Page 1: Service Manual
The Toro Company reserves the right to change product machine. specifications or this publication without notice. © The Toro Company - 1993, 1996, 1998, 2002, 2003...
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Page 3: Table Of Contents
Table Of Contents Chapter 1 - Safety Special Tools ......4 - 11 Troubleshooting .
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Page 5: Chapter 1 - Safety
While Operating......2 Safety Instructions The GROUNDSMASTER 455-D conforms to the Ameri can National Standards Institute’s safety standards for...
Page 6 long pants and a helmet is advisable and required by 8. Since diesel fuel is highly flammable, handle it some local ordinances and insurance regulations. carefully: 6. Assure interlock switches are adjusted correctly so A. Use an approved fuel container. engine cannot be started unless traction pedal is in B.
Page 7 To assure optimum performance and continued safety certification of the 30. Before disconnecting or performing any work on the machine, use genuine Toro replacement parts and ac hydraulic system, all pressure in system must be cessories. Replacement parts and accessories made...
Page 8 ® Safety Instructions Page 1 - 4 Groundsmaster 455-D...
Page 9: Product Records
Record information about your Groundsmaster 455-D Insert the Operator’s Manuals and Parts Catalogs for on the Equipment Operation and Service History Report your Groundsmaster 455-D at the end of this section. Form. Use this information when referring to your ma chine.
Page 10: Equivalents And Conversions
Equivalents and Conversions Decimal and Millimeter Equivalents ___________________________________________________________________________________________________ Fractions Decimals Fractions Decimals ___________________________________________________________________________________________________ 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 —...
Page 11: Torque Specifications
Torque Specifications Use these torque values when specific torque values The torque values listed below are for lubricated are not given. DO NOT use these values in place of threads. Plated threads are considered to be lubricated. specified values. Capscrew Markings and Torque Values - U.S. Customary SAE Grade Number ________________________________________________________________________________________________________________________________________________________ Capscrew Head Markings...
Page 12 Maintenance Schedules ® Rev. C Maintenance Schedules Page 2 - 4 Groundsmaster 455-D...
Page 13 ® Page 2 - 5 Rev. C Groundsmaster 455-D Maintenance Schedules...
Page 14 ® Maintenance Charts Page 2 - 6 Groundsmaster 455-D...
Page 15 Rotary Deck Numbers: __________-__________ Date Purchased: ____________________ Warranty Expires__________ Purchased From: ____________________ ____________________ ____________________ Contacts: Parts ____________________ Phone __________________ Service ____________________ Phone __________________ Sales ____________________ Phone __________________ See your TORO Distributor/Dealer for other Publications, Manuals, and Videos from The TORO Company.
Page 16 GROUNDSMASTER® 455-D Maintenance Schedule Minimum Recommended Maintenance Intervals: Maintenance Procedure Maintenance Interval & Service Type Every Every Every Every 800hrs Inspect Air Filter, Dust Cup, and Baffle Every 400hrs 200hrs 100hrs 50hrs Lubricate All Grease Fittings A Level Check Cutting Unit Gear Box Oil Level Service ‡...
Page 17 GROUNDSMASTER® 455-D Daily Maintenance Check List Unit Designation:__________ Daily Maintenance: TORO ID#:_______-_______ (duplicate this page for routine use) Daily Maintenance Check For Week Of _____________ TUES THURS _____ _____ _____ _____ _____ _____ _____ Maintenance Check Item Safety Interlock Operation...
Page 19 Assembly of External Components ..60 Compression Test ..... . . 28 Page 3 - 1 Rev. B Groundsmaster 455-D Engine...
Page 20: Introduction
® of the diesel engine used in the Groundsmaster 455-D Distributors. Repair parts may be ordered by TORO Part mowers. Number. If no parts list is available be sure to provide your dealer or distributor with the TORO Model Number Most repairs and adjustments require tools which are and Serial Number.
Page 21: Identification And Specifications
1 - 3 - 4 - 2 ________________________________________________________________________________________________________________________ ________________________________ Electrical System 12 volt, negative ground, 55 AMP alternator with integral regulator. 12 volt - 1.4 Kw starter motor with integral solenoid, pinion shaft type. Page 3 - 3 Rev. B Groundsmaster 455-D Engine...
Page 22 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).
Page 23 Intake: Faces x and y can machined a maximum of 0.2 mm Exhaust: No machining is permissible. Figure 5 Valve Recess Units: mm Intake Exhaust 0.5 to 1.05 0.9 to 1.45 Figure 6 Page 3 - 5 Rev. B Groundsmaster 455-D Engine...
Page 24 + 0.2 Production 14.02 13.981 14.13 14.051 Repair 1 14.29 14.211 52.00 36.50 8.02 Repair 2 14.59 14.511 øk is obtained by machining after fitting in the cylinder head Figure 8 Page 3 - 6 Rev. B Engine Groundsmaster 455-D...
Page 25 32.2 Repair 1 32.45 32.4 Repair 2 32.65 32.6 The protrusion j must be between 0 and 0.03 mm Dimension j is obtained by machining faces (x) and (y) Figure 10 Page 3 - 7 Rev. B Groundsmaster 455-D Engine...
Page 26 NOTE: The piston øb must be measured at dimension c. 25.00 NOTE: The repair dimension (x) is stamped on the cylinder block and pistons. Figure 11 Piston Pin Units: mm 24.994 to 25 ø external ø 13.8 to 14.1 internal Page 3 - 8 Rev. B Engine Groundsmaster 455-D...
Page 27 Repair 1 26.80 2.405 Repair 2 26.90 2.455 Repair 3 27.00 2.505 Units: mm Oil Seal Contact Surface Figure 13 øg Tolerance – 0 – 0.087 Production 90.00 Repair 1 89.80 Page 3 - 9 Rev. B Groundsmaster 455-D Engine...
Page 28: Tightening Torques
________________________________________________________________________________________________________________________ ________________________________ Manifold screws ________________________________________________________________________________________________________________________ ________________________________ Alternator bracket * NOTE: 40 + 60° is tighten to 40 Nm then an additional 60° (60 degrees) of rotation (one flat of bolt head) Page 3 - 10 Rev. B Engine Groundsmaster 455-D...
Page 29: Special Tools
Special Tools NOTE: Order special tools from the TORO SPECIAL Groundsmaster 455-D Parts Catalog. Some tools may TOOLS AND APPLICATIONS GUIDE (COMMERCIAL also be available from a local supplier. PRODUCTS) . Some tools may be l isted in the TOR4033 Overhaul Tool Set This tool kit includes tools required for overhauling the engine.
Page 30 TOR70153A1 Main Seal Installer Used to install the two side seals to the no. 1 main bearing cap. Figure 18 TOR70153A2 Shim Set Used with main seal installer TOR70153A1. Figure 19 Page 3 - 12 Rev. B Engine Groundsmaster 455-D...
Page 31 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 Page 3 - 13 Rev. B Groundsmaster 455-D Engine...
