Toro groundsmaster 322 d mower service repair manual
- 1. Part No. 92801SL, Rev. I Service Manual Groundsmaster® 300 Series Preface Groundsmaster 328-D Use this book along with the Toro Operator’s Manual and Parts Catalog for the specific model and serial number of the machine, and the Kubota 05 Series Workshop Manual. This publication will provide the service technician with information for troubleshooting, testing, and repair of major systems and components on the Groundsmaster 345, 322-D and 325-D (Model 30788 and 30795). REFER TO THE TRACTION UNIT AND CUTTING UNIT OPERATOR’S MANUALS FOR OPERATION, MAINTENANCE AND ADJUSTMENT INSTRUC- TIONS. Space is provided in Chapter 2 of this book to insert the Operator’s Manuals and Parts Catalogs for your machine. Replacement Operator’s Manuals are available by sending complete Model and Serial Num ber of traction unit and cutting unit to: The Toro Company 8111 Lyndale Avenue South Minneapolis, MN 55420 The Toro Company reserves the right to change product specifications 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 - 1992, 1996, 1998, 2001, 2003, 2004, 2005, 2007
- 2. Table Of Contents Chapter 1 - Safety Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1 Chapter 2 - Product Records and Manuals Product Records. . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 Equivalents and Conversions. . . . . . . . . . . . . . . . 2 - 2 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . 2 - 3 Maintenance Interval Charts. . . . . . . . . . . . . . . . . 2 - 4 Equipment Operational and Service Historical Report Record Chapter 3 - Ford VSG-411 Gasoline Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1 General Information . . . . . . . . . . . . . . . . . . . . . . . 3 - 2 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6 FORD VSG-411/413 ENGINE SERVICE MANUAL Chapter 4 - Mitsubishi K3D Diesel Engine Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2 Specificationis. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 11 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 13 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 15 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 18 Preparation for Engine Repair . . . . . . . . . . . . . . 4 - 25 External Engine Component Repair. . . . . . . . . . 4 - 26 Fuel System Repairs . . . . . . . . . . . . . . . . . . . . . 4 - 34 Removing and Installing the Engine. . . . . . . . . . 4 - 46 Cylinder Head Overhaul . . . . . . . . . . . . . . . . . . . 4 - 47 Cylinder Block Overhaul. . . . . . . . . . . . . . . . . . . 4 - 53 Chapter 4A - Kubota Diesel Engine General Information . . . . . . . . . . . . . . . . . . . . . . . 4 - 2 Specificationis. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3 Chapter 5 - Hydraulic System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2 General Information . . . . . . . . . . . . . . . . . . . . . . . 5 - 3 Hydraulic Schematics. . . . . . . . . . . . . . . . . . . . . . 5 - 6 Hydraulic Flow Diagrams . . . . . . . . . . . . . . . . . . . 5 - 7 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 12 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 18 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 22 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 26 Chapter 6 - Electrical System Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . 6 - 2 Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 3 Troubleshooting (Groundsmaster 345) . . . . . . . . . . . . 6 - 6 Troubleshooting (Groundsmaster 322-D/325-D) . . . . . 6 - 12 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 18 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 30 Chapter 6A - Electrical System (S/N 21000000 & Up) Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1 Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 2 Electrical System Quick ChecksT. . . . . . . . . . . . . 6 - 3 Component Identification and Testing. . . . . . . . . . 6 - 4 Service and Repairs . . . . . . . . . . . . . . . . . . . . . . 6 - 12 Chapter 7 - Differential Axle Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 2 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3 Chapter 8 - Steering and Brakes Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 1 Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 4 Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 5 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 7 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 9 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 11 Chapter 9 - Transmission Coupler and PTO Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 3 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 4 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 7 Chapter 10 - 4WD Rear Axle (GM322-D or GM325-D with Inasaka axle) Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 2 General Information . . . . . . . . . . . . . . . . . . . . . . 10 - 3 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 4 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 5 Chapter 10.1 - 4WD Rear Axle (GM325-D or GM328-D with Dae Dong axle) Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 2 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 3 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 4 Groundsmaster ® 300 Series
- 3. Chapter 11 - 72″ Cutting Units Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 2 General Information. . . . . . . . . . . . . . . . . . . . . . 11 - 3 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . 11 - 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 5 Adjustments. Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 8 Chapter 12 - Triflex® 88″ Cutting Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 2 General Information. . . . . . . . . . . . . . . . . . . . . . 12 - 3 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . 12 - 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 5 Adjustments. Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 13 Chapter 13 - Guardian® 72″ Recycler® Cutting Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 2 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . 13 - 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 4 Adjustments. Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 7 Groundsmaster ® 300 Series
