Commercial Products Troubleshooting Guide Groundsmaster 345/325-D Part No.
INDEX 1. Product Overview GM 325-D/GM 345 2. Ford VSG-411 Gas Engine (GM 345) 3. Mitsubishi K3D Diesel Engine (GM 325-D) 4. Hydraulic Systems Hydrostatic Drive Systems 5. Electrical Systems 6. Cutting Unit Drive 7.
TORO GM 345 / 325 - D Product Overview 1 Product Overview GM 300 series Groundsmaster The Groundsmaster 300 series mower is a medium size, maneuverable, commercial rotary with over twenty years of mowing experience. During those years its design has been continuously improved for optimum productivity and durability. GM 345 Features 1. Ford 4 cylinder gas engine (45hp). 2. Sunstrand series M15 inline variable speed hydrostatic drive. 3. Hydraulic power steering and lift functions 4. Available in 2wd.
2 Product Overview TORO GM 345
TORO GM 345 / 325 - D Product Overview 3 Attachments 1. 72” Side discharge mower deck. 2. 72” Rear discharge mower deck. 3. 72” Guardian Recycler deck. 4. 88” Triflex mower deck. 5. 48” Snowblower 6. Debris blower 7. Aerator 8. Plug pulverizer 9. Aero-seeder 10. V-Plow 11.
4 Ford VSG-411 Gas Engine TORO GM 345
TORO GM 345 Ford VSG-411 Gas Engine 5 In this section we will look at some troubleshooting procedures for the Ford Gas Engine. Engine Identification The engine is identified with a decal affixed to the left side of the valve cover. The decal contains the engine serial number. The model number and displacement. ( i.e. 411 = 4 cyl 1.1 liter) The special options (S.O.) number. The engine is also stamped on the left rear top edge of the block. This stamping includes: A - Serial number. B - Engine Code.
6 Ford VSG-411 Gas Engine TORO GM 345
TORO GM 345 Ford VSG-411 Gas Engine 7 Troubleshooting: High and Low Idle Checks. The idle settings are important for the proper operation and long life of the machine. Affects of incorrect idle speeds: 1. High idle too slow: • Low power. (engine not running at full speed) • Slow transport speed. (hydrostatic transmission input shaft speed too slow) • Poor Quality of cut. (Blade RPM and tip speed too slow) 2. High idle too fast: • Internal engine damage.
8 Ford VSG-411 Gas Engine TORO GM 345
TORO GM 345 Ford VSG-411 Gas Engine 9 Correction: Carburetor linkage adjustment. 1. With the engine shut off, move the throttle control to the FAST position. 2. Check the gap between the throttle arm and the stop on the carburetor base. The correct gap is 1/32” (0.78mm). 3. If the gap is not correct adjust the throttle rod by turning the ball joint until the proper gap is attained.
10 Ford VSG-411 Gas Engine TORO GM 345
TORO GM 345 Ford VSG-411 Gas Engine 11 The final adjustments are made with the engine running. To guard against possible personal injury, engage the parking brake and keep hands, feet, face and other parts of the body away from the fan or other moving parts. Low Idle Adjustment. 1. Start the engine and move the throttle to the slow position. 2. Manually rotate the throttle arm closed until it contacts the stop. 3.
12 Ford VSG-411 Gas Engine TORO GM 345
TORO GM 345 Ford VSG-411 Gas Engine 13 High Idle Adjustment. 1. Slowly move the throttle to the FAST position until the engine reaches 3200 ± 100. Shut off the engine. Adjust the high speed adjustment screw until it contacts the speed control lever. IMPORTANT: Do not overspeed the engine because transmission damaged could occur. 2. If 3200 rpm can not be attained, check the throttle cable adjustment. • The governor arm must not contact the cable cover when the unit is at high idle.
14 Ford VSG-411 Gas Engine TORO GM 345
TORO GM 345 Ford VSG-411 Gas Engine 15 Anti-Surge Adjustment. 1. Move the throttle rapidly from SLOW to FAST. The engine should not surge, if the engine surges proceed to step 2. 2. Check the V-belts from the engine to the governor pulley and assure that they are tight. • The belt is adjusted to 45 lbs of tension on a belt gauge for a new belt. • A used belt is re-tensioned to 28 lbs. • The replacement belt PN is 67-8510. 3. Loosen the jam nut that retains the anti-surge screw.