Page 32 TOR80117AM Timing Tool Kit For Roto Diesel DPC Pump Used with dial indicator to adjust timing of injection pump. Figure 26 TOR80117EZ Crankshaft Rotating Wrench Used with a 1/2" drive ratchet wrench to turn the crankshaft. Figure 27 Page 3 - 14 Rev. B Engine Groundsmaster 455-D...
Page 33 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 Page 3 - 15 Rev. B Groundsmaster 455-D Engine...
Page 34 TOR70153H Injector Pump Gear Puller Loosen the nut on the injector pump gear, then use this TOR70153H tool to loosen the pulley from the tapered shaft on the injector pump. Figure 33 Page 3 - 16 Rev. B Engine Groundsmaster 455-D...
Page 35: Adjustments
Adjust throttle cable at injection pump so throttle lever on injection pump operates at full range of motion without throttle control lever at operator’s station touch ing end of slot at either FAST or SLOW position. Page 3 - 17 Rev. B Groundsmaster 455-D Engine...
Page 36: Troubleshooting
Rectifier diode defective. Rectifier diode short-circuited. Battery voltage too high. Inline diode defective. Regulator defective. Poor connections. Alternator noisy. Rectifier diode short-circuited. Belt worn. Alternator mounting loose. Alternator pulley loose. Worn bearings. Page 3 - 18 Rev. B Engine Groundsmaster 455-D...
Page 37 End of injector body corroded Running temperature of engine Check thermostat too low Intermittent operation Run machine longer. Do not start and stop engine. (1) In these cases, replace the injector Page 3 - 19 Rev. B Groundsmaster 455-D Engine...
Page 38 Incorrect spray, or injectors out of Check, clean and adjust injectors adjustment Insufficient automatic advance Have pump repaired Discharge rates too high Have pump repaired Air intake restriction Check hoses and air cleaner Page 3 - 20 Rev. B Engine Groundsmaster 455-D...
Page 39 Check fuel lines and clamps Defective fuel injector Check injectors Jammed discharge valve Have pump repaired Engine will not stop Key switch defective Replace key switch Defective electric stop solenoid Check electric stop solenoid Page 3 - 21 Rev. B Groundsmaster 455-D Engine...
Page 40 Air getting into fuel system Idling stop out of adjustment Leaky injection pipe unions Speed fall-Off Clogged fuel filter Defective injection pump Engine speed rises to maximum Defective injection pump Throttle cable jammed Page 3 - 22 Rev. B Engine Groundsmaster 455-D...
Page 41 Lifters out of adjustment Foreign matter in a cylinder Seized injector Injection pump timing Sheared glow plug Timing out of adjustment Whistling, blowing Leaking cylinder head gasket Leaky glow plug Valve seats Leaky injector Page 3 - 23 Rev. B Groundsmaster 455-D Engine...
Page 42 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 Page 3 - 24 Rev. B Engine Groundsmaster 455-D...
Page 43 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 Page 3 - 25 Rev. B Groundsmaster 455-D Engine...
Page 44 Tank vent plugged Injection pump needs re-priming Shutdown control jammed in “stop” position Starter does not crank or cranks slowly Battery discharged Oil too thick Engine seized Faulty starter Faulty wiring Page 3 - 26 Rev. B Engine Groundsmaster 455-D...
Page 45: Testing And Inspection
(Fig. 34). If the glow plug glows red-hot in 9 to 12 seconds, the glow plug is operating correctly. DO NOT leave on more than 20 seconds. 5. Replace any glow plugs that do not operate correctly. Page 3 - 27 Rev. B Groundsmaster 455-D Engine...
Page 46 7. Repeat the test for the other three cylinders. Dif ference between cylinders should be no more than 5 bar (70 psi). 8. Connect the fuel stop solenoid electrical connector. 9. Install the glow plugs. Page 3 - 28 Rev. B Engine Groundsmaster 455-D...
Page 47 The point at which this fuel injection occurs is determined by the injection timing. If the nozzle is Page 3 - 29 Rev. B Groundsmaster 455-D Engine...
Page 48 (Fig. 36). straight 3. If the nozzle fails to spray properly, it must be cleaned, Figure 36 repaired or replaced. Page 3 - 30 Rev. B Engine Groundsmaster 455-D...
Page 49 C. Connect the fuel delivery pipe to the nozzle as- sembly so the tip of the nozzle is pointed away from 5. Repeat the test for the other cylinders. the engine. Tighten the fitting securely. Page 3 - 31 Rev. B Groundsmaster 455-D Engine...
Page 50 Starts to open at: 81 C (178 7 mm (0.28 in.) full open at 88 C (190 3. If the thermostat fails to open, only partially opens, or sticks, it should be replaced. Figure 37 Page 3 - 32 Rev. B Engine Groundsmaster 455-D...
Page 51: Fuel System Service
Lucas ROTO DIESEL service dealer - especially during vicing it. DO NOT spray water onto a hot injection the warranty period. Repairs by non-authorized dealers pump. WILL void the pump warranty. Page 3 - 33 Rev. B Groundsmaster 455-D Engine...
Page 52 Clean each 9. Injector holder nut injector separately to matched parts are not mixed up. 10. Thread The needle should slide freely and fall in the nozzle by its own weight. Page 3 - 34 Rev. B Engine Groundsmaster 455-D...
Page 53 4. Moderately tighten each union, 25 Nm (18 ft-lb) max., on pump and injector. Over-tightening will distort the end of the injector line. 5. Connect fuel return pipe. Page 3 - 35 Rev. B Groundsmaster 455-D Engine...
Page 54: Timing Belt Replacement
TDC Lock Pin tool and rotate the engine (clockwise) one revolution. Install the TDC Lock Pin, then install the bolts as instructed in steps 5 and 6. Figure 44 Page 3 - 36 Rev. B Engine Groundsmaster 455-D...
Page 55 (Item 10). 8. Rotate the roller tensioner bracket square (Item A) to compress the spring (Item 11). 9. Re-tighten the bolt (Item 9). 10. Remove the timing belt. Figure 45 Page 3 - 37 Rev. B Groundsmaster 455-D Engine...
Page 56 Tension on belt is only to be set by the spring (Fig. 46, Item 15) when tensioner plate is free to rotate. 3. Re-tighten the bolt (Item 18), then the nut (Item 19), when the belt is tensioned. Figure 47 Page 3 - 38 Rev. B Engine Groundsmaster 455-D...
Page 57 LOCTITE. Install the bolt (Item 1) and washer (Item 2) and tighten to a torque of 40 Nm (30 ft-lb). C. Tighten the bolt 60° further (one flat). Figure 50 Page 3 - 39 Rev. B Groundsmaster 455-D Engine...
Page 58: Injection Pump Timing
5. Remove the TDC Lock Pin tool TOR 70153N, then turn the crankshaft 1/4 to 1/3 turn in the opposite direc tion of running (counterclockwise as viewed from the timing belt end). Figure 53 Page 3 - 40 Rev. B Engine Groundsmaster 455-D...
Page 59 19. Remove TDC Lock Pin tool, three lock bolts, in TOR 70153N dicator and indicator bracket. Install pump cover plug. 20. Tighten injector lines. Figure 56 21. Install timing belt covers, clips and attachment nut. Page 3 - 41 Rev. B Groundsmaster 455-D Engine...
Page 60: Preparation For Engine Repair
5. Loud noises in the engine. It is important to find the cause of the engine failure before beginning repair. Symptoms 2 and 4 in the above Page 3 - 42 Rev. B Engine Groundsmaster 455-D...
Page 61: Engine Removal And Installation
Plug end of fuel line to prevent fuel and accessories from engine as necessary. Drain oil leakage. Disconnect injector return hose. from engine and remove engine oil filter. 7. Loosen hose clamp and disconnect PCV hose from engine. Page 3 - 43 Rev. B Groundsmaster 455-D Engine...