- 4. Chapter 1 Safety SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . 1 Before Operating. . . . . . . . . . . . . . . . . . . . . . . . . 1 While Operating. . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety Instructions The Groundsmaster 300 Series was tested and certified by TORO for compliance with the B71.4 1984 specifica- tions of the American National Standards Institute. Al- though hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern, and proper training of the person- nel involved in the operation, transport, maintenance, and storage of the machine. Before Operating 1. Read and understand the Operator’s Manual before starting and operating the machine. Become familiar with all controls and know how to stop quickly. Areplace- ment manual is available by sending complete Model and Serial Numbers to: The Toro Company 8111 Lyndale Avenue South Minneapolis, Minnesota 55420 2. Never allow children to operate the machine. Do not allow adults to operate the machine without proper instruction. Only trained operators, skilled in slope op- eration and who have read the Operator’s Manual should operate this machine. 3. Never operate machine when under the influence of drugs or alcohol. 4. Remove all debris or other objects that might be picked up and thrown by cutter blades or fast moving components from other attached implements. Keep all bystanders away from the operating area. 5. Keep all shields and safety devices in place. If a shield, safety device, or decal is defective or damaged, repair or replace it before operating the machine. Also, tighten any loose nuts, bolts, and screws to make sure machine is in safe operating condition. While Doing Maintenance, Troubleshooting, Testing, Adjustments or Repairs . . . . . . . . . . . . . 3 j Improper operation, maintenance, trou- bleshooting, testing, adjustments or repairs of the machine can result in in ury or death. To reduce the potential for injury or death, comply with the following safety instructions. CAUTION 6. Do not wear loose fitting clothing because it could get caught in moving parts. Always wear long pants and substantial shoes. Wearing safety glasses, safety shoes, and a helmet is advisable and required by some local ordinances and insurance regulations. 7. Be sure interlock switches are adjusted correctly so engine cannot be started unless traction pedal is re- leased to neutral position and PTO lever is in OFF position. 8. Grass deflectors must be installed in lowest position on side discharge cutting units and properly attached to Triflex ® cutting unit wings. 9. Fill fuel tank with the proper fuel before starting the engine. Avoid spilling any fuel. Since fuel is very flam- mable, handle it carefully. A. Use an approved fuel container. B. Do not fill fuel tank when engine is hot or running. C. Do not smoke while handling fuel. D. Fill fuel tank outdoors and up to about one inch (25 mm) from the top of the tank, not the filler neck. E. Wipe up any spilled fuel. Groundsmaster® 300 Series Page 1 - 1 Safety Instructions
- 5. 10. Sit on the seat when starting the engine and oper- ating the machine. 11. On machines equipped with roll-over protection (ROPS), always use seat belt and ROPS together. Make sure seat pivot retaining pin is installed. 12. Before starting the engine: A. Engage parking brake, B. Make sure traction pedal is in neutral and PTO is in OFF (disengage) position. C. After engine is started, release parking brake and keep foot off traction pedal. Machine must not move. If movement is evident, the neutral return mecha- nism is adjusted incorrectly. Shut engine off and adjust until machine does not move when traction pedal is released. 13. Do not run the engine in a confined area without adequate ventilation. Exhaust fumes are hazardous and could possibly be deadly. 14. Maximum seating capacity is one person. Therefore, never carry passengers. 15. Check carefully for overhead clearances before driving under any objects. While Operating 16. Using the machine demands the operator’s com- plete attention. To prevent loss of control: A. Operate only in daylight or when there is good artificial light. B. Drive slowly. C. Avoid sudden stops and starts. D. Look behind machine before backing up. E. Watch for holes or other hidden hazards. F. Do not drive close to a sand trap, ditch, creek, or hazard. G. Reduce speed when making sharp turns and when turning on a hillside H. The cutting deck must be lowered when going down slopes for steering control. 17. To maintain machine control, 35 lb. of weight must be mounted on rear of traction unit before using the Triflex 88" cutting unit. More weight may be required in some steeper slope conditions. 18. Operator must be skilled and trained in how to drive on hillsides. Failure to use caution on slopes or hills may cause loss of control and vehicle to tip or roll possibly resulting in personal injury or death. 19. Traverse slopes carefully. Do not start or stop sud- denly when traversing slopes or when traveling uphill or downhill. 20. If engine stalls or machine loses headway and cannot make it to the top of a slope, do not turn machine around. Always back slowly straight down the slope. 21. The grass deflector(s) must always be installed and in lowest position on the cutting unit. This product is designed to drive objects into the ground where they lose energy quickly in grassy areas. However, don’t take an injury risk!! When a person or pet appears unexpect- edly in or near the mowing area, STOP MOWING. Careless operation, combined with terrain angles, rico- chets, or improperly positioned guards, can lead to thrown object injuries. Do not resume mowing until area is cleared. 