16 Ford VSG-411 Gas Engine TORO GM 345
TORO GM 345 Ford VSG-411 Gas Engine 17 Cylinder Leakage Test. The cylinder leakage test can locate the following problems: 1. Leaking intake valves. • Air leaking from carburetor. 2. Leaking exhaust valves. • Air leaking from muffler. 3. Leaking cylinder head gaskets. • Air leaking externally by head gasket. 4. Worn piston rings. • Air leaking from breather or dipstick tube. NOTE. There will always be some air leakage past the rings. Use the tester gauge to determine the severity of the leak.
18 Ford VSG-411 Gas Engine Special tools TORO GM 345 Helpful Hints 1. Electric tach. • OTC P/N - OEM1386 or equivalent. 1. All engine RPM checks should be performed with the engine warm. 2. Photo tach. • OTC P/N - OEM1057 or equivalent. 2. Governor oil is the same oil as is used in the crankcase 3. Belt tension gauge • OTC P/N - OEM1294 or equivalent 3. Cylinder leakage can identify the location and the extent of an internal engine problem • Cylinder leakage of 25 percent or less is acceptable 4.
TORO GM 345 Ford VSG-411 Gas Engine 19 Review Questions 1. Proper high idle setting is: 4. Normal engine compression is: a. b. c. d. a. b. c. d. 2800 ± 50 RPM 3200 ± 100 RPM 3000 ± 25 RPM 1500 ± 100 RPM 2. The final high idle adjustment is made at the carburetor. a. True b. False 100 PSI 205 PSI 185 PSI 415 PSI 5. Adding oil to a cylinder with a bad intake valve will increase the compression reading of the cylinder. a. True b. False 3. The recommended compression gauge is: a. b. c. d.
20 Mitsubishi K3D Diesel Engine TORO GM 325-D
TORO GM 325-D Mitsubishi K3D Diesel Engine 21 In this section we will look at some troubleshooting procedures for the Mitsubishi Diesel Engine. Engine Identification The engine model number and serial number is listed on a decal on the valve cover. The engine serial number is also stamped on the injection pump mounting surface. Complaint: Low engine power Affect: 1. 2. 3. 4. 5. Poor cutting unit performance. Poor hill climbing ability. Slow hydraulic response. Slow throttle response.
22 Mitsubishi K3D Diesel Engine TORO GM 325-D
TORO GM 325-D Mitsubishi K3D Diesel Engine 23 Analyzing Diesel Exhaust Smoke. The exhaust from a diesel engine can provide information about the running condition of the engine. A normally operating engine will have exhaust that is clear to a slight brownish/gray color. 1. Black Smoke. • Insufficient air. (Plugged or dirty air filter) • Excessive fuel. (Leaking injection nozzles) (Over fueled injection pump setting) • Engine Overloaded. (Excessive load on engine) 2. Blue Smoke.
24 Mitsubishi K3D Diesel Engine TORO GM 325-D
TORO GM 325-D Mitsubishi K3D Diesel Engine 25 Troubleshooting Cylinder Leakage Test. A cylinder leakage test may be performed if the test equipment is available. The leakage test can locate: 1. Leaking intake valve. • Air leaking from the air filter or intake manifold. 2. Leaking exhaust valve. • Air leaking from the muffler. 3. Piston rings not sealing properly. • Air leaking from crankcase breather or dipstick tube.
26 Mitsubishi K3D Diesel Engine TORO GM 325-D
TORO GM 325-D Mitsubishi K3D Diesel Engine 27 Troubleshooting: High and Low Idle Checks. The idle settings are important for the proper operation and long life of the machine. Affects of incorrect idle speeds: 1. High idle too slow. • Low power. (Engine not running at full speed) • Slow transport speed. (Hydrostatic transmission input shaft speed too slow) • Poor Quality of cut. (Blade RPM and tip speed too slow) 2. High idle too fast. • Internal engine damage.