Page 62: Installing The Engine
Check for oil and coolant leaks and repair as necessary. Peugeot recommended Coolant/Antifreeze is available in 1 U.S. Gallon containers under Toro Part No. 93-7213. IMPORTANT: The anti-freeze should contain no Borate and have a Ph of 7 to 8.5.
Page 63: Engine Overhaul
8. Remove the injector pipes (Item 12). 9. Remove the glow plug leads. 10. Remove the crankcase breather pipes/oil filter/filter pipe assembly (Item 13). 11. Remove the oil pressure switch (Item 14). Figure 57 Page 3 - 45 Rev. B Groundsmaster 455-D Engine...
Page 64 WILL void the pump warranty. IMPORTANT: Clean the injection pump and the area around the injection pump before removing or ser vicing it. DO NOT spray water onto a hot injection pump. Figure 58b Page 3 - 46 Rev. B Engine Groundsmaster 455-D...
Page 65 Figure 60 4. Remove the pump (Fig. 61, Item 5) / drive chain / crankshaft sprocket (Item 7) assembly. NOTE: Item 6 spacer is not used on engines used in TORO machines. Figure 61 Page 3 - 47 Rev. B...
Page 66 10. Remove the piston pin circlips and separate the pistons from the connecting rods. 11. Remove the plugs (Fig. 63 and 64, Item 12) from the oil galleries. Figure 64 Page 3 - 48 Rev. B Engine Groundsmaster 455-D...
Page 67 Maximum bow: 0.7 mm. 7. Check the condition of the valve seats and guides, valve, valve springs, swirl chambers, camshaft, cam shaft bearings and all tapped holes. (See Identification and Specifications section.) Figure 67 Page 3 - 49 Rev. B Groundsmaster 455-D Engine...
Page 68 15. Install the camshaft, with the DIST mark at the timing gear end. 16. Progressively tighten the bearing caps to a torque of 17.5 Nm (13 ft-lb). The bearing caps have cast-in markings for correct installation. Figure 70 Page 3 - 50 Rev. B Engine Groundsmaster 455-D...
Page 69 1), with the anti-friction faces towards the crankshaft. Figure 72 6. Install the no. 2 main bearing cap (Fig. 73, Item 2) with its two end float half-washers, with the anti-friction faces towards the crankshaft. Figure 73 Page 3 - 51 Rev. B Groundsmaster 455-D Engine...
Page 70 C. Lower it slowly. D. Tighten the two bearing cap bolts (Item 6) finger tight. E. Remove the capscrew securing the tool to the main bearing cap and withdraw the tool horizontally. Figure 75 Page 3 - 52 Rev. B Engine Groundsmaster 455-D...
Page 71 (1) – scraper ring (2) – tapered ring (3) – domed chrome ring Space the ring gaps at 120° in relation to the scraper ring gap (Item c). Figure 77 Page 3 - 53 Rev. B Groundsmaster 455-D Engine...
Page 72 3. Withdraw the tool with a twisting movement. Figure 79 Oil Pump Installation 1. Install the key (Fig. 80, Item 6). 2. Install the pump (Item 7), drive chain and sprocket (Item 8) assembly. Figure 80 Page 3 - 54 Rev. D Engine Groundsmaster 455-D...
Page 73 1. Install the flywheel. Put Locket thread lock on the flywheel mounting bolts. 2. Install a TORFD86 flywheel locking tool. 3. Tighten the flywheel bolts to a torque of 50 Nm (37 ft-lb). 4. Remove the flywheel locking tool. Page 3 - 55 Rev. B Groundsmaster 455-D Engine...
Page 74: Cylinder Head Installation
5. Install the cylinder head. 6. Carefully clean the threads of the cylinder head bolts with a brush. 7. Coat the bolt threads and washer contact faces with MOLYKOTE G RAPID. Figure 83 Page 3 - 56 Rev. B Engine Groundsmaster 455-D...
Page 75: Valve Clearance Adjustment
Set “on the rock” Inlet 4, Exhaust 4 Inlet 1, Exhaust 1 Check Inlet 1, Exhaust 1 Inlet 4, Exhaust 4 Inlet 2, Exhaust 3 Inlet 3, Exhaust 2 Figure 85 Page 3 - 57 Rev. B Groundsmaster 455-D Engine...
Page 76 Difference + 0.10 Shim installed 2.425 * Shim to be installed 2.50 Clearance obtained 0.175 * Basic shim 9. Install the shims as determined in step 8. 10. Install the tappets. Page 3 - 58 Rev. B Engine Groundsmaster 455-D...
Page 77 16. Install a new oil seal on tool TOR 976697 on the side where the inner flange is the farthest away (Fig. 88). 17. Use a camshaft gear or pulley bolt to install the two camshaft oil seals. Figure 88 Page 3 - 59 Rev. B Groundsmaster 455-D Engine...
Page 78 14. Install the exhaust manifold with new seals. 15. Install the intake manifold. 16. Remove the engine from the stand. 17. Install the clutch housing centering pin. Figure 90 18. Install the TDC sensor. Page 3 - 60 Rev. B Engine Groundsmaster 455-D...
Page 79 Break-in Engine After Overhaul After disassembling or overhauling the engine, install the a new oil filter. Replace this filter with a new filter after the first 20 to 50 hours of operation. Page 3 - 61 Rev. B Groundsmaster 455-D Engine...
Page 80 Page 3 - 62 Rev. B Engine Groundsmaster 455-D...
Page 81: General Information
Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS ......2 TESTING ....... . 19 GENERAL INFORMATION .
Page 82 Specifications Item Description __________________________________________________________________________________________ Traction Pump Variable axial piston pump 6000 ± 100 PSI at high idle Traction relief pressure PSI at 3000 ± 50 RPM Charge pressure – 10 ________________________________________________________________________________________________________________________________________________________ Charge/Auxiliary Pump Gear pump with flow divider 1200 ± 100 PSI at 3000 ± 50 RPM Steering pressure ________________________________________________________________________________________________________________________________________________________ Traction Motor (front)
Page 83: General Information
General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as, pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage condi WARNING tions or mishandling during operation or maintenance. These conditions can cause damage or premature de Before disconnecting or performing any work terioration.
Page 84 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.
Page 85: Two (2) Wheel Drive
Hydraulic Schematic -- Two (2) Wheel Drive T--1495--2 Groundsmaster 455--D Page 4 -- 5 Rev. C Hydraulic Schematics...
Page 86: Four (4) Wheel Drive
Hydraulic Schematic -- Four (4) Wheel Drive T--1496--2 Groundsmaster 455--D Hydraulic Schematics Page 4 -- 6 Rev. C...
Page 87: Hydraulic Flow Diagrams
Hydraulic Flow Diagrams ® Groundsmaster 455-D Page 4 - 7 Hydraulic Flow Diagrams...
Page 88 ® Hydraulic Flow Diagrams Page 4 - 8 Groundsmaster 455-D...
Page 89 ® Groundsmaster 455-D Page 4 - 9 Hydraulic Flow Diagrams...
Page 90 ® Hydraulic Flow Diagrams Page 4 - 10 Groundsmaster 455-D...
Page 91: Special Tools
Special Tools NOTE: Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS) . Some tools may be listed in the Groundsmaster 455-D Parts Catalog. Some tools may also be available from a local supplier. Hydraulic Pressure Test Kit Used to take various pressure readings for diagnostic tests.
Page 92 You must have o-ring face seal (ORFS) adapter fittings 4. HIGH PRESSURE GAUGE: High range gauge to for this tester to use it on the Groundsmaster 455-D. accommodate pressure beyond the capacity of the low pressure gauge, 0 - 10,000 PSI.
Page 93: Troubleshooting
