• Toro Groundsmaster 328d Parts Manual

. Commercial ProductsTroubleshooting GuideGroundsmaster345/325-DPart No.

Product Overview GM 325-D/GM 3452. Ford VSG-411 Gas Engine (GM 345)3. Mitsubishi K3D Diesel Engine (GM 325-D)4. Hydraulic SystemsHydrostatic Drive Systems5. Electrical Systems6. Cutting Unit Drive7.

TORO GM 345 / 325 - DProduct Overview1Product OverviewGM 300 series Groundsmaster®®The Groundsmaster® 300 series mower is a medium size, maneuverable, commercial rotary with over twentyyears of mowing experience. During those years its design has been continuously improved for optimumproductivity and durability.GM 345Features1. Ford 4 cylinder gas engine (45hp).2.

Sunstrand series M15 inline variable speed hydrostatic drive.3. Hydraulic power steering and lift functions4. Available in 2wd.

2Product OverviewTORO GM 345. TORO GM 345 / 325 - DProduct Overview3Attachments1. 72” Side discharge mower deck.2. 72” Rear discharge mower deck.3. 72” Guardian® Recycler® deck.4. 88” Triflex® mower deck.5.

48” Snowblower6. Debris blower7. Plug pulverizer9. 4Ford VSG-411 Gas EngineTORO GM 345. TORO GM 345Ford VSG-411 Gas Engine 5In this section we will look at some troubleshooting procedures for the Ford Gas Engine.Engine IdentificationThe engine is identified with a decal affixed to the left side of the valve cover.The decal contains the engine serial number.The model number and displacement. 411 = 4 cyl 1.1 liter)The special options (S.O.) number.The engine is also stamped on the left rear top edge of the block.This stamping includes:A - Serial number.B - Engine Code.

6Ford VSG-411 Gas EngineTORO GM 345. TORO GM 345Ford VSG-411 Gas Engine 7Troubleshooting:High and Low Idle Checks.The idle settings are important for the proper operation and long life of the machine.Affects of incorrect idle speeds:1. High idle too slow:.Low power. (engine not running at full speed).Slow transport speed. (hydrostatic transmission input shaft speed too slow).Poor Quality of cut.

(Blade RPM and tip speed too slow)2. High idle too fast:.Internal engine damage. 8Ford VSG-411 Gas EngineTORO GM 345. TORO GM 345Ford VSG-411 Gas Engine 9Correction:Carburetor linkage adjustment.1. With the engine shut off, move the throttle control to the FAST position.2. Check the gap between the throttle arm and the stop on the carburetor base. The correct gap is 1/32”(0.78mm).3.

If the gap is not correct adjust the throttle rod by turning the ball joint until the proper gap is attained. 10 Ford VSG-411 Gas EngineTORO GM 345. TORO GM 345Ford VSG-411 Gas Engine 11The final adjustments are made with the engine running. To guard againstpossible personal injury, engage the parking brake and keep hands, feet, faceand other parts of the body away from the fan or other moving parts.Low Idle Adjustment.1. Start the engine and move the throttle to the slow position.2. Manually rotate the throttle arm closed until it contacts the stop.3.

12 Ford VSG-411 Gas EngineTORO GM 345. TORO GM 345Ford VSG-411 Gas Engine 13High Idle Adjustment.1. Slowly move the throttle to the FAST position until the engine reaches 3200 ± 100. Shut off the engine.Adjust the high speed adjustment screw until it contacts the speed control lever.IMPORTANT: Do not overspeed the engine because transmission damaged could occur.2.

If 3200 rpm can not be attained, check the throttle cable adjustment. The governor arm must not contact the cable cover when the unit is at high idle. 14 Ford VSG-411 Gas EngineTORO GM 345. TORO GM 345Ford VSG-411 Gas Engine 15Anti-Surge Adjustment.1.

Move the throttle rapidly from SLOW to FAST. The engine should not surge, if the engine surges proceed tostep 2.2. Check the V-belts from the engine to the governor pulley and assure that they are tight.The belt is adjusted to 45 lbs of tension on a belt gauge for a new belt.A used belt is re-tensioned to 28 lbs.The replacement belt PN is 67-8510.3. Loosen the jam nut that retains the anti-surge screw. 16 Ford VSG-411 Gas EngineTORO GM 345. TORO GM 345Ford VSG-411 Gas Engine 17Cylinder Leakage Test.The cylinder leakage test can locate the following problems:1.