28 Mitsubishi K3D Diesel Engine TORO GM 325-D
TORO GM 325-D Mitsubishi K3D Diesel Engine 29 Injection Nozzles. The diesel engine requires that the fuel be sprayed into the combustion chamber, at a precise point in the compression stroke. The point at which this fuel injection occurs is the injection timing. If the nozzle is defective, damaged, or adjusted incorrectly, the injection timing can be affected. This can cause hard starting, low power output, excessive smoke or engine knocking. IMPORTANT: Always use fresh filtered fuel in the nozzle tester.
30 Mitsubishi K3D Diesel Engine TORO GM 325-D
TORO GM 325-D Mitsubishi K3D Diesel Engine 31 1. Nozzle Leakage Test. • • The leakage test checks the nozzle tip for proper sealing. A leaking nozzle should be repaired or replaced. 2. Operate the pump until 1500 psi (108 kg/cm²) is reached, maintain this pressure. 3. Check the nozzle end. • If the nozzle end is dry or a slight film of fuel is present, the nozzle is OK. • If a drop of fuel forms or the nozzle drips fuel, the nozzle must be serviced or replaced.
32 Mitsubishi K3D Diesel Engine TORO GM 325-D
TORO GM 325-D Mitsubishi K3D Diesel Engine 33 1. Nozzle spray Test. The ability of the nozzle to correctly atomize the fuel can be checked by performing a nozzle spray test. Pump the nozzle tester and watch the spray pattern. • • A solid stream or large droplets indicates a faulty nozzle. Fuel should be well atomized and in a consistent spray pattern. Leaking injection nozzles can cause: 1. 2. 3. 4. 5. 6. Hard starting. Excessive smoke. Low power. Engine knocking. Injection pump damage.
34 Mitsubishi K3D Diesel Engine TORO GM 325-D
TORO GM 325-D Mitsubishi K3D Diesel Engine 35 Glow Plug Testing. The diesel engine requires glow plugs to warm the combustion chamber to assist in starting. Evidence of faulty glow plugs includes: hard starting, excessive smoke, or engine knocking. There are several ways to test glowplugs. The resistance of the glow plug can be measured with an Ohmmeter. Normal resistance is 2 to 3 ohms. 0 ohms indicates a shorted glow plug. An O.L. reading on the ohmmeter indicates an open circuit in the glow plug.
36 Mitsubishi K3D Diesel Engine Special Tools TORO GM 325-D Service Tips 1. Photo tach. • OTC P/N - OEM1057 or equivalent. 1. All engine RPM checks should be performed with the engine warm. 2. Belt tension gauge • OTC P/N OEM1294 or equivalent 2. Cylinder leakage can identify the location and the extent of an internal engine problem • Cylinder leakage of 25 percent or less is acceptable 3. Cylinder leakage tester. • OTC P/N TOR4075 or equivalent. 4. • • • 5. • Compression tester. 0 - 1000 psi.
TORO GM 325-D Mitsubishi K3D Diesel Engine 37 Study Questions 1. Blue exhaust smoke indicates : 4. Cylinder leakage of 50 % is acceptable a. b. c. d. a. True b. False Excessive fuel water in the combustion chamber. High oil consumption. Excessive engine load. 5. Maximum injection nozzle opening pressure is: 2. When performing a compression test, add oil to the pistons before the test a. True b. False 3. Proper low idle setting is: a. b. c. d. 1000 ± 100 1000 ± 50 1500 ±100 1500 ± 50 a. b. c. d.
38 Hydraulics Hydrostatic Charge Circuit TORO GM 345 / 325-D
TORO GM 345 / 325-D Hydraulics 39 Hydrostatic Drive and Hydraulic Systems The drive system on the Groundsmaster 300 series consists of a Sunstrand Series 15, inline hydrostatic pump and motor assembly. This assemble is connected to a Dana GT-20 axle/differential assembly. Engine power is transmitted from the engine to the input shaft of the hydrostatic unit. The output of the hydrostatic unit transmits the power to the pinion shaft, through the differential and to the wheels.