Troubleshooting The cause of an improperly functioning hydraulic sys system could lead to extensive internal component tem is best diagnosed with the use of proper testing damage. equipment and a thorough understanding of the com plete hydraulic system. The charts that follow contain detailed information to assist in troubleshooting.
Page 94: Traction Response Is Sluggish
Traction Response Is Sluggish Cause Correction __________________________________________________________________________________________ Brakes dragging. Inspect brakes and adjust or repair if necessary. ________________________________________________________________________________________________________________________________________________________ Charge pressure low - TEST NO. 6. Inspect charge relief valve and adjust or repair if NOTE: Counterbalance pressure will also be necessary.
Page 95: Four Wheel Drive Does Not Engage
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. Check for faulty front axle HI/LOW switch, four wheel drive solenoid or wiring and repair if necessary.
Page 96: Cutting Unit(S) Do Not Lift Or Lift Too Slowly
Cutting Unit Does Not Lift or Lift Too Slowly Cause Correction __________________________________________________________________________________________ Hydraulic oil level too low. Fill to proper level. ________________________________________________________________________________________________________________________________________________________ Low engine RPM. Adjust engine RPM - use tachometer. ________________________________________________________________________________________________________________________________________________________ Lift arm or cylinder pivots binding. Lubricate bushings. Inspect for damage. Repair or replace damaged parts.
Page 97: Cutting Units Will Not Drop Or Follow Ground Contours
Cutting Unit Will Not Drop or Follow Ground Contours Cause Correction ___________________________________________________________________________________________ Low engine RPM. Adjust engine RPM - use tachometer. ________________________________________________________________________________________________________________________________________________________ Lift arm or cylinder pivots binding. Lubricate bushings. Inspect for damage. Repair or replace damaged parts. ________________________________________________________________________________________________________________________________________________________ Lift cylinder damaged. Check lift cylinder(s) and repair or replace if necessary.
Page 98: Cutting Unit(S) Lower Or Raise Too Quickly
Cutting Unit Lowers or Raises Too Quickly Cause Correction __________________________________________________________________________________________ Missing or improperly installed orifice in hydraulic Properly install orifice between left valve and line. hydraulic hose to hydraulic lift cylinder(s). NOTE: Orifice must be installed to avoid interference with adapter fitting.
Page 99: Testing
Testing The most effective method for isolating problems in the 1. Thoroughly clean the machine before disconnecting hydraulic system is by using hydraulic test equipment or disassembling any hydraulic components. Always such as pressure gauges and flow meters in the circuits keep in mind the need for cleanliness when working on during various operational checks.
Page 100: Test No. 1: Checking Traction Circuit Working Pressure Or Relief Pressure
TEST NO. 1: Checking Traction Circuit Working Pressure or Relief Pressure WORKING Pressure Check: 1. Make sure hydraulic oil is at normal operating tem perature by operating machine for approximately 10 minutes. 2. Lower cutting units, engage parking brake and stop the engine.
Page 101: Test No. 2: Checking Counterbalance Pressure
TEST NO. 2: Checking Counterbalance Pressure 1. Make sure hydraulic oil is at normal operating tem perature by operating machine for approximately 10 minutes. 2. Lower cutting units, engage parking brake and stop the engine. 3. Raise and support seat to get access to hydraulic test fittings.
Page 102: Test No. 3: Checking Wing Deck Counterbalance Pressure
TEST NO. 3: Checking Wing Deck Counterbalance Pressure Wing Deck Counterbalance Pressure 1. Make sure hydraulic oil is at normal operating tem perature by operating machine for approximately 10 minutes. 2. Lower cutting units, engage parking brake and stop the engine. 3.
Page 103: Test No. 4: Checking Steering Circuit Working Pressure Or Relief Pressure
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.
Page 104: Test No. 5: Checking Lift Circuit Working Pressure Or Relief Pressure
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. 2. Lower cutting units, engage parking brake and stop the engine.
Page 105: Test No. 6: Checking Charge Pressure
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.
Page 106: Adjustments
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.
Page 107: Repairs
Repairs Removing Hydraulic System Components 1. Thoroughly clean the machine before disconnecting, 3. If a pump was disconnected or removed, prime removing or disassembling any hydraulic components. system before operating. Disconnect fuel stop solenoid Always keep in mind the need for cleanliness when electrical connector on engine to prevent fuel delivery working on hydraulic equipment.
Page 108: Traction Pump Shaft Seal Replacement
Traction Pump Shaft Seal Replacement (Fig. 17) Figure 17 1. Park machine on a level surface, lower cutting units, 6. Put seal carrier in an arbor press and press out old engage parking brake and stop the engine. seal (Item 29). Use a properly sized pipe spacer or socket wrench for a press tool.
Page 109: Traction Pump Trunnion Seal Replacement
Traction Pump Trunnion Seal Replacement (Fig. 18) Figure 18 1. Park the machine on a level surface, lower cutting 7. Using an arbor press, press seal into position from units, engage parking brake and stop the engine. inside of seal cover until it bottoms out in its bore. Be careful not to damage the seal.
Page 110: Traction Pump Check And High Pressure Relief Valves
Traction Pump Check and High Pressure Relief Valves (Fig. 19) Forward Reverse Figure 19 1. Park the machine on a level surface, lower cutting be removed from the special plug by pulling out at a units, engage parking brake and stop the engine. slight angle.
Page 111: Traction Pump Charge Pressure Relief Valve
Traction Pump Charge Pressure Relief Valve (Fig. 20) Figure 20 1. Park the machine on a level surface, lower cutting the parts unless shims need to be added or removed to units, engage parking brake and stop the engine. adjust the pressure setting. 2.
Page 112: Disassembly Of Traction Pump
Disassembly of Traction Pump (Fig. 21) Figure 21 1. End cap 16. Screw 30. Seal carrier 2. Plug 17. Trunnion cover 31. O-ring 18. O-ring 32. Retaining ring 4. O-ring 19. Trunnion spacer 33. Pump housing 5. Conical spring 20. Shim 34.
Page 113 4. Remove end cap (Item 1) from pump housing. an o-ring (Item 18), on the side opposite the control. Remove these parts from the housing. (See Trunnion IMPORTANT: The valve plate (Item 39) may stick to Seal Replacement). the end cap. Do not allow valve plate to fall from end cap.
Page 114: Assembly Of Traction Pump
