________________________________________________________________________________ PTO Clutch air gap 0.011 - 0.
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Adjustments PTO Belt Adjustment 1 1. Remove (2) screws securing PTO belt cover to adapt er plate and (1) screw securing belt cover to tab on spring anchor. Remove cover. 2 Figure 1 1. PTO belt cover 2. Adapter plate 2. Loosen (3) flange screws and flange nuts securing adapter plate to clutch plate. 1 4 2 3 Figure 2 1. PTO belt 2. Adapter plate 3. Clutch plate 4. Flange nuts (3) 3. Insert end of 1/2" drive, 20" long,torque wrench into square hole in clutch plate.
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PTO Clutch Adjustment 1. To adjust clutch, tighten or loosen locknuts on flange studs. 2. Check adjustment by inserting feeler gauge through slots next to flange studs. 1 3. The proper disengaged clearance between the clutch plates is 0.011 - 0.021 inches. It will be necessary to check this clearance at each of the three slots to ensure the plates are parallel to each other. 2 Figure 3 1. PTO clutch 2.
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Repairs PTO Belt Replacement 1 1. Remove (2) screws securing PTO belt cover to adapt er plate and (1) screw securing belt cover to tab on spring anchor. Remove cover. 2 Figure 4 1. PTO belt cover 2. Adapter plate 2. Remove tension on belt by loosening three (3) flange screws and flange nuts securing adapter plate to clutch plate. 1 4 2 3 Figure 5 3. Clutch plate 4. Flange nuts (3) PTO System 1. PTO belt 2.
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45 ft-lb 4 3 6 5 NOTE: Always use new coupler flange head screws (Items 2 and 6) when repairing PTO systems. 4 3 7 9 2 8 10 1 6 13 11 Install with steel shell toward spline 12 8 14 Index to get wrench clearance for hex flange screws (Item 6) 15 16 17 150 - 200 ft-lb 18 16 45 ft-lb 19 20 Figure 6 1. Bearing locknut 2. Hex flange head screw 3. Hex head capscrew 4. Flat washer 5. Locknut 6. Hex flange head screw 7. Engine 8. Rubber coupling 9. Retaining ring 10. Grease seal 11.
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Engine Coupling Service 1. Remove three (3) flange head screws (Fig. 6, Item 6) securing driveshaft (Item 13) to rubber coupling (Item 8). Make sure you account for spacers (Item 12). 2. Remove three (3) flange head screws (Item 6) secur ing rubber coupling to engine. Be sure you account for flat washers (Item 4). 3. Push driveshaft into splined hub (Item 11) and remove coupling assembly. 5. Install grease seal (Item 10) so steel shell is towards spline. secure seal in place with retaining ring (Item 9).
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PTO Clutch Removal and Installation 19 18 NOTE: Always use new coupler flange head screws (Items 2 and 6) when repairing PTO systems.
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1. Disconnect clutch electrical connector. 2. Loosen PTO shaft bearing collar (Fig. 8, Item 2) to allow shaft movement. 3. Remove three (3) bolts (Item 11) securing clutch adapter (Item 13) to clutch. 4. Remove three (3) flange head screws (Item 6) and flat washers (Item 7) securing rubber flange (Item 40) to clutch adapter (Item 13). P.T.O. Clutch 5. Remove clutch adapter (Item 13). 6.
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Lower Pulley and Bearing Service 19 18 NOTE: Always use new coupler flange head screws (Items 2 and 6) when repairing PTO systems.
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6. Use a press to remove pulley (Item 17). 7. Use a puller to remove bearings (Item 16). Remove bearing spacer (Item 15). 8. Inspect bearings and pulley. Replace parts if worn or damaged. 9. Use a press to install one bearing (Item 16) into lower bearing housing (Item 14). When installing bearing, press on OUTER race of bearing 10. Install lower bearing spacer (Item 15) and press other bearing (Item 16) into bearing housing until bear ings contact the spacer.
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Driveshaft Removal and Installation 1. To prevent possible PTO engagement, disconnect wire harness connector. 1 Figure 11 1. Wire harness connector 2. Remove socket head capscrews securing driveshaft yoke to gearbox input shaft. 3. Slide yoke off of gearbox input shaft. 1 Figure 12 1. Socket head capscrew 4. Remove socket head capscrews securing driveshaft yoke to PTO shaft. 5. Slide yoke off of PTO shaft.
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Driveshaft Universal Joint Replacement 1. Remove the driveshaft. (See Driveshaft Removal and Installation in this section of the book.) 2. Separate the two sections of the driveshaft. 3. Use a press or large vise to remove the cross and bearings by putting a small socket against one roller and a large socket against the yoke on the opposite side. As the vise is closed, the small socket will force the cross to push the opposite roller part way into the large socket. 4.