40 Hydraulics Drive circuit TORO GM 345 / 325-D
TORO GM 345 / 325-D Hydraulics 41 Drive Circuit The drive circuit consists of a variable displacement pump and the hydrostatic motor. Drive circuit operation. 1. When the traction pedal is depressed the swash plate in the pump rotates and the pump begins to pump. 2. The oil from the pump flows to the hydrostatic motor. 3. The oil flows through the hydrostatic motor and returns to the pump. (The oil flows in a closed loop). There is a bypass valve located in the drive circuit.
42 Hydraulics Acceleration valves TORO GM 345 / 325-D
TORO GM 345 / 325-D Hydraulics 43 Acceleration valves 1. The drive oil from the hydrostatic pump also flows to the acceleration valves. 2. The oil is allowed to flow through the orifice in the valve, until sufficient pressure is created to close the acceleration valve. 3. Bleeding away some of this initial oil flow allows for a smoother unit start and direction change. 4. The acceleration valves do not serve as the drive circuit relief valve. 5. The 2 wheel drive unit does not have a relief valve.
44 Hydraulics TORO GM 345 / 325-D
TORO GM 345 / 325-D Hydraulics 45 Troubleshooting To test the hydrostatic system there are several test ports on the hydrostatic unit. 1. Charge pressure test port, (located on the left side rear of the hydrostatic unit, next to the steering and lift supply line). 2. Forward and reverse drive pressure test ports, (located in the middle section of the hydrostatic unit). • Forward drive is the RH test port. • Reverse drive is the LH test port.
46 Hydraulics Drive Pressure Test TORO GM 345 / 325-D
TORO GM 345 / 325-D Hydraulics 47 1. Testing drive pressure. • Remove the test port plug using a 3/16” allen wrench. • Connect 10,000 psi gauge into the test port using a 3/8 - 24 adapter. • Chain machine and lock brakes. • Operate engine at 3200 RPM. • 2WD, drive pressure should read 4000-4500 psi. (DO NOT exceed 5000 psi) • 4WD, drive pressure should read 5200 psi. Low drive pressure. (Charge pressure “OK”) 2. Possible causes. • Leaking check valves. • Leaking acceleration valves.
48 Hydraulics Charge Flow Test TORO GM 345 / 325-D
TORO GM 345 / 325-D Hydraulics 49 1. Testing charge flow. • Connect hydraulic flow meter. • Operate engine at 3200 RPM. • Restrict oil flow through flow tester. Should be able to read 1GPM at 700 PSI. Low charge flow (charge pressure “OK”) 2. Possible causes: • Leaking implement relief valve. • Worn drive pump. • Worn drive motor. 3. Performance results: • Slow steering response. • Slow hydraulic response. • System overheating.
50 Hydraulics TORO GM 345 / 325-D
TORO GM 345 / 325-D Hydraulics 51 Steering Circuit 1. Oil from the hydrostatic charge pump flows to the IN port of the steering valve. 2. With the steering wheel in neutral the oil flows out the AUX port to the lift valve. 3. When the steering wheel is turned to the right the AUX port is closed and oil is director out the RT port to the steering cylinder. NOTE: The steering valve will not allow oil to flow through it to the lift valve when the steering wheel is being turned.
52 Hydraulics TORO GM 345 / 325-D
TORO GM 345 / 325-D Hydraulics 53 Cutting Unit Lift Circuit. 1. When the steering wheel is in neutral, oil flows out of the AUX port to the lift valve. 2. When the valve is in neutral oil flows through the valve, to the oil cooler, and then to the reservoir. 3. When the lift valve is actuated, oil is directed to the lift cylinder.
54 Hydraulics Special Tools TORO GM 345 / 325-D Service Tips 1. Hydraulic flow tester kit • OTC P/N TOR214678 or equivalent 1. Hydraulic testing is done with the hydraulic oil at normal operating temperature. 2. Hydraulic pressure test kit. • OTC P/N TOR47009 or equivalent 2. Before testing hydraulics check the system for the proper oil level and fluid type. 3. Check or replace the hydraulic filter to eliminate the possibility of a plugged filter.