22. Never raise the cutting unit or other attached imple- ment while the blades or other parts are rotating. 23. If cutting blades or other implement components strike a solid object or the machine vibrates abnormally, disengage PTO, move throttle to SLOW, set parking brake, and shut engine off. Remove key from switch to prevent possibility of accidental starting. Check cutting unit or other implement and traction unit for damage and defective parts. Repair any damage before restarting the engine and operating the implement or cutting unit. Assure cutting unit blades are in good condition and blade bolts are torqued to proper specifications (See Cutting Unit Operator’s Manual). 24. To stop machine, remove foot from traction pedal and use brakes. Gradually reversing the traction pedal can provide additional braking. 25. Do not touch engine, muffler, or radiator while engine is running or soon after it has stopped. These areas could be hot enough to cause a burn. 26. Lower the cutting unit or other attached implement to the ground and remove key from switch whenever machine is left unattended. Safety Instructions Page 1 - 2 Groundsmaster® 300 Series
- 6. 27. Before getting off the seat: B. Set the parking brake and disengage the PTO. A. Move traction pedal to neutral position and re- C. Shut the engine off and remove key from ignition move foot from pedal. switch. Wait for all movement to stop before getting off the seat. While Doing Maintenance, Troubleshooting, Testing, Adjustments or Repairs 28. Remove key from ignition switch to prevent acciden- tal starting of the engine when servicing, adjusting, or storing the machine. 29. Make sure you understand a service procedure before working on the machine. Unauthorized modifica- tions to the machine may impair the function, safety and life of the machine. If major repairs are ever needed or assistance is desired, contact an Authorized TORO Distributor. 30. To reduce potential fire hazard, keep the engine free of excessive grease, grass, leaves, and accumulations of dirt. Clean protective screen on front of engine fre- quently. When cleaning parts, do not use flammable solvents, such as diesel fuel, kerosene or gasoline. 31. THE ASBESTOS BRAKE LININGS CONTAIN ASBES- TOS FIBERS. BREATHING ASBESTOS DUST MAY BE HAZ- ARDOUS TO YOUR HEALTH AND MAY CAUSE SERIOUS RESPIRATORY OR OTHER BODILY HARM. For your pro- tection: A. AVOID CREATING DUST. B. Do not remove brake drum without proper equipment. C. Do not work on brake linings without proper protective equipment. D. Do not replace brake linings without proper pro- tective equipment. E. Do not attempt to sand, grind, chisel, file, hammer, or alter brake linings in any manner without proper protective equipment. F. Follow O.S.H.A standards for proper protective devices to be used when working with asbestos materials. 32. If the cutting unit discharge area ever plugs, disen- gage PTO and shut engine off before removing the obstruction. 33. Make sure machine is in safe operating condition by keeping nuts, bolts, and screws tight. Check all cutting unit blade mounting bolts frequently to assure they are torqued to proper specifications (See Cutting Unit Op- erator’s Manual). 34. If machine is equipped with roll-over protection (ROPS), periodically inspect the roll bar and roll bar mounting. Repair as necessary. Do not weld, cut, drill, or modify roll bar in any manner. 35. Make sure all hydraulic line connectors are tight, and all hydraulic hoses and lines are in good condition before applying pressure to the system. 36. Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks. Hydraulic fluid escaping under pressure can have suffi- cient force to penetrate skin and do serious damage. If fluid is ejected into the skin, it must be surgically re- moved within a few hours by a doctor familiar with this form of injury or gangrene may result. 37. Before disconnecting or performing any work on the hydraulic system, all pressure in system must be re- lieved by stopping engine and lowering implement to the ground. 38. If the engine must be running to perform mainte- nance or an adjustment, keep clear of PTO shaft, cutting unit blades, and other moving parts. 39. Do not over-speed the engine by changing the governor settings. To ensure safety and accuracy, have an Authorized TORO Distributor check maximum en- gine speed with a tachometer. 40. Engine must be shut off before checking oil or adding oil to the crankcase. 41. Disconnect the cables from the battery before serv- icing the machine. If battery voltage is required for troubleshooting or test procedures, temporarily connect the battery. 42. Do not charge a frozen battery because it can explode and cause injury. Let the battery warm to 60° F (15.5° C) before connecting to a charger. Charge the battery in a well-ventilated place so that gases produced while charging can dissipate. Since the gasses are explosive, keep open flame and electrical spark away from the battery; do not smoke. Nausea may result if the gases are inhaled. Unplug the charger from the electri- cal outlet before connecting or disconnecting the charger leads from the battery posts. Groundsmaster® 300 Series Page 1 - 3 Safety Instructions
- 7. 43. Wear safety glasses, goggles or a face shield to prevent possible eye injury when using compressed air for cleaning or drying components. 44. Failure to follow proper procedures when mounting a tire on a wheel or rim can produce an explosion which may result in serious injury. Do not attempt to mount a tire unless you have the proper equipment and experi- ence to perform the job. Have it done by your Toro Distributor or a qualified tire service. 45. When changing attachments or performing other service, use the correct blocks, hoists and jacks. Always use jack stands to safely support the machine when it is raised by a jack or hoist. 46. At the time of manufacture, the machine conformed to safety standards in effect for riding mowers. To ensure optimum performance and continued safety certification of the machine, use genuine TORO replacement parts and accessories. Replacement parts and accessories made by other manufacturers may result in non confor- mance with the safety standards, and the warranty may be voided. Safety Instructions Page 1 - 4 Groundsmaster® 300 Series