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PTO Clutch Service Figure 15 1. Retaining ring 2. Bearing 3. Brake plate 4. Bearing collar 5. Armature ass’y (Items 1, 2, 4, 5) 6. Field coil assembly 7. Field bearing NOTE: Individual parts (such as bearings) in the field rotor assembly or armature assembly are not serviceable and must be replaced as an assembly. 1. Remove the clutch assembly (see Clutch Removal and Installation in this section of the book). 2. Remove the three (3) lock nuts (Fig. 15, Item 10).
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Chapter 8 Cutting Unit Table of Contents Inspecting and Sharpening Blade . . . . . . . . . . . Blade Spindle Service . . . . . . . . . . . . . . . . . . . . Gearbox Removal and Installation . . . . . . . . . . Gearbox Repair . . . . . . . . . . . . . . . . . . . . . . . . . Deck Clutch Service . . . . . . . . . . . . . . . . . . . . . Wing Pivot Arm Installation and Ball Joint Service . . . . . . . . . . . . . . . . . . Safety Door Service. . . . . . . . . . . . . . . . . . . . . .
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Specifications Item Specification ________________________________________________________________________________________________________________________________________________________ Cutting width 126" 54" center section 36" each wing 90" with one wing up ________________________________________________________________________________________________________________________________________________________ Height of cut range 1" - 5" _______________________________________________________________
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General Information Pivot (Tilt) Cutting Unit Upright NOTE: Drive front wheels onto ramps before doing this procedure so there is room for cutting unit to pivot (tilt) upright. 1. Lower center and wing cutting units to the ground, then raise center cutting unit slightly, until rear deck straps hang freely on lift arm brackets. Stop engine after cutting unit is raised. Set parking brake. 1 1 2. Disconnect (3) hydraulic lines (quick couplers) and wire harness at rear of deck. 2 3.
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Adjustments Height of Cut Adjustment The height of cut is adjustable from 1 to 5 inches in 1/2 inch increments. Positioning the castor wheel axles in the top holes of the castor forks or pivots (see Chart below) allows low range height of cut settings from 1 to 3-1/2 inches. Positioning the castor wheel axles in the lower holes of the front castor forks or rear castor pivots allows (see Chart below) high range height of cut set tings from 2-1/2 to 5 inches. 1.
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2 Front Castor Wheels 1. Remove lynch pin from spindle shaft and slide spindle out of front castor arm. Slide spacers onto spindle shaft to get desired height of cut. 3 4 2. Push castor spindle through front castor arm install remaining spacers onto spindle and install lynch pin to secure assembly. 1 NOTE: Make sure washer remains on bottom of spindle shaft. Figure 5 1. Front castor wheel 2. Lynch pin 3. Spacers 4. Washer Rear Castor Wheels 1. Remove hairpin cotter and H.O.C.
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Safety Door Adjustment On each side of the center deck is a safety door that opens and closes as the wing decks are lowered and raised. The doors open to provide overlap of the cutting blades when the wing units are down. The doors close to provide safety and protection when the wing units are raised. Check to make sure the forward, lower edge of door is even or 1/4" higher then lower edge of door guide when wing decks are in the fully raised, transport posi tion.
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Blade Adjustment To assure proper operation of the cutting unit, there must be 0.25 ± 0.12" clearance between the tips of the wing and center cutting unit blades. 1. Raise cutting unit so blades are visible and block center deck section so it cannot fall accidentally. Wing decks must be horizontal to center cutting unit. 2. Rotate a center and adjoining wing blade so there blade tips are aligned. Measure distance between blade tips, distance should be approximately 0.25 ± 0.12". 3.
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Belt Tension Adjustment Each cutting unit drive belt is individually tensioned by a self tensioning spring loaded idler. When the idlers are properly adjusted, the black plastic sleeve should be flush (even) with the edge of the idler support. When 1/2" of the plastic sleeve is exposed, an adjustment is required. To assure proper operation of the cutting unit, check adjustment of spring loaded idler after first 10 hours of operation and every time maintenance on the belt is required. 2 0 - 1/2" 3 1 1.
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Repairs Separating Cutting Unit From Traction Unit 1. Lower center and wing cutting units to the ground: then raise center cutting unit slightly, until rear deck straps hang freely on lift arm brackets. Stop engine after cutting unit is raised. Set parking brake. 2. Remove hairpin cotters and H.O.C. pins securing rear deck straps to H.O.C. brackets on deck. Start engine and lower center cutting unit completely to floor. Make sure all lift levers are in float position, then stop the engine. 2 1 4 3 3.