Leaking intake valves.Air leaking from carburetor.2. Leaking exhaust valves.Air leaking from muffler.3. Leaking cylinder head gaskets.Air leaking externally by head gasket.4. Worn piston rings.Air leaking from breather or dipstick tube.NOTE. There will always be some air leakage past the rings. Use the tester gauge to determine the severity ofthe leak. 18 Ford VSG-411 Gas EngineSpecial toolsTORO GM 345Helpful Hints1.

Electric tach. OTC P/N - OEM1386 or equivalent.1. All engine RPM checks should be performedwith the engine warm.2.

Photo tach. OTC P/N - OEM1057 or equivalent.2. Governor oil is the same oil as is used in thecrankcase3.

Belt tension gauge. OTC P/N - OEM1294 or equivalent3. Cylinder leakage can identify the location andthe extent of an internal engine problem.Cylinder leakage of 25 percent or less isacceptable4. TORO GM 345Ford VSG-411 Gas Engine 19Review Questions1.

Proper high idle setting is:4. Normal engine compression is:a.b.c.d.a.b.c.d.2800 ± 50 RPM3200 ± 100 RPM3000 ± 25 RPM1500 ± 100 RPM2.

The final high idle adjustment is made at thecarburetor.a. False100 PSI205 PSI185 PSI415 PSI5. Adding oil to a cylinder with a bad intake valvewill increase the compression reading of thecylinder.a. The recommended compression gauge is:a.b.c.d. 20 Mitsubishi K3D Diesel EngineTORO GM 325-D.

TORO GM 325-DMitsubishi K3D Diesel Engine 21In this section we will look at some troubleshooting procedures for the Mitsubishi Diesel Engine.Engine IdentificationThe engine model number and serial number is listed on a decal on the valve cover.The engine serial number is also stamped on the injection pump mounting surface.Complaint: Low engine powerAffect:1.2.3.4.5.Poor cutting unit performance.Poor hill climbing ability.Slow hydraulic response.Slow throttle response. 22 Mitsubishi K3D Diesel EngineTORO GM 325-D.

TORO GM 325-DMitsubishi K3D Diesel Engine 23Analyzing Diesel Exhaust Smoke.The exhaust from a diesel engine can provide information about the running condition of the engine. A normallyoperating engine will have exhaust that is clear to a slight brownish/gray color.1. Black Smoke.Insufficient air.(Plugged or dirty air filter).Excessive fuel.(Leaking injection nozzles)(Over fueled injection pump setting).Engine Overloaded.(Excessive load on engine)2. 24 Mitsubishi K3D Diesel EngineTORO GM 325-D. TORO GM 325-DMitsubishi K3D Diesel Engine 25TroubleshootingCylinder Leakage Test.A cylinder leakage test may be performed if the test equipment is available.The leakage test can locate:1. Leaking intake valve.Air leaking from the air filter or intake manifold.2.

Leaking exhaust valve.Air leaking from the muffler.3. Piston rings not sealing properly.Air leaking from crankcase breather or dipstick tube.

26 Mitsubishi K3D Diesel EngineTORO GM 325-D. TORO GM 325-DMitsubishi K3D Diesel Engine 27Troubleshooting:High and Low Idle Checks.The idle settings are important for the proper operation and long life of the machine.Affects of incorrect idle speeds:1. High idle too slow.Low power. (Engine not running at full speed).Slow transport speed.

(Hydrostatic transmission input shaft speed too slow).Poor Quality of cut. (Blade RPM and tip speed too slow)2. High idle too fast.Internal engine damage.

28 Mitsubishi K3D Diesel EngineTORO GM 325-D. TORO GM 325-DMitsubishi K3D Diesel Engine 29Injection Nozzles.The diesel engine requires that the fuel be sprayed into the combustion chamber, at a precise point in thecompression stroke. The point at which this fuel injection occurs is the injection timing.

