Toro GROUNDSMASTER 325-D Troubleshooting Manual
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Toro GROUNDSMASTER 325-D Troubleshooting Manual

Commercial rotary mower
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Commercial Products
Groundsmaster
®
345/325-D
Part No. 96904SL

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Summary of Contents for Toro GROUNDSMASTER 325-D

  • Page 1: Troubleshooting Guide

    Commercial Products Troubleshooting Guide Groundsmaster ® 345/325-D Part No. 96904SL...
  • Page 2 INDEX 1. Product Overview GM 325-D/GM 345 2. Ford VSG-411 Gas Engine (GM 345) 3. Mitsubishi K3D Diesel Engine (GM 325-D) 4. Hydraulic Systems Hydrostatic Drive Systems 5. Electrical Systems 6. Cutting Unit Drive 7. Cutting Units...

  • Page 3: Product Overview

    TORO GM 345 / 325 - D Product Overview Product Overview GM 300 series Groundsmaster The Groundsmaster 300 series mower is a medium size, maneuverable, commercial rotary with over twenty years of mowing experience. During those years its design has been continuously improved for optimum productivity and durability.
  • Page 4 Product Overview TORO GM 345...
  • Page 5 TORO GM 345 / 325 - D Product Overview Attachments 1. 72” Side discharge mower deck. 2. 72” Rear discharge mower deck. 3. 72” Guardian Recycler deck. 4. 88” Triflex mower deck. 5. 48” Snowblower 6. Debris blower 7. Aerator 8.
  • Page 6 Ford VSG-411 Gas Engine TORO GM 345...

  • Page 7: Engine Identification

    TORO GM 345 In this section we will look at some troubleshooting procedures for the Ford Gas Engine. Engine Identification The engine is identified with a decal affixed to the left side of the valve cover. The decal contains the engine serial number.
  • Page 8 Ford VSG-411 Gas Engine TORO GM 345...