- 8. Chapter 2 Product Records and Manuals Table of Contents PRODUCT RECORD FORM . . . . . . . . . . . . . . . . . . 1 EQUIVALENTS AND CONVERSIONS . . . . . . . . . . 2 Decimal and Millimeter Equivalents . . . . . . . . . . 2 U.S. to Metric Conversions . . . . . . . . . . . . . . . . . 2 Product Records Record information about your Groundsmaster 345, 322-D or 325-D on the Equipment Operation and Serv- ice History Report Form. Use this information when referring to your machine. TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . 3 Capscrew Markings and Torque Values - U.S. . . 3 Capscrew Markings and Torque Values - Metric . 3 EQUIPMENT OPERATION AND SERVICE HISTORY REPORT FORM Insert Operator’s Manuals and Parts Manuals for your Groundsmaster 345, 322-D or 325-D at the end of this section. Groundsmaster® 300 Series Page 2 - 1 Rev. A Product Records
- 9. ___________________________________________________________________________________________________ ___________________________________________________________________________________________________ ___________________________________________________________________________________________________ ___________________________________________________________________________________________________ ___________________________________________________________________________________________________ ___________________________________________________________________________________________________ ___________________________________________________________________________________________________ ___________________________________________________________________________________________________ ___________________________________________________________________________________________________ ___________________________________________________________________________________________________ ___________________________________________________________________________________________________ ___________________________________________________________________________________________________ ___________________________________________________________________________________________________ ___________________________________________________________________________________________________ Equivalents and Conversions Decimal and Millimeter Equivalents Fractions Decimals mm Fractions Decimals mm 1/64 0.015625 — 0.397 33/64 0.515625 — 13.097 1/32 ––––– 0.03125 — 0.794 17/32 –––– 0.53125 — 13.494 3/64 0.046875 — 1.191 35/64 0.546875 — 13.891 1/16–––––––––––– 0.0625 — 1.588 9/16 –––––––––––– 0.5625 — 14.288 5/64 0.078125 — 1.984 37/64 0.578125 — 14.684 3/32 ––––– 0.9375 — 2.381 19/32 –––– 0.59375 — 15.081 7/64 0.109275 — 2.778 39/64 0.609375 — 15.478 1/8––––––––––––– 0.1250 — 3.175 5/8 ––––––––––––– 0.6250 — 15.875 9/64 0.140625 — 3.572 41/64 0.640625 — 16.272 5/32 ––––– 0.15625 — 3.969 21/32 –––– 0.65625 — 16.669 11/64 0.171875 — 4.366 43/64 0.671875 — 17.066 3/16–––––––––––– 0.1875 — 4.762 11/16 ––––––––––– 0.6875 — 17.462 13/64 0.203125 — 5.159 45/64 0.703125 — 17.859 7/32 ––––– 0.21875 — 5.556 23/32 –––– 0.71875 — 18.256 15/64 0.234375 — 5.953 47/64 0.734375 — 18.653 1/4––––––––––––– 0.2500 — 6.350 3/4 ––––––––––––– 0.7500 — 19.050 17/64 0.265625 — 6.747 49/64 0.765625 — 19.447 9/32 ––––– 0.28125 — 7.144 25/32 –––– 0.78125 — 19.844 19/64 0.296875 — 7.541 51/64 0.796875 — 20.241 5/16–––––––––––– 0.3125 — 7.938 13/16 ––––––––––– 0.8125 — 20.638 21/64 0.328125 — 8.334 53/64 0.828125 — 21.034 11/32 –––– 0.34375 — 8.731 27/32 –––– 0.84375 — 21.431 23/64 0.359375 — 9.128 55/64 0.859375 — 21.828 3/8––––––––––––– 0.3750 — 9.525 7/8 ––––––––––––– 0.8750 — 22.225 25/64 0.390625 — 9.922 57/64 0.890625 — 22.622 13/32 –––– 0.40625 — 10.319 29/32 –––– 0.90625 — 23.019 27/64 0.421875 — 10.716 59/64 0.921875 — 23.416 7/16–––––––––––– 0.4375 — 11.112 15/16 ––––––––––– 0.9375 — 23.812 29/64 0.453125 — 11.509 61/64 0.953125 — 24.209 15/32 –––– 0.46875 — 11.906 31/32 –––– 0.96875 — 24.606 31/64 0.484375 — 12.303 63/64 0.984375 — 25.003 1/2––––––––––––– 0.5000 — 12.700 1 –––––––––––––– 1.000 — 25.400 1 mm = 0.03937 in. 0.001 in. = 0.0254 mm U.S to Metric Conversions To Convert Into Multiply By Linear Miles Kilometers 1.609 Measurement Yards Meters 0.9144 Feet Meters 0.3048 Feet Centimeters 30.48 Inches Meters 0.0254 Inches Centimeters 2.54 Inches Millimeters 25.4 Area Square Miles Square Feet Square Inches Acre Square Kilometers 2.59 Square Meters 0.0929 Square Centimeters 6.452 Hectare 0.4047 Volume Cubic Yards Cubic Feet Cubic Inches Cubic Meters 0.7646 Cubic Meters 0.02832 Cubic Centimeters 16.39 Weight Tons (Short) Pounds Ounces (Avdp.) Metric Tons 0.9078 Kilograms 0.4536 Grams 28.3495 Pressure Pounds/Sq. In. Kilopascal 6.895 Work Foot-pounds Foot-pounds Inch-pounds Newton-Meters 1.356 Kilogram-Meters 0.1383 Kilogram-Centimeters 1.152144 Liquid Volume Quarts Liters 0.9463 Gallons Liters 3.785 Liquid Flow Gallons/Minute Liters/Minute 3.785 Temperature Fahrenheit Celsius 1. Subract 32o 2. Multiply by 5/9 Equivalents and Conversions Page 2 - 2 Groundsmaster® 300 Series