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Mounting Cutting Unit to Traction Unit 1. With cutting unit on a level surface, move traction unit into position, aligning drive shaft yoke with gear box input shaft and lift arm ball joints with mounting holes in castor arms. Shut engine off. 2. Secure ball joint mounts to castor arms with cap screws, flat washers and flange nuts. Flat washers to be positioned to outside of castor arm. Tighten cap screws and flange nuts to a torque of 80 - 90 ft-lb. 2 1 4 3 3.
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Drive Belt Replacement Signs of a worn belt are: squealing when belt is rotating, blades slipping when cutting grass, frayed edges, burn marks and cracks. Replace a belt if any of these condi tions are evident. IMPORTANT: When installing new belts, do not force over pulleys or kink belt in place. This could fracture cords in belt, resulting in reduced belt life. NOTE: Check tension of new belts after first 25 hours of operation. 2 1 1. Lower cutting unit to the shop floor.
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To Remove Center Deck Belt 6. Wing deck belts must be removed before center deck belt can be removed, repeat steps 1 - 3 on previous page. 7. Remove (2) flange head screws securing drive shaft cover to gear box support and remove cover. 14. While holding idler pulley adjuster in position, care fully remove capscrew securing idler adjust or tube to tube sleeve. Allow idler pulley to release, tensioning belt. 15. Check idler pulley adjustment (see Belt Tension Adjustment). 16. Reinstall belt covers. 8.
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Front Castor Arm Bushing Service To check the bushings, move castor fork back and forth and from side to side. If castor spindle is loose inside the bushings, bushings are worn and must be replaced. 1. Raise cutting unit so wheels are off floor and block it so it cannot fall accidentally. 2. Remove lynch pin and spacer(s) from top of castor spindle. 2 1 2 3. Pull castor spindle out of mounting tube. Allow spacer(s) to remain on bottom of spindle. 4.
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Castor Wheel and Bearing Service A wobbly castor wheel usually indicates a worn bearing. 1. Remove locknut from capscrew holding castor wheel assembly between front castor fork or rear castor pivot arm. Grasp castor wheel and slide capscrew out of fork or pivot arm. 2. Remove bearing from wheel hub and allow bearing spacer to fall out. Remove bearing from opposite side of wheel hub. 2 1 3. Check the bearings, spacer and inside of wheel hub for wear. Replace defective parts. 4.
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Blade Removal and Installation The blade must be replaced if a solid object is hit, the blade is out of balance or if the blade is bent. Always use genuine TORO replacement blades to be sure of safety and optimum performance. Never use replace ment blades made by other manufacturers because they could be dangerous. 3 2 CAUTION Do not try to straighten a blade that is bent, and never weld a broken or cracked blade. Always use a now blade to assure continued safety certification of the product.
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Inspecting and Sharpening Blade 1. Raise cuffing unit to highest position, shut the engine off and engage the parking brake. Engage locking latches to prevent cutting unit from falling accidentally. 2. Examine cutting ends of the blade carefully, espe cially where the flat and curved parts of the blade meet. Since sand and abrasive material can wear away the metal that connects the flat and curved parts of the blade, check the blade before using the machine.
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Blade Spindle Service Removing Spindle and Bearings From Spindle Housing 1. Lower the cutting unit, shut the engine off and engage the parking brake. 1 2. Remove deck covers from top of cutting unit. Release belt tension (see Belt Tension Adjustment). 3. Remove belt from spindle to be serviced (see Belt Replacement). 2 4. If removing spindle with clutch, remove clutch rod. Unplug clutch electrical connector from harness. Figure 26 5. Start the engine and raise the cutting unit.
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6. Remove the hex flange head screws (Item 8) and lock nuts (Item 10) securing spindle housing to deck. Slide spindle housing assembly out the bottom of the cut ting unit. 1 2 3 150 - 170 ft-lb 18 7. Remove the nut (Item 2) and washer (Item 18) retaining the spindle pulley or clutch on the spindle shaft. Slide the pulley or clutch (Item 3), spacer (Item 5) and pulley (Item 6) off of the shaft. Make sure you account for the key (Item 4).
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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 still has a snap ring installed: refer to step 2 below. 10.
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Gearbox Removal and Installation Removing Gearbox and Drive Pulley 1. To relieve tension on center deck belt, pull back on idler pulley until holes in idler adjuster tube and tube sleeve are aligned. Thread a 5/16-18 capscrew into holes retaining parts. 1 2. Disconnect drive shaft from gearbox input shaft. 2 CAUTION Do not start the engine and engage the P.T.O. when the P.T.O. shaft is not connected to the gearbox. If engine is started and the P.T.O.
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Installing Gearbox and Drive Pulley 1. If replacing rubber mounts for gearbox support, use soapy water or lubricant to ease installation. Install left-hand mounts from top and right-hand mounts from bottom of bracket as shown. 2. Install gearbox to support bracket with with four (4) capscrews. 3. Slide pulley onto gearbox output shaft and secure by tightening two (2) capscrews. 6. Secure front of gear box support to deck channels with capscrews and nuts.