  • Page 9: Troubleshooting

    TORO GM 345 Troubleshooting: High and Low Idle Checks. The idle settings are important for the proper operation and long life of the machine. Affects of incorrect idle speeds: 1. High idle too slow: Low power. (engine not running at full speed) Slow transport speed.
  • Page 10 Ford VSG-411 Gas Engine TORO GM 345...
  • Page 11 TORO GM 345 Correction: Carburetor linkage adjustment. 1. With the engine shut off, move the throttle control to the FAST position. 2. Check the gap between the throttle arm and the stop on the carburetor base. The correct gap is 1/32”...
  • Page 12 Ford VSG-411 Gas Engine TORO GM 345...
  • Page 13 TORO GM 345 The final adjustments are made with the engine running. To guard against possible personal injury, engage the parking brake and keep hands, feet, face and other parts of the body away from the fan or other moving parts.
  • Page 14 Ford VSG-411 Gas Engine TORO GM 345...
  • Page 15 TORO GM 345 High Idle Adjustment. 1. Slowly move the throttle to the FAST position until the engine reaches 3200 Adjust the high speed adjustment screw until it contacts the speed control lever. IMPORTANT: Do not overspeed the engine because transmission damaged could occur.
  • Page 16 Ford VSG-411 Gas Engine TORO GM 345...
  • Page 17 TORO GM 345 Anti-Surge Adjustment. 1. Move the throttle rapidly from SLOW to FAST. The engine should not surge, if the engine surges proceed to step 2. 2. Check the V-belts from the engine to the governor pulley and assure that they are tight.
  • Page 18 Ford VSG-411 Gas Engine TORO GM 345...
  • Page 19 TORO GM 345 Cylinder Leakage Test. The cylinder leakage test can locate the following problems: 1. Leaking intake valves. Air leaking from carburetor. 2. Leaking exhaust valves. Air leaking from muffler. 3. Leaking cylinder head gaskets. Air leaking externally by head gasket.
  • Page 20 5. Normal engine compression at cranking speed is 185 PSI. 6. The actual compression reading is not as important as the relationship between all the cylinder readings. 7. Part Numbers Engine oil filter, Motorcraft P/N FL.400-A. Fuel filter, Motorcraft P/N FG795A. Air filter Toro P/N 27-7110...
  • Page 21 TORO GM 345 1. Proper high idle setting is: a. 2800 ± 50 RPM b. 3200 ± 100 RPM c. 3000 ± 25 RPM d. 1500 ± 100 RPM 2. The final high idle adjustment is made at the carburetor.
  • Page 22 Mitsubishi K3D Diesel Engine TORO GM 325-D...
  • Page 23 TORO GM 325-D In this section we will look at some troubleshooting procedures for the Mitsubishi Diesel Engine. Engine Identification The engine model number and serial number is listed on a decal on the valve cover. The engine serial number is also stamped on the injection pump mounting surface.
  • Page 24 Mitsubishi K3D Diesel Engine TORO GM 325-D...
  • Page 25 TORO GM 325-D Analyzing Diesel Exhaust Smoke. The exhaust from a diesel engine can provide information about the running condition of the engine. A normally operating engine will have exhaust that is clear to a slight brownish/gray color. 1. Black Smoke.
  • Page 26 Mitsubishi K3D Diesel Engine TORO GM 325-D...
  • Page 27 TORO GM 325-D Troubleshooting Cylinder Leakage Test. A cylinder leakage test may be performed if the test equipment is available. The leakage test can locate: 1. Leaking intake valve. Air leaking from the air filter or intake manifold. 2. Leaking exhaust valve.
  • Page 28 Mitsubishi K3D Diesel Engine TORO GM 325-D...
  • Page 29 TORO GM 325-D Troubleshooting: High and Low Idle Checks. The idle settings are important for the proper operation and long life of the machine. Affects of incorrect idle speeds: 1. High idle too slow. Low power. (Engine not running at full speed) Slow transport speed.
  • Page 30 Mitsubishi K3D Diesel Engine TORO GM 325-D...
  • Page 31 TORO GM 325-D Injection Nozzles. The diesel engine requires that the fuel be sprayed into the combustion chamber, at a precise point in the compression stroke. The point at which this fuel injection occurs is the injection timing. If the nozzle is defective, damaged, or adjusted incorrectly, the injection timing can be affected.
  • Page 32 Mitsubishi K3D Diesel Engine TORO GM 325-D...
  • Page 33 TORO GM 325-D 1. Nozzle Leakage Test. The leakage test checks the nozzle tip for proper sealing. A leaking nozzle should be repaired or replaced. 2. Operate the pump until 1500 psi (108 kg/cm²) is reached, maintain this pressure. 3. Check the nozzle end.
  • Page 34 Mitsubishi K3D Diesel Engine TORO GM 325-D...
  • Page 35 TORO GM 325-D 1. Nozzle spray Test. The ability of the nozzle to correctly atomize the fuel can be checked by performing a nozzle spray test. Pump the nozzle tester and watch the spray pattern. A solid stream or large droplets indicates a faulty nozzle.
  • Page 36 Mitsubishi K3D Diesel Engine TORO GM 325-D...
  • Page 37 TORO GM 325-D Mitsubishi K3D Diesel Engine Glow Plug Testing. The diesel engine requires glow plugs to warm the combustion chamber to assist in starting. Evidence of faulty glow plugs includes: hard starting, excessive smoke, or engine knocking. There are several ways to test glowplugs.
  • Page 38 5. The actual compression reading is not as important as the relationship between all the cylinder readings 6. Part Numbers Engine oil filter, Toro P/N 42-9030 Fuel filter/Water separator Toro P/N 63-8300 Fuel pump filter Toro P/N 43-2550 Air filter Toro P/N 27-7110...
  • Page 39 TORO GM 325-D 1. Blue exhaust smoke indicates : a. Excessive fuel b. water in the combustion chamber. c. High oil consumption. d. Excessive engine load. 2. When performing a compression test, add oil to the pistons before the test a.
  • Page 40 Hydraulics TORO GM 345 / 325-D Hydrostatic Charge Circuit...
  • Page 41 TORO GM 345 / 325-D Hydrostatic Drive and Hydraulic Systems The drive system on the Groundsmaster pump and motor assembly. This assemble is connected to a Dana GT-20 axle/differential assembly. Engine power is transmitted from the engine to the input shaft of the hydrostatic unit. The output of the hydrostatic unit transmits the power to the pinion shaft, through the differential and to the wheels.
  • Page 42 Hydraulics TORO GM 345 / 325-D Drive circuit...
  • Page 43 TORO GM 345 / 325-D Hydraulics Drive Circuit The drive circuit consists of a variable displacement pump and the hydrostatic motor. Drive circuit operation. 1. When the traction pedal is depressed the swash plate in the pump rotates and the pump begins to pump.
  • Page 44 Hydraulics TORO GM 345 / 325-D Acceleration valves...
  • Page 45 TORO GM 345 / 325-D Acceleration valves 1. The drive oil from the hydrostatic pump also flows to the acceleration valves. 2. The oil is allowed to flow through the orifice in the valve, until sufficient pressure is created to close the acceleration valve.
  • Page 46 Hydraulics TORO GM 345 / 325-D...
  • Page 47 TORO GM 345 / 325-D Troubleshooting To test the hydrostatic system there are several test ports on the hydrostatic unit. 1. Charge pressure test port, (located on the left side rear of the hydrostatic unit, next to the steering and lift supply line).
  • Page 48 Hydraulics TORO GM 345 / 325-D Drive Pressure Test...
  • Page 49 TORO GM 345 / 325-D 1. Testing drive pressure. Remove the test port plug using a 3/16” allen wrench. Connect 10,000 psi gauge into the test port using a 3/8 - 24 adapter. Chain machine and lock brakes. Operate engine at 3200 RPM.
  • Page 50 Hydraulics TORO GM 345 / 325-D Charge Flow Test...
  • Page 51 TORO GM 345 / 325-D 1. Testing charge flow. Connect hydraulic flow meter. Operate engine at 3200 RPM. Restrict oil flow through flow tester. Should be able to read 1GPM at 700 PSI. Low charge flow (charge pressure “OK”) 2. Possible causes: Leaking implement relief valve.
  • Page 52 Hydraulics TORO GM 345 / 325-D...
  • Page 53 TORO GM 345 / 325-D Steering Circuit 1. Oil from the hydrostatic charge pump flows to the IN port of the steering valve. 2. With the steering wheel in neutral the oil flows out the AUX port to the lift valve.
  • Page 54 Hydraulics TORO GM 345 / 325-D...
  • Page 55 TORO GM 345 / 325-D Hydraulics Cutting Unit Lift Circuit. 1. When the steering wheel is in neutral, oil flows out of the AUX port to the lift valve. 2. When the valve is in neutral oil flows through the valve, to the oil cooler, and then to the reservoir.
  • Page 56 1. Hydraulic flow tester kit OTC P/N TOR214678 or equivalent 2. Hydraulic pressure test kit. OTC P/N TOR47009 or equivalent TORO GM 345 / 325-D Service Tips 1. Hydraulic testing is done with the hydraulic oil at normal operating temperature.
  • Page 57 TORO GM 345 / 325-D 1. All hydraulic and hydrostatic test should be conducted with the oil warm. a. True b. False 2. Proper engine RPM for hydraulic testing is: a. 1500 RPM b. 2000 RPM c. 3000 RPM d. 3200 RPM 3.
  • Page 58 Electrical Systems Start Circuit Position START Circuit Make NONE B + I + A X + Y B + I + s TORO GM 345 / 325-D...