- 10. __________ ______________ __________ ______________ o crew To _______________________________________________________________________ _________________________________ arkings _______________________________________________________________________ _________________________________ rew Torque - Class 8.8 Capscrew Torque - Class 10.9 rew To - Class 12.9 ___________________________________________________________ ___________________________________________ __________________________ ___________________________________________________________ ___________________________________________ __________________________ ________________________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________ __________________________ _______________ _______ __________________________ _______________ _______ ________________________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________ Torque Specifications Use these torque values when specific torque values specified values. Torque values listed are for lubricated are not given. DO NOT use these values in place of threads. Plated threads are considered to be lubricated. Capscrew Markings and Torque Values - U.S. Customary SAE Grade Number 5 8 Capscrew Head Markings Capscrew T rque - Grade 5 Caps rque - Grade 8 Capscrew Body Size Cast Iron Aluminum Cast Iron Aluminum ft-lb Nm ft-lb Nm ft-lb Nm ft-lb Nm 1/4-20 7 9 6 8 11 15 9 12 -28 9 12 7 9 13 18 10 14 5/16-18 15 20 12 16 22 30 18 24 -24 17 23 14 19 24 33 19 25 3/8-16 30 40 20 25 40 55 30 40 -24 30 40 25 35 45 60 35 45 7/16-14 45 60 35 45 65 90 50 65 -20 50 65 40 55 70 95 55 75 1/2-13 70 95 55 75 95 130 75 100 -20 75 100 60 80 110 150 90 120 9/16-12 100 135 80 110 140 190 110 150 -18 110 150 85 115 155 210 125 170 5/8-11 135 180 110 150 190 255 150 205 -18 155 210 120 160 215 290 170 230 3/4-10 240 325 190 255 340 460 270 365 -16 270 365 210 285 380 515 300 410 7/8-9 360 490 280 380 550 745 440 600 -14 390 530 310 420 610 825 490 660 1-8 530 720 420 570 820 1100 660 890 -14 590 800 480 650 890 1200 710 960 Capscrew Markings and Torque Values – Metric Commercial Steel Class 8.8 10.9 12.9 Capscrew Head M Thread Capsc Capsc rque Diameter Cast Iron Aluminum Cast Iron Aluminum Cast Iron Aluminum mm ft-lb Nm ft-lb Nm ft-lb Nm ft-lb Nm ft-lb Nm ft-lb Nm 6 5 9 4 7 9 14 7 11 9 14 7 11 7 9 14 7 11 14 18 11 14 18 23 14 18 8 18 25 14 18 23 32 18 25 27 36 21 28 10 30 40 25 30 45 60 35 45 50 70 40 55 12 55 70 40 55 75 105 60 80 95 125 75 100 14 85 115 65 90 120 160 95 125 145 195 110 150 16 130 180 100 140 175 240 135 190 210 290 165 220 18 170 230 135 180 240 320 185 250 290 400 230 310 Groundsmaster® 300 Series Page 2 - 3 Torque Specifications
- 11. GROUNDSMASTER® 345 Maintenance Schedule Minimum Recommended Maintenance Intervals: Maintenance Procedure Maintenance Interval & Service Every Every Every Check Battery Fluid Level Every 400hrs 200hrs 100hrs Check Battery Cable Connections 50hrs Lubricate All Grease Fittings Lubricate Brake Cables Check Cutting Unit Gear Box Oil Level Clean Under Cutting Unit Belt Covers Check Cutting Unit Drive Belt Adjustment Check PTO Belt Adjustment A Level Inspect Air Filter, Dust Cup, and Baffle Service ‡ Change Engine Oil and Filter † Check Fan and Alternator Belt Tension B Level Inspect Cooling System Hoses Service † Replace Transmission Oil Filter Service Air Filter Check Governor Oil Level Decarbon Spark Arrestor Muffler Check Rear Wheel Toe-In and Steering Linkage C Level † Torque Wheel Lug Nuts Service Replace Fuel Filter Change Transmission Oil Change Cutting Unit Gear Box Oil Replace Spark Plugs Pack Rear Wheel Bearings D Level Torque Head, Adjust Valves,Check Engine RPM Service † Initial break in at 10 hours ‡ Initial break in at 50 hours Replace Moving Hoses Annual Recommendations: Replace Safety Switches Coolant System - Flush/Replace Fluid Items listed are recommended every 1500 hours or 2 years whichever occurs first. (See Operator's and Service Manual for specifications and procedures)
- 12. _____________ 1 GROUNDSMASTER® 345 Daily Maintenance Check List Unit Designation:__________ Daily Maintenance:(duplicate this page for routine use) TORO ID#:_______-_______ Maintenance Check Item Daily Maintenance Check For Week Of MON _____HRS TUES _____HRS WED _____HRS THURS _____HRS FRI _____HRS SAT _____HRS SUN _____HRS Safety Interlock Operation Grass Deflector in Down Position Brake Operation Fuel Level Engine Oil Level Cooling System Fluid Level Dust Cup and Baffle (Air Filter) Radiator & Screen for Debris Unusual Engine Noises Unusual Operating Noises Transmission Oil Level Hydraulic Hoses for Damage Fluid Leaks Tire Pressure Instrument Operation Condition of Blades Lubricate All Grease Fittings 1 Touch-up damaged paint = Immediately after every washing, regardless of the intervals specified. Notation for areas of concern: Inspection performed by:________________ Item Date Information 1 2 3 4 5 6 7 (See Operator's and Service Manual for specifications and procedures)
- 14. GROUNDSMASTER® 322-D and 325-D Maintenance Schedule Minimum Recommended Maintenance Intervals: Maintenance Procedure Maintenance Interval & Service Every Every Every Check Battery Fluid and Cable Connections Every 400hrs 200hrs 100hrs Lubricate Grease Fittings 50hrs Lubricate Brake Cables Check Cutting Unit Gear Box Oil Level Clean Under Cutting Unit Belt Covers Check Cutting Unit Drive Belt Adjustment Change Engine Oil Check PTO Belt Tension A Level Inspect Air Filter, Dust Cup and Baffle Service ‡ Replace Engine Oil Filter † Check Fan and Alternator Belt Tension B Level Inspect Cooling System Hoses Service † Replace Transmission Oil Filter Service Air Filter Decarbon Spark Arrestor Muffler Check Rear Wheel Toe-In and Steering Linkage C Level † Torque Wheel Lug Nuts Service Replace Diesel/Water Separator Filter Replace Electric Fuel Pump Filter Check Fuel Lines and Connections Change Cutting Unit Gear Box Oil Pack rear wheel bearings (2WD) Change Rear Axle Lubricant (4WD) Change Transmission Oil D Level ‡ Torque Head, Adjust Valves, and Check RPM Service † Initial break in at 10 hours ‡ Initial break in at 50 hours Replace Moving Hoses Annual Recommendations: Replace Safety Switches Items listed are recommended every 1500 hours or 2 years whichever occurs Coolant System - Flush/Replace Fluid first. Fuel Tank - Drain/Flush (See Operator's and Service Manual for specifications and procedures)