If the nozzle is defective,damaged, or adjusted incorrectly, the injection timing can be affected. This can cause hard starting, low poweroutput, excessive smoke or engine knocking.IMPORTANT: Always use fresh filtered fuel in the nozzle tester.

30 Mitsubishi K3D Diesel EngineTORO GM 325-D. TORO GM 325-DMitsubishi K3D Diesel Engine 311. Nozzle Leakage Test.The leakage test checks the nozzle tip for proper sealing.A leaking nozzle should be repaired or replaced.2.

Toro Groundsmaster 328d Parts Manual

Operate the pump until 1500 psi (108 kg/cm²) is reached, maintain this pressure.3. Check the nozzle end.If the nozzle end is dry or a slight film of fuel is present, the nozzle is OK.If a drop of fuel forms or the nozzle drips fuel, the nozzle must be serviced or replaced. 32 Mitsubishi K3D Diesel EngineTORO GM 325-D. TORO GM 325-DMitsubishi K3D Diesel Engine 331. Nozzle spray Test.The ability of the nozzle to correctly atomize the fuel can be checked by performing a nozzle spray test.Pump the nozzle tester and watch the spray pattern.A solid stream or large droplets indicates a faulty nozzle.Fuel should be well atomized and in a consistent spray pattern.Leaking injection nozzles can cause:1.2.3.4.5.6.Hard starting.Excessive smoke.Low power.Engine knocking.Injection pump damage.

34 Mitsubishi K3D Diesel EngineTORO GM 325-D. TORO GM 325-DMitsubishi K3D Diesel Engine 35Glow Plug Testing.The diesel engine requires glow plugs to warm the combustion chamber to assist in starting. Evidence of faultyglow plugs includes: hard starting, excessive smoke, or engine knocking.There are several ways to test glowplugs.The resistance of the glow plug can be measured with an Ohmmeter.Normal resistance is 2 to 3 ohms.0 ohms indicates a shorted glow plug.An O.L. Reading on the ohmmeter indicates an open circuit in the glow plug. 36 Mitsubishi K3D Diesel EngineSpecial ToolsTORO GM 325-DService Tips1. Photo tach.

OTC P/N - OEM1057 or equivalent.1. All engine RPM checks should be performedwith the engine warm.2. Belt tension gauge. OTC P/N OEM1294 or equivalent2. Cylinder leakage can identify the location andthe extent of an internal engine problem.Cylinder leakage of 25 percent or less isacceptable3.

Cylinder leakage tester. OTC P/N TOR4075 or equivalent.4.5.Compression tester.0 - 1000 psi. TORO GM 325-DMitsubishi K3D Diesel Engine 37Study Questions1. Blue exhaust smoke indicates:4. Cylinder leakage of 50% is acceptablea.b.c.d.a. FalseExcessive fuelwater in the combustion chamber.High oil consumption.Excessive engine load.5. Maximum injection nozzle opening pressure is:2.

When performing a compression test, add oil tothe pistons before the testa. Proper low idle setting is:a.b.c.d.1000 ± 1001000 ± 501500 ±1001500 ± 50a.b.c.d. 38 HydraulicsHydrostatic Charge CircuitTORO GM 345 / 325-D. TORO GM 345 / 325-DHydraulics 39Hydrostatic Drive and Hydraulic SystemsThe drive system on the Groundsmaster® 300 series consists of a Sunstrand® Series 15, inline hydrostaticpump and motor assembly. This assemble is connected to a Dana® GT-20 axle/differential assembly.Engine power is transmitted from the engine to the input shaft of the hydrostatic unit. The output of thehydrostatic unit transmits the power to the pinion shaft, through the differential and to the wheels.

40 HydraulicsDrive circuitTORO GM 345 / 325-D. TORO GM 345 / 325-DHydraulics 41Drive CircuitThe drive circuit consists of a variable displacement pump and the hydrostatic motor.Drive circuit operation.1.

When the traction pedal is depressed the swash plate in the pump rotates and the pump begins to pump.2. The oil from the pump flows to the hydrostatic motor.3. The oil flows through the hydrostatic motor and returns to the pump.