Assembly of Traction Pump (Fig. 22) Figure 22 1. End cap 16. Screw 30. Seal carrier 2. Plug 17. Trunnion cover 31. O-ring 18. O-ring 32. Retaining ring 4. O-ring 19. Trunnion spacer 33. Pump housing 5. Conical spring 20. Shim 34.
Page 115 5. Install trunnion seal cover (Item 35) with o-ring 13. Coat back (steel side) of valve plate (Item 39) with (Item 18), seal (Item 34) and trunnion bearing into hous petroleum jelly to hold it in position and install valve plate ing and over swashplate trunnion (see Trunnion Seal onto end cap (Item 1), with the bronze face visible.
Page 116 Auxiliary/Steering Pump No. 92-7761 (Fig. 23) (S/N 69999 and Below) Figure 23 1. Dowel pin 11. Bearing seal 21. Spring 2. Idler gear assembly 12. Backup gasket 22. Back plate assembly 3. Drive gear assembly 13. Wear plate 23. Spool assembly 4.
Page 117 10. Remove backup-up gasket (Item 12) from 5. If gear width is less than 0.636", the gear assembly front plate. should be replaced. 11. Remove bearing seal (Item 11) from front plate by 6. Be sure snap rings are in grooves on either side of prying with a sharp tool.
Page 118 Figure 23 General Auxiliary/Steering Pump Information Assembly of Back Plate Parts It is important that the relationship of the back plate 1. Install relief valve (Item 17) with new o-rings (Item 22), body (Item 14), wear plate (Item 13) and front (Item 15, 16).
Page 119 Assembly of Auxiliary/Steering Pump 6. Put wear plate (Item 13) on top of back-up gasket with bronze face up. The side with the mid section cut away 1. The wear plate (Item 13), bearing seal (Item 11), must be on suction side of pump. molded o-ring (Item 10), back-up gasket (Item 12), shaft seal (Item 5) and o-rings (Item 9) should be replaced as 7.
Page 120 Gear Pump No. 94--8297 (Fig. 23a) (S/N 70001 & Up) Figure 23a 1. O--ring 8. Washer 15. Key 2. Body asm. 9. Cap screw 16. Adaptor plate 3. Drive gear asm. 10. Shaft seal 17. O--ring 4. Wear plate 11. Washer 18.
Page 121 Repair Information 11. Remove the wear plates (4) from front plate (7) and adapter plate (16). Work in a clean area, cleanliness is extremely important when repairing hydraulic pumps. Before disconnecting 12. Remove o--rings (1) from front plate (7), adapter the lines, clean port area of pump.
Page 122 Front Plate, Backplate 4. Place balance pressure seal (6) in groove in front and Adapter Plates Inspection plate (7) and adapter plate (16). 1. Oil groove in bushings in front plate, backplate and 5. Apply a thin coat of petroleum jelly to both milled gear adapter plates should be in line with dowel pin holes and pockets of front body (2).
Page 123 This page is blank. Groundsmaster 455--D Repairs Page 4 -- 39.4 Rev. C...
Page 124: Front Traction Motor Repairs
Front Traction Motor Repairs (Fig. 24) Figure 24 1. Valve plate 7. Sleeve 13. Straight 2. Cylinder block kit 8. Roller bearing 14. End cap assembly 3. Shaft assembly 9. Housing 15. Flat washer 4. Plug 10. Thrust plate 16. Capscrew 5.
Page 125 Major Repair Figure 25 When the four (4) cap screws (Item 16) are loosened, The end cap (Item 14) can now be removed from the the internal spring loading will cause the end cap motor, however, be certain that the valve plate (Item 1) (Item 14) to separate slightly.
Page 126 Figure 26 Lift out the cylinder block assembly (Item 2). The pistons Remove thrust plate (Item 10) from counter bore in may come out of cylinder block bores. There is no motor housing (Item 9). Visually inspect both sides for special orientation of piston to bore that needs to be damage and flatness.
Page 127 Figure 27 Press shaft (Item 3) and bearing (Item 8) together, then Place the housing assembly in a horizontal position. press into housing (Item 9). Install retaining ring (Item 17) if used. Slide cylinder block assembly (Item 2) over shaft and engage spline.
Page 128 Figure 28 ® Repairs Page 4 - 44 Groundsmaster 455-D...
Page 129 Figure 29 Properly orient the end cap (Item 14) and housing (Item Place gasket (Item 11) on housing (Item 9), then install 9). Refer to previously scribed lines for assembly guide. end cap and valve plate. Hold the valve plate so it does not drop off during assembly.
Page 130: Rear Axle 4Wd Motor Repairs
Rear Axle 4WD Motor Repairs (Fig. 30) Figure 30 1. Capscrew 6. Housing 11. Spacer 2. Back plate 7. Bearing 12. Drive shaft 3. O-ring 8. Retaining ring 13. Retaining ring 4. Bearing 9. Thrust race 14. Rotating assembly 5. Cam plate insert 10.
Page 131 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.
Page 132: Lift Valve Repairs
Lift Valve Repairs (Fig. 31) Figure 31 1. Plug 14. Lock nut 27. Spring 2. Disc 15. Washer 28. Spacer 3. Spring 16. Plug 29. Retaining ring 4. Detent plunger 17. O-ring seal 30. Cap 5. O-ring seal 18. Washer 31.
Page 133 7. Remove plugs (Item 6). 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). 3. Install relief valve components (Items 22, 21, 20, 19, 18) with new o-ring (Item 17) on plug (Item 16).
Page 134: Steering Control Unit Repairs
Steering Control Unit Repair (Fig. 32) Figure 32 1. Set screw 10. Control sleeve 20. Centering pin 2. Dust seal 11. Centering springs 21. Check ball retainer 3. Retaining ring 12. Control spool 22. Check ball 4. Gland seal bushing 13.
Page 135 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.
Page 136 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.
Page 137 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 14. Remove 2 bearing races and the needle thrust bearing from spool and sleeve assembly. Figure 40 15.
Page 138 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.
Page 139 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.
Page 140 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.
Page 141 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.
Page 142 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 ...
Page 143 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 22.
Page 144 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.
Page 145 Chapter 5 Electrical System Table of Contents WIRING SCHEMATICS ..... . 2 Battery ....... . 23 Engine Crank and Start Circuit .
Page 146: Wiring Schematics
Wiring Schematics Wiring Schematics Page 5 -- 1.1 Rev. C Groundsmaster 455--D...
Page 147 Groundsmaster 455--D Page 5 -- 1.2 Rev. C Wiring Schematics...
Page 148 Wiring Schematics Page 5 -- 1.3 Rev. C Groundsmaster 455--D...
Page 149 Groundsmaster 455--D Page 5 -- 1.4 Rev. C Wiring Schematics...
Page 150: Engine Crank And Start Circuit
Wiring Schematics Engine Crank and Start Circuit (S/N 49999 and Below) ® Wiring Schematics Page 5 - 2 Rev. C Groundsmaster 455-D...
Page 151: Engine Run Circuit
Engine Run Circuit (S/N 49999 and Below) ® Groundsmaster 455-D Page 5 - 3 Wiring Schematics Rev. C...
Page 152: Engine Run And Mowing Circuits
Engine Run and Mow Circuits (S/N 49999 and Below) ® Wiring Schematics Page 5 - 4 Rev. C Groundsmaster 455-D...
Page 153: Special Tools
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.
Page 154 Skin-Over Grease Special non-conductive grease which forms a light protective skin to help waterproof electrical switches and contacts. Figure 3 ® Special Tools Page 5 - 6 Groundsmaster 455-D...