- 15. _____________ GROUNDSMASTER® 322-D and 325-D Daily Maintenance Check List Unit Designation:__________ Daily Maintenance:(duplicate this page for routine use) TORO ID#:_______-_______ Maintenance Check Item Daily Maintenance Check For Week Of MON _____HRS TUES _____HRS WED _____HRS THURS _____HRS FRI _____HRS SAT _____HRS SUN _____HRS Safety Interlock Operation Grass Deflector in Down Position Brake Operation Fuel Level Engine Oil Level Cooling System Fluid Level Drain Water/Fuel Separator Dust Cup and Baffle (Air Filter) Radiator & Screen for Debris Unusual Engine Noises 1 Unusual Operating Noises Transmission Oil Level Hydraulic Hoses for Damage Fluid Leaks Tire Pressure Instrument Operation Condition of Blades Lubricate All Grease Fittings 2 Touch-up damaged paint 1 = Check diesel glow plug and injector nozzles, if hard starting, excess smoke, or rough running is noted. 2 = Immediately after every washing, regardless of the intervals specified. Notation for areas of concern: Inspection performed by:________________ Item Date Information 1 2 3 4 5 6 7 (See Operator's and Service Manual for specifications and procedures)
- 17. Chapter 3 (For Groundsmaster 345 only) Ford VSG-411 Engine Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 1 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 2 Spark Plug Inspection and Replacement . . . . . . 2 ADJUSTMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Alternator Belt Adjustment. . . . . . . . . . . . . . . . . . 3 Coolant Fan Belt Adjustment. . . . . . . . . . . . . . . . 3 Governor Adjustment. . . . . . . . . . . . . . . . . . . . . . 4 Specifications REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Crankshaft Pulley Installation . . . . . . . . . . . . . . . 6 Engine Removal and Installation. . . . . . . . . . . . . 7 Engine Repair Information. . . . . . . . . . . . . . . . . . 8 FORD VSG-411/413 ENGINE SERVICE MANUAL Item Specification Make / Designation Ford Model VSG-411 Firing order 1-2-4-3 Ignition timing Distributorless Ignition System (DIS) Timing controlled by Universal Electronic Spark Control (UESC) Spark plug Motorcraft AGSF22C or AGRF22 or equivalent Spark plug gap 0.040 in. (1.0 mm) Crankcase oil capacity 3.5 U.S. qt. (3.25 liter) including filter Oil service classification API SG, SG/CC, SG/CD Oil viscosity Ambient temperature (single viscosity oil) –10° to +60°F SAE 10 +10° to +90°F SAE 20 Above +32°F SAE 30 Above +50°F SAE 40 Ambient temperature (multi-viscosity oil) Below +60°F SAE 5W-30 –10° to +90°F SAE 10W-30 Above –10°F SAE 10W-40 or 10W50 Above +10°F SAE 20W40 or 20W50 Fuel Unleaded gasoline 87 octane or higher Coolant 50 / 50 ethylene glocol anti-freeze and water Cooling system capacity 6 U.S. qt. (5.7 liter) Carburetor idle speed setting (throttle arm against stop) 1350 ± 50 RPM Governor idle speed setting 1500 ± 50 RPM Governor high speed setting 3200 ± 100 RPM Groundsmaster® 300 Series Page 3 - 1 Rev. C Specifications
- 18. General Information Spark Plug Inspection and Replacement Since air gap between center and side electrodes in- creases gradually during normal engine operation, check condition of electrodes at 100 hour intervals. The correct spark plugs to use in the engine are Motor- craft AGSF22C or AGRF22 or equivalent. Set air gap at 0.040 in. (1.0 mm). 1. Clean area around spark plugs so dirt does not fall into cylinder when plugs are removed. 2. Pull wire off spark plugs and remove plugs from cylinder head. 3. Check condition of center and side electrodes to determine operating temperature of engine. A. Light brown insulator tip indicates correct spark plug and heat range. B. Black or oily insulator tip indicates an excessively rich fuel mixture, possibly caused by a dirty air cleaner element or a carburetor that is set too rich. C. Light gray or blistered-white insulator indicates overheating caused by a lean carburetor setting or incorrect spark plug (heat range too high). IMPORTANT: A cracked, fouled or dirty spark plug must be replaced. Do not sandblast, scrape or clean electrodes by using a wire brush because grit may release from the plug and enter combustion cham- ber resulting in engine damage. 4. After setting air gap at 0.040 in. (1.0 mm), install spark plug in cylinder head. Tighten the plug to 11 - 15 ft-lb. Push wire onto spark plug. General Information Page 3 - 2 Groundsmaster® 300 Series
- 19. Adjustments Alternator Belt Adjustment (Fig. 1) A new alternator belt is to be tensioned to 65 lbs. A used belt is to be re-tensioned to 40 lbs. 1. To adjustable tension, loosen bolt securing brace to engine, bolt securing alternator to brace and alternator mounting bolts. 2. Insert pry bar between alternator and engine and pry out on alternator. 3. Hold alternator in position after proper tension is achieved and tighten alternator and brace bolts to se- cure adjustment. Figure 1 1. Alternator 2. Brace Coolant Fan Belt Adjustment (Fig. 2) A new fan belt is to be tensioned to 45 lbs. A used belt is to be re-tensioned to 28 lbs. 1. To adjust belt tension, loosen upper and lower nuts securing idler arm to front engine mount. 2. Pull out on idler arm until desired belt tension is achieved. 3. Tighten mounting nuts to secure adjustment. Figure 2 1. Edler arm 2. Engine mount Groundsmaster® 300 Series Page 3 - 3 Adjustments
- 20. Governor Adjustment (Fig. 3, 4) l i guard engage 1. With engine shut off, move throttle contro to FAST position and open hood. Check between throttle arm and stop on carburetor base to make sure there is a 1/32 in. (0.8 mm) gap. If gap s not correct, adjust throttle rod by turning ball joint ends until gap is 1/32 in. (0.8 mm). If gap is correct, to to step 2. Engine must be running so final adjustment of governor can be performed. To against possible personal injury, parking brake and keep hands, feet, face, and other parts of body away from fan and other moving parts. WARNING Figure 3 2. Start engine and move throttle to SLOW position. Allow engine to warm up to normal operating tempera- 1. 1/32" (0.8 mm) 4. Stop ture. 2. Throttle rod 5. Throttle arm 3. Carbruetor idle speed screw 3. Rotate throttle arm closed until it contacts stop. 4. Check idle speed and adjust carburetor idle speed screw if necessary to attain 1350 ± 50 rpm. Adjustments Page 3 - 4 Groundsmaster® 300 Series