(The oil flows in a closed loop).There is a bypass valve located in the drive circuit. 42 HydraulicsAcceleration valvesTORO GM 345 / 325-D. TORO GM 345 / 325-DHydraulics 43Acceleration valves1. The drive oil from the hydrostatic pump also flows to the acceleration valves.2.

The oil is allowed to flow through the orifice in the valve, until sufficient pressure is created to close theacceleration valve.3. Bleeding away some of this initial oil flow allows for a smoother unit start and direction change.4. The acceleration valves do not serve as the drive circuit relief valve.5. The 2 wheel drive unit does not have a relief valve. 44 HydraulicsTORO GM 345 / 325-D. TORO GM 345 / 325-DHydraulics 45TroubleshootingTo test the hydrostatic system there are several test ports on the hydrostatic unit.1.

Charge pressure test port, (located on the left side rear of the hydrostatic unit, next to the steering and liftsupply line).2. Forward and reverse drive pressure test ports, (located in the middle section of the hydrostatic unit). Forward drive is the RH test port. Reverse drive is the LH test port.

46 HydraulicsDrive Pressure TestTORO GM 345 / 325-D. TORO GM 345 / 325-DHydraulics 471. Testing drive pressure.Remove the test port plug using a 3/16” allen wrench.Connect 10,000 psi gauge into the test port using a 3/8 - 24 adapter.Chain machine and lock brakes.Operate engine at 3200 RPM.2WD, drive pressure should read 4000-4500 psi. (DO NOT exceed 5000 psi).4WD, drive pressure should read 5200 psi.Low drive pressure. (Charge pressure “OK”)2. Possible causes.Leaking check valves.Leaking acceleration valves.

48 HydraulicsCharge Flow TestTORO GM 345 / 325-D. TORO GM 345 / 325-DHydraulics 491. Testing charge flow.Connect hydraulic flow meter.Operate engine at 3200 RPM.Restrict oil flow through flow tester. Should be able to read 1GPM at 700 PSI.Low charge flow (charge pressure “OK”)2.

Possible causes:.Leaking implement relief valve.Worn drive pump.Worn drive motor.3. Performance results:.Slow steering response.Slow hydraulic response.System overheating. 50 HydraulicsTORO GM 345 / 325-D.

TORO GM 345 / 325-DHydraulics 51Steering Circuit1. Oil from the hydrostatic charge pump flows to the IN port of the steering valve.2. With the steering wheel in neutral the oil flows out the AUX port to the lift valve.3. When the steering wheel is turned to the right the AUX port is closed and oil is director out the RT port to thesteering cylinder.NOTE: The steering valve will not allow oil to flow through it to the lift valve when the steering wheel is beingturned.

52 HydraulicsTORO GM 345 / 325-D. TORO GM 345 / 325-DHydraulics 53Cutting Unit Lift Circuit.1. When the steering wheel is in neutral, oil flows out of the AUX port to the lift valve.2. When the valve is in neutral oil flows through the valve, to the oil cooler, and then to the reservoir.3.

When the lift valve is actuated, oil is directed to the lift cylinder. 54 HydraulicsSpecial ToolsTORO GM 345 / 325-DService Tips1. Hydraulic flow tester kit.

OTC P/N TOR214678 or equivalent1. Hydraulic testing is done with the hydraulic oilat normal operating temperature.2.

Hydraulic pressure test kit. OTC P/N TOR47009 or equivalent2. Before testing hydraulics check the system forthe proper oil level and fluid type.3. Check or replace the hydraulic filter to eliminatethe possibility of a plugged filter. TORO GM 345 / 325-DHydraulics 55Study Questions1. All hydraulic and hydrostatic test should beconducted with the oil warm.a. The acceleration valves prevent:a.b.c.d.Abrupt direction changeExcessive drive pressureLoss of charge pressureExcessive travel speed2.