Page 155: Troubleshooting
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 CAUTION check that area, repairing one component at a time. Attempting to repair more than one system at one time Remove all jewelry, especially rings and will lead to confusion.
Page 156 Starting Problems (continued) Condition Possible Cause Correction __________________________________________________________________________________________ Nothing happens when start Battery is dead. Charge battery. Replace battery if attempt is made. it will not hold a charge. Loose or corroded battery cables. Clean and tighten or repair as Loose or corroded ground.
Page 157 Starting Problems (continued) Condition Possible Cause Correction ___________________________________________________________________________________________ Engine cranks, but does not start Injection pump ETR solenoid Clean and tighten or repair as (if engine cranks, cause of wiring loose or corroded. necessary. problem is not in interlock system). Injection pump ETR solenoid faulty.
Page 158: General Run And Transport Problems
General Run and Transport Problems Condition Possible Cause Correction __________________________________________________________________________________________ Engine continues to run (but Seat switch plunger depressed Check for seat support spring should not) when traction pedal with no operator on seat. that is broken, missing or stuck in depressed with no operator on down position.
Page 159 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 Test HI/LOW switch. Check for faulty. proper installation and operation of plunger assembly.
Page 160: Cutting Operation Problems
Cutting Unit Operation Problems Condition Possible Cause Correction __________________________________________________________________________________________ Engine continues to run (but Seat switch plunger depressed Check for seat support spring should not) when PTO switch is with no operator on seat. that is broken, missing or stuck in ON with no operator on the seat.
Page 161 Cutting Unit Operation Problems (continued) Condition Possible Cause Correction ___________________________________________________________________________________________ No cutting units Operate. 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.
Page 162 Cutting Unit Operation Problems (continued) Condition Possible Cause Correction __________________________________________________________________________________________ One wing cutting unit does not Wing switch faulty. Test switch. Replace if faulty. operate. Wing switch wiring loose, corroded Repair wiring. or damaged. Wing clutch air gap out of Check air gap and adjust if adjustment.
Page 163: Verify Interlock Operation
Verify Interlock System Operation The purpose of the interlock system is to prevent the 5. Raise off the seat and depress the traction pedal while engine from cranking or starting unless the traction engine is running and the cutting unit engagement pedal is in NEUTRAL and the cutting unit engagement switch is DISENGAGED.
Page 164: Testing
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 When testing electrical components for con trically disconnect the component being tested from the tinuity with a volt-ohm meter or continuity circuit (e.g.
Page 165: Seat Switch, Relay And Time Delay Capacitor
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.
Page 166: Traction (Neutral) Switch
Traction (Neutral) Switch The traction switch is a normally closed and opens when traction pedal is depressed in either direction. IMPORTANT: The traction switch has three (3) ter- minals. Make sure the wires are connected to the “COMMON” and “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.
Page 167: Axle Hi/Low Switch
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.
Page 168: Pto Switch
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. Figure 13 1.
Page 169: Start, Cutting Unit, Time Delay And High Temp. Relays
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...
Page 170: Glow Relay And Glow Plugs
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.
Page 171: Battery
Battery Use a hydrometer to test the battery. Charge the battery if necessary (see Battery Service). Electrolyte specific gravity Fully charged: 1.250 - 1.280 Discharged: less than 1.240 Figure 20 Injection Pump (ETR) Solenoid ® The Groundsmaster 455-D has an energize-to-run (ETR) fuel stop solenoid.
Page 172: Gauges And Indicator Lights
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 Temperature Light or if the oil pressure switch closes during operation - oil pressure below 7 psi (0.5 kg/cm...
Page 173: High Temperature Shut-Down Switch
High Temperature Shut-Down Switch 1. Lower the coolant level in the engine and remove the high temperature shut-down switch. 2. Put the switch in a container of oil with a thermometer and heat the oil. 3. The switch is normally open (N.O.) and should close at approximately 221 F (105 CAUTION...
Page 174: Engine Oil Pressure Switch
Engine Oil Pressure Switch The switch is normally closed (NC) and opens with pressure. The switch opens at approximately 8 psi. 1. Turn ignition key switch ON. Oil pressure lamp should be on. If lamp is not on: 1. Disconnect wire from switch and touch wire to a good ground, such as the engine block.
Page 175: 4Wd Solenoid
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.
Page 176 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. 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.
Page 177: Repairs
Repairs IMPORTANT: Before welding on the machine, dis connect both battery cables from the battery and disconnect the terminal connector from the alter nator to prevent damage to the electrical system. Battery Service IMPORTANT: To prevent damage to electrical com Electrolyte Specific Gravity ponents, do not operate the engine with the battery Fully charged: 1.250 - 1.280...
Page 178: Fuses
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.
Page 179: Traction (Neutral) Switch Replacement
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.
Page 180: 4Wd Solenoid Coil Replacement
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. 3. Remove coil nut. 4. Remove coil assembly. 5. Install new coil assembly and secure with coil nut. Apply “Locktite 242"...
Page 181: Wing Switch Replacement
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.
Page 182 ® Repairs Page 5 - 34 Groundsmaster 455-D...
Page 183 Chapter 6 Axles and Brakes Table of Contents SPECIFICATIONS ......2 REPAIRS ....... . . 8 GENERAL INFORMATION .
Page 184: Specifications
Specifications Item Specification __________________________________________________________________________________________ Tire pressure 20 PSI front and rear ________________________________________________________________________________________________________________________________________________________ Wheel bolt torque 85 - 100 ft-lb rear, 45 - 55 ft-lb front ________________________________________________________________________________________________________________________________________________________ Front axle hub nut torque 300 - 350 ft-lb ________________________________________________________________________________________________________________________________________________________ Transaxle adapter plate screw torque 65 ft-lb ________________________________________________________________________________________________________________________________________________________ Front axle housing cap screw torque...