- 21. 5. Release throttle arm, loosen jam nut on governor low idle stop screw and adjust it to get 1500 ± 100 rpm. Tighten jam nut. 6. Slowly move throttle to FAST position until engine speed reaches 3200 ± 100 rpm. Shut off engine. Adjust high idle stop screw until it contacts speed control lever. IMPORTANT: Do not over-speed the engine because the transmission could be damaged. 7. Move throttle rapidly from SLOW to FAST. The engine should not surge. If engine surges, go to step 8. 8. Check V-belts from engine to governor pulley and make sure they are tight. If belts are loose, engine will surge. If belts are tensioned properly, loosen jam nut that retains anti-surge screw. Rotate screw clockwise 1/8 turn at a time until surging stops. Should governor continue to surge, check the following: A. Carburetor too rich or too lean. B. Binding in throttle linkage. C. Governor worn internally. IMPORTANT: Never rotate anti-surge screw in too far so that speed of engine increases. 9. Bump throttle lever with your hand so engine speeds up momentarily. If governor is working properly, engine speed should return to normal within one or two surges of governor. More than two surges of governor usually indicates that the anti-surge screw must be turned in slightly more than it is. When adjustment is correct, lock jam nut against governor body. 10. Check low and high idle speed to be sure there is no change from initial setting. If high idle speed has increased, anti-surge screw has been turned into gov- ernor too far and it must be backed out. Then, repeat the entire adjustment procedure. NOTE: If the throttle control on instrument panel will not stay in FAST position during operation, remove panel cover and tighten nut and capscrew at base of throttle lever assembly. Figure 4 1. High idle stop screw 5. Oil check plug 2. Speed control lever 6. Low idle stop screw 3. Jam nut 7. Oil fill plug 4. Anti-surge screw Groundsmaster® 300 Series Page 3 - 5 Adjustments
- 22. Repairs Crankshaft Pulley Installation 1. Insert three of four locking rings into crankshaft pulley. NOTE: Outside locking rings have tapered I.D. and flat O.D. Inside locking rings have flat I.D. and tapered O.D. A. Install first outside ring seated against small inter- nal shoulder of pulley, flat edge of ring touching small pulley shoulder. B. Install second inside ring, mating taper to taper with first ring. C. Install third outside ring with flat edge against previous inside ring. D. Align ring end gaps with key slot in pulley. 2. Align pulley key slot with crankshaft key. Install pulley approximately 1/4" onto crankshaft. 3. Insert fourth locking ring, taper to taper, with third ring. 4. Insert bolt through special washer. Shoulder on washer contacts shoulder of fourth locking ring. 5. Draw pulley onto crankshaft by tightening crankshaft bolt. Resistance will be felt as crankshaft passes through locking rings. 6. Tighten crankshaft bolt to a torque of 40-44 ft-lb. Check pulley alignment between crankshaft and water pump. Figure 5 1. Woodruff key 4. Special washer 2. Pulley 5. Metric bolt 3. Locking rings Repairs Page 3 - 6 Groundsmaster® 300 Series
- 23. Engine Removal and Installation Removing the Engine 1. Put machine on a level surface, stop engine, remove key from ignition switch and engage parking brake. 2. Remove intake hose from air cleaner and carburetor. 3. Remove transmission drive coupling (see Chapter 10 - Transmission Coupler and PTO). 4. Remove PTO belt (see Chapter 10 - Transmission Coupler and PTO). 5. Disconnect battery cables from battery terminals. 6. Disconnect and tag all wires connected to engine and engine accessories. 7. Put a drain pan under radiator, loosen radiator cap, loosen radiator petcock and allow radiator to drain com- pletely. 8. Move drain pan under lower radiator hose. Discon- nect hose from radiator and allow coolant to drain into pan. Remove lower and upper radiator hoses. 9. Move drain pan under rear of engine and remove cylinder block plug (located above starter) to drain cool- ant from cylinder block. Install cylinder block plug. 10. Remove cable tie securing control cables and vacuum sensor hose near caburetor. 11. Disconnect vacuum sensor hose from fuel trap on carbruetor. 12. Disconnect choke control cable from carburetor. 13. Disconnect throttle control cable from governor. 14. Remove fuel line from inlet side of fuel pump. NOTE: Be prepared to insert a plug into fuel line to prevent fuel spill. 15. Remove capscrews securing fan shroud to radiator so fan shroud can be move during engine removal for cooling fan clearance. 16. Attach a short section of chain between the two lifting shakles on the engine. Attach block and tackle or hoist chain to this short section of chain, approximately mid- way between the two shakles. 17. Remove four bolts securing rear engine mount to frame. 18. Remove slack from lifting chain and carefully re- move two capscrews which pass through the two rubber front engine mounts. 19. Lift and guide engine from engine compartment. Be careful not to damage the radiator cooling fan or other components during removal. Installing the Engine 1. Do steps 2 - 19 of “Removing the Engine” in reverse order. 2. Fill cooling system with new coolant. Install a new oil filter and fill engine with correct oil. 3. Inspect for oil and coolant leaks. 4. Check engine idle speed and maximum governed speed settings. Groundsmaster® 300 Series Page 3 - 7 Repairs
- 24. Thank you very much for your reading. Please Click Here Then Get More Information. NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.