TORO GM 345 / 325-D Hydraulics 55 Study Questions 1. All hydraulic and hydrostatic test should be conducted with the oil warm. a. True b. False 4. The acceleration valves prevent: a. b. c. d. Abrupt direction change Excessive drive pressure Loss of charge pressure Excessive travel speed 2. Proper engine RPM for hydraulic testing is: 5. Drive pressure is tested with a: a. b. c. d. 1500 RPM 2000 RPM 3000 RPM 3200 RPM 3. Proper maximum drive pressure for a 2wd unit is: a. b. c. d.
56 Electrical Systems TORO GM 345 / 325-D Start Circuit 1 2 3 Position OFF ON START Circuit NONE B+I+A B+I+s Make X+Y
TORO GM 345 / 325-D Electrical Systems 57 Electrical System (GM 345 / 325-D) The electrical system on the 300 Series Goundsmaster can be broken into the following circuits: 1. 2. 3. 4. Starting/Charging. Safety Interlock. Gauges and warning. Engine. With a basic understanding of these circuits we can troubleshoot a variety of electrical problems. System Operation Start Circuit. (GM 345 Shown, 325-D similar) 1. 2. 3. 4. 5. 6. 7. 8. Power from the battery flows to the (-) terminal of the ammeter.
58 Electrical Systems TORO GM 345 / 325-D Interlock Circuit 1 2 3 Position OFF ON START Circuit NONE B+I+A B+I+s Make X+Y
TORO GM 345 / 325-D Electrical Systems 59 Interlock Circuit Normal Operation. 1. 2. 3. 4. With an operator in the seat and the PTO engaged, the PTO switch opens. Current flows through the seat switch to the “A” terminal of the ignition switch. In the run position, the power flows from the “A” terminal to the “I” terminal. From the “I” terminal power flows to the ignition system.
60 Electrical Systems TORO GM 345 / 325-D Interlock Circuit 1 2 3 Position OFF ON START Circuit NONE B+I+A B+I+s Make X+Y
TORO GM 345 / 325-D Electrical Systems 61 PTO Engaged, Operator Not In The Seat. 1. 2. 3. 4. If the operator leaves the seat while the PTO is engaged. Power is interrupted by the seat switch. Current stops flowing to the “A” terminal of the ignition switch. Power is stopped to the ignition module and the engine stops. Caution: Do not disconnect the safety switches because they are there for the operators protection.
62 Electrical Systems TORO GM 345 / 325-D
TORO GM 345 / 325-D Electrical Systems 63 Interlock System Testing PTO Switch and Traction Neutral Switch Testing. 1. Move the PTO switch to the OFF position. 2. Remove foot from the traction pedal so it is fully released. 3. Rotate the ignition key to start. Engine should crank. If the engine does not crank, there may be a malfunction in the PTO or Neutral switch.
64 Electrical Systems TORO GM 345 / 325-D
TORO GM 345 / 325-D Electrical Systems 65 Seat Switch and Traction Neutral Switch Testing 1. Raise off the seat and engage the PTO switch while the engine is running. 2. The engine should stop within 2 seconds. If the engine stops, the switch is operating correctly. If the engine does not stop, there is a problem in the seat switch of the PTO switch. . 1. Raise of the seat and depress the traction pedal with the PTO disengaged. 2. The engine should stop within 2 seconds.
66 Electrical Systems TORO GM 345 / 325-D
TORO GM 345 / 325-D Electrical Systems 67 Electrical circuit breaker. The GM325 electrical system has a 40 amp circuit breaker to protect the electrical system from overload. If all electric functions are lost, resetting the circuit breaker might remedy the problem. If the circuit breaker open frequently the source of the problem must be found and repaired.
68 Electrical Systems Special Tools 1. Digital volt, ohm meter. OTC PN. OEM1428 or equivalent 2. Electrical “skin over grease” OTC PN. TOR50547 TORO GM 345 / 325-D Helpful Hints 1. Interlock switches • Neutral switch closed with traction pedal in neutral • PTO switch closed with PTO disengaged • Seat switch open with no operator in the seat 2. Unit will start without an operator in the seat, if the PTO is disengaged and the traction pedal is in neutral. 3.