Page 185: General Information
General Information 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 Locked 49 RPM one for the rear axle. The drive for the rear axle incor...
Page 186: Special Tools
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.
Page 187 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 –...
Page 188: Adjustments
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”...
Page 189: Transaxle Shift Linkage Adjustment
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 Low position 1.2 - 1.3 in.
Page 190: Repairs
Repairs Wheel Bearing Service (2WD Rear Axle) 1. Jack up rear of machine until tire is off the floor. 7. Use No. 2 general purpose lithium base grease Support machine with jack stands or blocks to prevent containing E.P. additive. Pack both bearings with it from falling.
Page 191 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.
Page 192: Front Axle Removal And Disassembly
Front Axle Removal and Disassembly Figure 17 Install belleville washers (Item 28) as shown Figure 18 ® Repairs Page 6 - 10 Groundsmaster 455-D...
Page 193 Front Axle Removal 5. Remove brake disks (Item 4) and brake actuator (Item 5). 1. Drain oil from transaxle. 6. Remove adapter plate (Item 2) and transaxle spacer 2. Jack up front of machine and support chassis frame (Item 1). with jack stands.
Page 194: Transaxle Service
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. Figure 19 Figure 20 ® Repairs Page 6 - 12 Groundsmaster 455-D...
Page 195 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 1.
Page 196: Rear 4Wd Axle Service
Rear 4WD Axle Service Axle Housing ( Axle Housing ( Figure 23 Figure 24 ® Repairs Page 6 - 14 Groundsmaster 455-D...
Page 197 Disassembly The two gear cases, right and left can be removed from the housing without requiring the entire axle to be dis assembled. 1. Remove tie rod by disconnecting rod end ball joint on each end. Disconnect hydraulic cylinder rod end from drag link arm.
Page 198 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: 5. Remove differential gear assembly (Fig. 23, Items A.
Page 199 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.
Page 200 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. 43 ± 0.05mm Cone center specification (1.69 ± 0.002 in.) Shim stock for this adjustment is available in the follow ...
Page 201 Adjusting Backlash 0.25 ∼ 0.35 mm Backlash specification (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.)
Page 202 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: 2.5 ∼ 3.0 kg-m Torque specification (18 ∼...
Page 203 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.
Page 204 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.
Page 205 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.
Page 206 ® Repairs Page 6 - 24 Groundsmaster 455-D...
Page 207 Chapter 7 System (Power Take-Off) Table of Contents SPECIFICATIONS ......2 PTO Drive Pulley and Bearing Service ..7 SPECIAL TOOLS .
Page 208: Specifications
Special Tools Order special tools from TORO SPECIAL TOOLS AND Some tools may be listed in the Groundsmaster 455-D APPLICATIONS GUIDE (Commercial Products) . Parts Catalog. Tools may also be available from a local supplier.
Page 209: Adjustments
Adjustments PTO Belt Adjustment 1. Remove (2) screws securing PTO belt cover to adapt er plate and (1) screw securing belt cover to tab on spring anchor. Remove cover. Figure 1 1. PTO belt cover 2. Adapter plate 2. Loosen (3) flange screws and flange nuts securing adapter plate to clutch plate.
Page 210: Pto Clutch Adjustment
PTO Clutch Adjustment 1. To adjust clutch, tighten or loosen locknuts on flange studs. 2. Check adjustment by inserting feeler gauge through slots next to flange studs. 3. The proper disengaged clearance between the clutch plates is 0.011 - 0.021 inches. It will be necessary to check this clearance at each of the three slots to ensure the plates are parallel to each other.
Page 211: Repairs
Repairs PTO Belt Replacement 1. Remove (2) screws securing PTO belt cover to adapt er plate and (1) screw securing belt cover to tab on spring anchor. Remove cover. Figure 4 1. PTO belt cover 2. Adapter plate 2. Remove tension on belt by loosening three (3) flange screws and flange nuts securing adapter plate to clutch plate.
Page 212 45 ft-lb NOTE: Always use new coupler flange head screws (Items 2 and 6) when repairing PTO systems. Install with steel shell toward spline Index to get wrench clearance for hex flange screws (Item 6) 150 - 200 ft-lb 45 ft-lb Figure 6 1.
Page 213: Engine Coupling Service
Engine Coupling Service 1. Remove three (3) flange head screws (Fig. 6, Item 6) 5. Install grease seal (Item 10) so steel shell is towards securing driveshaft (Item 13) to rubber coupling spline. secure seal in place with retaining ring (Item 9). (Item 8).
Page 214: Pto Clutch Removal And Installation
PTO Clutch Removal and Installation NOTE: Always use new coupler flange head screws (Items 2 and 6) when repairing PTO systems. 150 - 200 ft-lb 28 27 Apply Never- Seez to bore 35 - 40 ft-lb 21 22 23 24 45 ft-lb Apply Never-Seez to spline and bearing mount...
Page 215 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 P.T.O.
Page 216: Lower Pulley And Bearing Service
Lower Pulley and Bearing Service NOTE: Always use new coupler flange head screws (Items 2 and 6) when repairing PTO systems. 150 - 200 ft-lb 28 27 Apply Never- Seez to bore 35 - 40 ft-lb 21 22 23 24 45 ft-lb Apply Never-Seez to spline and bearing mount...
Page 217: Pto Shaft And Bearing Service
6. Use a press to remove pulley (Item 17). 11. Use a press to push the lower bearing housing and bearings onto the lower pulley (Item 17). Press on 7. Use a puller to remove bearings (Item 16). Remove INNER race of bearing. bearing spacer (Item 15).
Page 218: Driveshaft Removal And Installation
Driveshaft Removal and Installation 1. To prevent possible PTO engagement, disconnect wire harness connector. Figure 11 1. Wire harness connector 2. Remove socket head capscrews securing driveshaft yoke to gearbox input shaft. 3. Slide yoke off of gearbox input shaft. Figure 12 1.
Page 219: Driveshaft Universal Joint Replacement
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.
Page 220: Pto Clutch Service
PTO Clutch Service Figure 15 1. Retaining ring 5. Armature ass’y (Items 1, 2, 4, 5) 8. Field rotor ass’y (Items 6, 7, 8) 2. Bearing 6. Field coil assembly 9. Spring 3. Brake plate 7. Field bearing 10. Locknut 4.
Page 221 Chapter 8 Cutting Unit Table of Contents SPECIFICATIONS ......2 Inspecting and Sharpening Blade ... 16 GENERAL INFORMATION .
Page 222: Specifications