Proper engine RPM for hydraulic testing is:5. Drive pressure is tested with a:a.b.c.d.1500 RPM2000 RPM3000 RPM3200 RPM3. Proper maximum drive pressure for a 2wd unitis:a.b.c.d. 56 Electrical SystemsTORO GM 345 / 325-DStart Circuit123PositionOFFONSTARTCircuitNONEB+I+AB+I+sMakeX+Y. TORO GM 345 / 325-DElectrical Systems 57Electrical System(GM 345 / 325-D)The electrical system on the 300 Series Goundsmaster can be broken into the following circuits:1.2.3.4.Starting/Charging.Safety Interlock.Gauges and warning.Engine.With a basic understanding of these circuits we can troubleshoot a variety of electrical problems.System OperationStart Circuit. (GM 345 Shown, 325-D similar)1.2.3.4.5.6.7.8.Power from the battery flows to the (-) terminal of the ammeter.

58 Electrical SystemsTORO GM 345 / 325-DInterlock Circuit123PositionOFFONSTARTCircuitNONEB+I+AB+I+sMakeX+Y. TORO GM 345 / 325-DElectrical Systems 59Interlock CircuitNormal Operation.1.2.3.4.With an operator in the seat and the PTO engaged, the PTO switch opens.Current flows through the seat switch to the “A” terminal of the ignition switch.In the run position, the power flows from the “A” terminal to the “I” terminal.From the “I” terminal power flows to the ignition system.

60 Electrical SystemsTORO GM 345 / 325-DInterlock Circuit123PositionOFFONSTARTCircuitNONEB+I+AB+I+sMakeX+Y. TORO GM 345 / 325-DElectrical Systems 61PTO Engaged, Operator Not In The Seat.1.2.3.4.If the operator leaves the seat while the PTO is engaged.Power is interrupted by the seat switch.Current stops flowing to the “A” terminal of the ignition switch.Power is stopped to the ignition module and the engine stops.Caution: Do not disconnect the safety switches because they are there for the operators protection. 62 Electrical SystemsTORO GM 345 / 325-D. TORO GM 345 / 325-DElectrical Systems 63Interlock System TestingPTO Switch and Traction Neutral Switch Testing.1. Move the PTO switch to the OFF position.2. Remove foot from the traction pedal so it is fully released.3. Rotate the ignition key to start.

Engine should crank.If the engine does not crank, there may be a malfunction in the PTO or Neutral switch. 64 Electrical SystemsTORO GM 345 / 325-D. TORO GM 345 / 325-DElectrical Systems 65Seat Switch and Traction Neutral Switch Testing1.

Raise off the seat and engage the PTO switch while the engine is running.2. The engine should stop within 2 seconds.If the engine stops, the switch is operating correctly.If the engine does not stop, there is a problem in the seat switch of the PTO switch.1. Raise of the seat and depress the traction pedal with the PTO disengaged.2. The engine should stop within 2 seconds. 66 Electrical SystemsTORO GM 345 / 325-D.

TORO GM 345 / 325-DElectrical Systems 67Electrical circuit breaker.The GM325 electrical system has a 40 amp circuit breaker to protect the electrical system from overload.If all electric functions are lost, resetting the circuit breaker might remedy the problem.If the circuit breaker open frequently the source of the problem must be found and repaired. 68 Electrical SystemsSpecial Tools1. Digital volt, ohm meter.OTC PN. OEM1428 or equivalent2. Electrical “skin over grease”OTC PN. TOR50547TORO GM 345 / 325-DHelpful Hints1.

Interlock switches. Neutral switch closed with traction pedal inneutral. PTO switch closed with PTO disengaged. Seat switch open with no operator in the seat2. Unit will start without an operator in the seat, ifthe PTO is disengaged and the traction pedal isin neutral.3.

TORO GM 345 / 325-DElectrical Systems 69Review Questions1. How many interlock switches does the unituse?4. The diesel unit has a resetable 40 amp breakerin the circuita.b.c.d.a. The engine should start with the cutting unit ingear2. The neutral switch is:a.

Open when the traction pedal is depressedb. Closed when the neutral switch is depresseda. The unit will start with the operator out of theseat.a. 70 Cutting Unit DriveTORO GM 345 / 235-D. TORO GM 345 / 325-DCutting Unit Drive71Attachment Drive (PTO)GM325/GM345Pto Operation1. The power take-off (PTO) system transmits power from the engine to the cutting deck or other implementattached to the front of the machine.2.