TORO GM 345 / 325-D Electrical Systems 69 Review Questions 1. How many interlock switches does the unit use? 4. The diesel unit has a resetable 40 amp breaker in the circuit a. b. c. d. a. True b. False 1. 2. 3. 4. 5. The engine should start with the cutting unit in gear 2. The neutral switch is: a. Open when the traction pedal is depressed b. Closed when the neutral switch is depressed a. True b. False 3. The unit will start with the operator out of the seat. a. True b. False c.
70 Cutting Unit Drive TORO GM 345 / 235-D
TORO GM 345 / 325-D Cutting Unit Drive 71 Attachment Drive (PTO) GM325/GM345 Pto Operation 1. The power take-off (PTO) system transmits power from the engine to the cutting deck or other implement attached to the front of the machine. 2. The PTO lever has two positions: ON (engage) and OFF (disengage). To engage the PTO shaft, slowly push the PTO lever fully forward to the ON position; this will start the implement or cutting unit blades.
72 Cutting Unit Drive TORO GM 345 / 235-D
TORO GM 345 / 325-D Cutting Unit Drive 73 Troubleshooting 1. Poor cutting unit performance: • Drive belt slipping. • Tighten the drive belt. • Adjust PTO belt tension spring to 3 3/16 in.(80.96 mm). 2. Drive belt failure: • Improper belt alignment. • Align drive belt. NOTE: See the operators manual or the service manual for the complete adjustment procedure.
74 Cutting Units TORO GM 345/325-D
TORO GM 345/325-D Cutting Units 75 Cutting Units Maintenance and Service Spindle service If noisy operation of the cutting unit is encountered and the blade spindles need to be repaired, refer to the complete repair procedures in the service manual. The replacement bearing set consists of: 1. The upper and lower bearings races. 2. A snap ring spacer that positions the bearing races in the spindle housing. 3. An outside spacer to set the distance between the bearing races. 4. Two bearings. 5.
76 Cutting Units TORO GM 345/325-D
TORO GM 345/325-D Cutting Units 77 Quality Of Cut Inspecting and Sharpening Rotary Mower Blades Rotary mowers cut grass by the blade’s cutting surface impacting against the grass stems at a high velocity. To assure good quality of cut, the cutting edge of the blade must be kept in a sharp condition. A dull blade will produce a ragged cut and will require an excessive amount of engine horsepower to rotate the blade through the grass.
78 Cutting Units TORO GM 345/325-D
TORO GM 345/325-D Cutting Units 79 Mismatch cut. When a mismatch condition occurs the blade tip height should be checked. It the blade tip height is different, the blades will cut at a different height and the grass will be uneven. Another quality of cut problem is striping. Striping can be caused by the mower blades being sharpened too much that the actual blade length is shorter. This causes a small line of uncut grass to be left between the blades Inconsistent height of cut.
80 Cutting Units Special tools 1. Blade balancing tool OTC PN. TOR4029 or equivalent 2. Blade holding fixture OTC PN. TOR4030 or equivalent 3. Portable bench grinder OTC PN TOR4031 or equivalent TORO GM 345/325-D Helpful Hints 1. Fill the spindle bearing housing with grease when replacing the bearings. (This assures that the upper bearing gets grease when the spindle is greased). 2. The small inside spacer ring does not have a groove in the spindle to sit in.
TORO GM 345/325-D Cutting Units 81 Review Questions 1. Bearings and spacers should be replaced as a set 4. Balancing the blade after sharpening is not necessary. a. True b. False a. True b. False 2. The drive belt engagement spring should be adjusted to a length of: 5. The small spacer ring fits in a groove in the spindle shaft. a. b. c. d. a. True b. False 2 1/4 inches 3 3/16 inches 1 1/2 inches 4 inches 3. The cutting unit raise/lower lever should be in the neutral position when mowing 6.
Commercial products FORM 96-904-SL The Toro Company - 1996 Printed in U.S.