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Gearbox Repair Figure 33 5. If oil seal (Item 13) is removed, it will be destroyed. To remove the oil seal, cut it out of the bore with a screw driver or chisel. Be careful not to damage the bore. Gear Box Disassembly 1. Drain lubricant from gear box. 2. Remove capscrews (Item 1) and lift out shaft and cap assemblies. NOTE: Mark each gear (Item 10 and 21) so they are installed on the proper shaft (Item 8 or 19) when reassembled. 3.
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13 11 12 23 22 1 14 7 10 9 5 6 19 8 18 3 4 2 21 17 16 15 Figure 34 8. Press a bearing cup (Item 16) into outer end of hub (Item 17). NOTE: Apply a coating of lubricating oil to bearings before assembling. 1. Start with input shaft (Item 8) and put gear (Item 9) over shaft so tooth side is towards turned end of shaft. Align keyway in gear with keyway in shaft and install one of keys (Item 9) in keyway. 2. Press bearing cone (Item 4) over turned end of shaft. 3.
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13 11 12 23 22 1 14 7 10 9 5 6 19 8 18 3 4 2 21 17 16 15 Figure 35 Gearbox Final Assembly 1. Bearing drag for input shaft (Item 8) is adjusted by amount of gaskets (Item 7) used between thru cap (Item 14), and housing machined surfaces. 2. Put two 0.015 in. gaskets on machined surface of housing, then install shaft and thru cap assembly in housing so bearing cone (Item 4) on shaft assembly and bearing cup (Item 3) in blank cap (Item 2) are mating.
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Deck Clutch Service Failure to get clutch engagement would likely be caused by a clutch air gap that is too large (see Clutch Adjust ment), a circuit fault in clutch electromagnet, or other electrical problem (see Troubleshooting section of Chapter 5 - Electrical System). NOTE: It is recommended that clutch be serviced in sub-assemblies, however, some individual parts of clutch can be replaced. 1. Follow steps 1 - 7 under Blade Spindle Service to remove clutch. 2.
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Wing Pivot Arm Installation and Ball Joint Service When assembling wing pivot arms, adjust ball joint thread engagement to get a length of 8.06" for proper blade plane setting, then tighten jam nut (also see Blade Adjustment). IMPORTANT: Before installing wing pivot arms, clean tapered surfaces of ball joints and mounting bosses on deck with solvent degreaser. Apply Loctite 242 or equivalent to nut securing ball joint and tighten to a torque of 150 - 180 ft-lb.
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Safety Door Service When assembling safety door actuator, adjust threaded rod to get a dimension of 6.25" between center of each ball joint. Apply Loctite 242 or equivalent to threads of each ball joint before installing in deck and safety door. After installing actuator, adjust threaded rod so lower edge of door is even to 0.25" higher than lower edge of door guide when wing decks are in fully raised (transport) position, then tighten jam nuts (see Safety Door Adjustment). 6.
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Wing Cylinder Installation and Ball Joint Service When assembling wing cylinders, adjust ball joint thread engagement to get a retracted length of 17.00" to eliminate movement of wing decks in the fully raised (transport) position, then tighten jam nut. IMPORTANT: Before installing wing cylinders, clean tapered surfaces of ball joints and mounting bosses on deck with solvent degreaser. Apply Loctite 242 or equivalent to nuts securing ball joints and tighten to a torque of 150 - 180 ft-lb.
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Clean tapered surfaces of all ball joints and mounting bosses with solvent degreaser If more than 0.34" of ball joint stud extends through nut, add washers as needed Clean tapered surfaces of all ball joints and mounting bosses with solvent degreaser Loctite 242 150 - 180 ft-lb 2.50" Figure 40 Center Deck Lift Arm Ball Joint Service IMPORTANT: Before install ball joints to deck, clean tapered surfaces of ball joints and mounting bosses on deck with solvent degreaser.
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Idler Pulley Service Apply Loctite 242 or equivalent to threads of bolt securing idler pulley to deck. Tighten bolt to a torque of 35 to 40 ft-lb. Make sure center idler pulley on center deck is installed in hole closest to edge of pulley support. Install in adjacent hole if using optional high speed (larger diameter) gearbox pulley. When installing V-groove idler pulleys, make sure bolt heads are facing down.
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Wing Deck Spring Loaded Locking Mechanism Service rod back, until large clevis pin is loose, then remove clevis pin. WARNING 4. Remove socket head screw to relieve spring tension and remove locking mechanism. This mechanism is spring loaded. Use proper disassembly procedures to prevent possible personal injury. To install locking mechanism: 1. Replace worn or damaged parts in mechanism. NOTE: Some early production units were not equipped with rod caps and socket head screws.
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