The PTO lever has two positions: ON (engage) and OFF (disengage). To engage the PTO shaft, slowlypush the PTO lever fully forward to the ON position; this will start the implement or cutting unit blades. 72 Cutting Unit DriveTORO GM 345 / 235-D. TORO GM 345 / 325-DCutting Unit Drive73Troubleshooting1. Poor cutting unit performance:.Drive belt slipping.Tighten the drive belt.Adjust PTO belt tension spring to 3 3/16 in.(80.96 mm).2.

Drive belt failure:.Improper belt alignment.Align drive belt.NOTE: See the operators manual or the service manual for the complete adjustment procedure. 74 Cutting UnitsTORO GM 345/325-D. TORO GM 345/325-DCutting Units75Cutting UnitsMaintenance and ServiceSpindle serviceIf noisy operation of the cutting unit is encountered and the blade spindles need to be repaired, refer to thecomplete repair procedures in the service manual.The replacement bearing set consists of:1. The upper and lower bearings races.2. A snap ring spacer that positions the bearing races in the spindle housing.3.

An outside spacer to set the distance between the bearing races.4. Two bearings.5. 76 Cutting UnitsTORO GM 345/325-D. TORO GM 345/325-DCutting Units77Quality Of CutInspecting and Sharpening Rotary Mower BladesRotary mowers cut grass by the blade’s cutting surface impacting against the grass stems at a high velocity. Toassure good quality of cut, the cutting edge of the blade must be kept in a sharp condition. A dull blade willproduce a ragged cut and will require an excessive amount of engine horsepower to rotate the blade through thegrass.

78 Cutting UnitsTORO GM 345/325-D. TORO GM 345/325-DCutting Units79Mismatch cut.When a mismatch condition occurs the blade tip height should be checked.It the blade tip height is different, the blades will cut at a different height and the grass will be uneven.Another quality of cut problem is striping.Striping can be caused by the mower blades being sharpened too much that the actual blade length is shorter.This causes a small line of uncut grass to be left between the bladesInconsistent height of cut. 80 Cutting UnitsSpecial tools1. Blade balancing toolOTC PN. TOR4029 or equivalent2.

Blade holding fixtureOTC PN. TOR4030 or equivalent3.

Portable bench grinderOTC PN TOR4031 or equivalentTORO GM 345/325-DHelpful Hints1. Fill the spindle bearing housing with greasewhen replacing the bearings. (This assures thatthe upper bearing gets grease when the spindleis greased).2.

The small inside spacer ring does not have agroove in the spindle to sit in. TORO GM 345/325-DCutting Units81Review Questions1. Bearings and spacers should be replaced as aset4. Balancing the blade after sharpening is notnecessary.a.

The drive belt engagement spring should beadjusted to a length of:5. The small spacer ring fits in a groove in thespindle shaft.a.b.c.d.a.

False2 1/4 inches3 3/16 inches1 1/2 inches4 inches3. The cutting unit raise/lower lever should be inthe neutral position when mowing6. Commercial productsFORM 96-904-SL© The Toro Company - 1996Printed in U.S.

What Chainsaw is Right for You? There are three general categories of chainsaw that include the Trimming Saw, the Ground Saw and the Multi-purpose Saw. Within each category, a brand may have homeowner, mid-duty and commercial versions. Trimming Saws are compact and light. Homeowner versions are less expensive and designed for occasional use trimming branches while your feet are on the ground. Commercial versions are more expensive, more powerful and designed for 8-hour/day usage while climbing in a tree-top.

Ground Saws are the big, heavy, high-powered saws designed for felling large trees and cutting-up the trunks. Multi-purpose Saws are capable of felling many trees while still light enough to swing around to take the branches off the tree while it is on the ground. Neither the Ground Saw nor the Multi-purpose Saw belong in the standing tree-top. Choose between homeowner, mid-duty and commercial by how often and how hard you will use the saw. If you and your wife will use it in the backyard 2-3 times a year for maintenance, get a homeowner grade.

If you are putting it in the truck for your survey crew to use daily for light clearing consider a mid-duty and if you have 10-acres of forest to clear using a crew, get a commercial grade saw. Finally, select the bar/chain combination for the size of trees/branches you will be cutting.