- 25. Engine Repair Information Ford VSG-411 Component Changes Ford VSG-411 engines with a date code of 2D21 or later have five (5) main bearings, which is the same design used on the VSG-413 engine. VSG-411 engines pro- duced before this date have four (4) main bearings (see Page 1-01, under IDENTIFICATION in the Ford VSG-411/413 Engine Service Manual for an explana- tion of Ford corporate date system). Listed below is a summary of changes from the four (4) main bearing design to the five (5) main bearing design of the VSG-411 engine: Cylinder block – New, five main bearing design. Crankshaft – Same as VSG-413. Crankshaft lower main bearing – No change. Crankshaft upper main bearing – No change. Crankshaft rear oil seal retainer – Same as VSG-413. Crankshaft rear bearing oil seal gasket – Same as VSG-413 Repairs Page 3 - 8 Groundsmaster® 300 Series
- 26. Chapter 4 (For Groundsmaster 322-D/325-D only) Mitsubishi K3D Diesel Engine For Groundsmaster 328-D, use the Toro Operator's Manual and Parts Catalog Table of Contents along with the Kubota 05 Series Workshop Manual (Toro Part No. 01090SL). INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Stop Solenoid Replacement . . . . . . . . . . . . . . . 32 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Water Pump Servicing. . . . . . . . . . . . . . . . . . . . 33 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 FUEL SYSTEM REPAIRS . . . . . . . . . . . . . . . . . . . 34 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Bleeding the Fuel System . . . . . . . . . . . . . . . . . 34 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . 7 Bleeding Air From the Injectors . . . . . . . . . . . . . 35 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Fuel Pump Service . . . . . . . . . . . . . . . . . . . . . . 35 Governor System . . . . . . . . . . . . . . . . . . . . . . . . 8 Governor Mechanism Operation . . . . . . . . . . . . 37 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Governor Inspection . . . . . . . . . . . . . . . . . . . . . 37 Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . 9 Injection Pump Servicing. . . . . . . . . . . . . . . . . . 38 Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . 10 Nozzle Servicing . . . . . . . . . . . . . . . . . . . . . . . . 45 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 REMOVING AND INSTALLING THE ENGINE. . . . 46 ADJUSTMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Removing the Engine . . . . . . . . . . . . . . . . . . . . 46 Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . 13 Installing the Engine . . . . . . . . . . . . . . . . . . . . . 46 Engine Speed Adjustments . . . . . . . . . . . . . . . . 14 CYLINDER HEAD OVERHAUL . . . . . . . . . . . . . . . 47 Throttle Linkage Adjustment . . . . . . . . . . . . . . . 15 Cylinder Head Removal. . . . . . . . . . . . . . . . . . . 47 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . 15 Cylinder Head Servicing . . . . . . . . . . . . . . . . . . 48 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Glow Plug Test . . . . . . . . . . . . . . . . . . . . . . . . . 18 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Compression Test . . . . . . . . . . . . . . . . . . . . . . . 19 Valve Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nozzle Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Valve Springs. . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Injection Pump Test. . . . . . . . . . . . . . . . . . . . . . 22 Rocker Arm and Rocker Shaft Service . . . . . . . 51 Injection Timing Test . . . . . . . . . . . . . . . . . . . . . 23 Cylinder Head Reassembly and Installation . . . 52 Fuel Pump Test . . . . . . . . . . . . . . . . . . . . . . . . . 24 CYLINDER BLOCK OVERHAUL . . . . . . . . . . . . . . 53 Thermostat Test. . . . . . . . . . . . . . . . . . . . . . . . . 24 Cylinder Block Disassembly . . . . . . . . . . . . . . . 53 PREPARATION FOR ENGINE REPAIR. . . . . . . . . 25 Camshaft and Bearing. . . . . . . . . . . . . . . . . . . . 55 Cylinder and Cylinder Block Overhaul . . . . . . . 25 Fuel Injection Pump Camshaft . . . . . . . . . . . . . 55 EXTERNAL ENGINE COMPONENT REPAIR . . . . 26 Crankshaft Bearings . . . . . . . . . . . . . . . . . . . . . 56 Crankcase Breather System . . . . . . . . . . . . . . . 26 Timing Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Alternator Belt Service . . . . . . . . . . . . . . . . . . . 27 Connecting Rod and Connecting Rod Bearings 57 Fan Belt Service . . . . . . . . . . . . . . . . . . . . . . . . 27 Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Fan, Fan Pulley and Fan Shaft Service . . . . . . 28 Oversized Pistons, Cylinder Bore and Rings. . . 58 Glow Plug Replacement . . . . . . . . . . . . . . . . . . 29 Piston and Pin Replacement . . . . . . . . . . . . . . . 59 Oil Pressure Switch Replacement. . . . . . . . . . . 29 Engine Reassembly. . . . . . . . . . . . . . . . . . . . . . 59 Oil Pump Servicing . . . . . . . . . . . . . . . . . . . . . . 30 Groundsmaster® 300 Series Page 4 - 1 Rev. C Table of Contents