Specifications Item Specification ________________________________________________________________________________________________________________________________________________________ Cutting width 126" 54" center section 36" each wing 90" with one wing up ________________________________________________________________________________________________________________________________________________________ Height of cut range 1" - 5" ________________________________________________________________________________________________________________________________________________________ Height of cut adjustment 1/2" increments ________________________________________________________________________________________________________________________________________________________ Blade bolt torque 85 - 110 ft-lb ________________________________________________________________________________________________________________________________________________________ Spindle nut torque 150 - 170 ft-lb...
Page 223: General Information
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.
Page 224: Adjustments
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.
Page 225 Front Castor Wheels 1. Remove lynch pin from spindle shaft and slide spindle out of front castor arm. Slide spacers onto spindle shaft to get desired height of cut. 2. Push castor spindle through front castor arm install remaining spacers onto spindle and install lynch pin to secure assembly.
Page 226: Safety Door Adjustment
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.
Page 227: Blade Adjustment
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.
Page 228: Belt Tension Adjustment
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"...
Page 229: Repairs
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.
Page 230: Mounting Cutting Unit To Traction Unit
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.
Page 231: Drive Belt Replacement
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.
Page 232: Belt Routing
To Remove Center Deck Belt 14. While holding idler pulley adjuster in position, care fully remove capscrew securing idler adjust or tube to 6. Wing deck belts must be removed before center deck tube sleeve. Allow idler pulley to release, tensioning belt can be removed, repeat steps 1 - 3 on previous belt.
Page 233: Front Castor Arm Bushing Service
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.
Page 234: Castor Wheel And Bearing Service
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.
Page 235: 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 ...
Page 236: Inspecting And Sharpening Blade
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.
Page 237: Blade Spindle Service
Blade Spindle Service Removing Spindle and Bearings From Spindle Housing 1. Lower the cutting unit, shut the engine off and engage the parking brake. 2. Remove deck covers from top of cutting unit. Release belt tension (see Belt Tension Adjustment). 3.
Page 238 6. Remove the hex flange head screws (Item 8) and lock nuts (Item 10) securing spindle housing to deck. Slide 150 - 170 ft-lb spindle housing assembly out the bottom of the cut ting unit. 7. Remove the nut (Item 2) and washer (Item 18) retaining the spindle pulley or clutch on the spindle shaft.
Page 239 Installing Spindle, Bearings 10. Slide the pulley end of the spindle assembly through and Seals Into Spindle Housing the hole in the cutting unit. Mount the spindle assembly in place with the eight (8) hex flange head bolts and IMPORTANT: If a new spindle housing is being used, flange nuts.
Page 240: Gearbox Removal And Installation
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. 2.
Page 241 Installing Gearbox and Drive Pulley 6. Secure front of gear box support to deck channels with capscrews and nuts. Tighten capscrews and nuts 1. If replacing rubber mounts for gearbox support, use securing rear of gearbox support to deck channels. soapy water or lubricant to ease installation.
Page 242: Gearbox Repair
Gearbox Repair Figure 33 Gear Box Disassembly 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 1. Drain lubricant from gear box. driver or chisel. Be careful not to damage the bore. 2.
Page 243 13 11 Figure 34 Gearbox Pre-Assembly 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. 9. Install shaft through outer end of hub so bearing cone on shaft mates with bearing cone in hub.
Page 244 13 11 Figure 35 Gearbox Final Assembly 5. Gear lash is adjusted by amount of gaskets (Item 7) used between hub (Item 17), and housing machined 1. Bearing drag for input shaft (Item 8) is adjusted by surfaces. amount of gaskets (Item 7) used between thru cap (Item 14), and housing machined surfaces.
Page 245: Deck Clutch Service
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).
Page 246: Wing Pivot Arm Installation And Ball Joint Service
Wing Pivot Arm Installation and Ball Joint Service When assembling wing pivot arms, adjust ball joint IMPORTANT: Before installing wing pivot arms, thread engagement to get a length of 8.06" for proper clean tapered surfaces of ball joints and mounting blade plane setting, then tighten jam nut (also see Blade bosses on deck with solvent degreaser.
Page 247: Safety Door Service
Safety Door Service When assembling safety door actuator, adjust threaded After installing actuator, adjust threaded rod so lower rod to get a dimension of 6.25" between center of each edge of door is even to 0.25" higher than lower edge of ball joint.
Page 248: Wing Cylinder Installation And Ball Joint Service
Wing Cylinder Installation and Ball Joint Service When assembling wing cylinders, adjust ball joint thread IMPORTANT: Before installing wing cylinders, clean engagement to get a retracted length of 17.00" to elimi- tapered surfaces of ball joints and mounting bosses nate movement of wing decks in the fully raised (trans- on deck with solvent degreaser.
Page 249: Center Deck Lift Arm Ball Joint Service
Clean tapered surfaces of all ball joints and mounting bosses with solvent degreaser If more than 0.34" Clean tapered surfaces of ball joint stud extends of all ball joints and through nut, add mounting bosses with washers as needed solvent degreaser Loctite 242 150 - 180 ft-lb 2.50"...
Page 250: Idler Pulley Service
Idler Pulley Service Apply Loctite 242 or equivalent to threads of bolt secur- Make sure center idler pulley on center deck is installed ing idler pulley to deck. Tighten bolt to a torque of 35 to in hole closest to edge of pulley support. Install in 40 ft-lb.
Page 251: Wing Deck Spring Loaded Locking Mechanism Service
These parts 2. Place rod cap on bracket so large end is facing spring must be used for the following procedure. Order Toro support rod and install socket head screw. Parts 92-4036, Cap – Rod and 92-4037, Screw – Hex Socket Hd.
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Toro Groundsmaster 455-D Service Manual

Table of Contents

Chapter 1 - Safety

Chapter 2 - Product Records and Manuals

Chapter 3 - Peugeot XUD9 Diesel Engine

Chapter 6 - Axles and Brakes

Chapter 4 Hydraulic System

Chapter 8 - Cutting Unit

Chapter 5 Electrical System

Chapter 6 Axles and Brakes

Chapter 7 Pto System (Power Take-Off)

Chapter 8 Cutting Unit

Quick Links

Service Manual

Chapters

Troubleshooting

Related Manuals for Toro Groundsmaster 455-D

Summary of Contents for Toro Groundsmaster 455-D

Table of Contents