  • Page 59: Electrical System

    TORO GM 345 / 325-D Electrical Systems Electrical System (GM 345 / 325-D) The electrical system on the 300 Series Goundsmaster can be broken into the following circuits: 1. Starting/Charging. 2. Safety Interlock. 3. Gauges and warning. 4. Engine. With a basic understanding of these circuits we can troubleshoot a variety of electrical problems.
  • Page 60 Electrical Systems Interlock Circuit Position START Circuit Make NONE B + I + A X + Y B + I + s TORO GM 345 / 325-D...
  • Page 61 TORO GM 345 / 325-D Electrical Systems Interlock Circuit Normal Operation. 1. With an operator in the seat and the PTO engaged, the PTO switch opens. 2. Current flows through the seat switch to the “A” terminal of the ignition switch.
  • Page 62 Electrical Systems Interlock Circuit Position START Circuit Make NONE B + I + A X + Y B + I + s TORO GM 345 / 325-D...
  • Page 63 TORO GM 345 / 325-D Electrical Systems PTO Engaged, Operator Not In The Seat. 1. If the operator leaves the seat while the PTO is engaged. 2. Power is interrupted by the seat switch. 3. Current stops flowing to the “A” terminal of the ignition switch.
  • Page 64 Electrical Systems TORO GM 345 / 325-D...
  • Page 65 TORO GM 345 / 325-D Electrical Systems Interlock System Testing PTO Switch and Traction Neutral Switch Testing. 1. Move the PTO switch to the OFF position. 2. Remove foot from the traction pedal so it is fully released. 3. Rotate the ignition key to start. Engine should crank.
  • Page 66 Electrical Systems TORO GM 345 / 325-D...
  • Page 67 TORO GM 345 / 325-D Electrical Systems Seat Switch and Traction Neutral Switch Testing 1. Raise off the seat and engage the PTO switch while the engine is running. 2. The engine should stop within 2 seconds. If the engine stops, the switch is operating correctly.
  • Page 68 Electrical Systems TORO GM 345 / 325-D...
  • Page 69 TORO GM 345 / 325-D Electrical Systems Electrical circuit breaker. The GM325 electrical system has a 40 amp circuit breaker to protect the electrical system from overload. If all electric functions are lost, resetting the circuit breaker might remedy the problem.
  • Page 70 Special Tools 1. Digital volt, ohm meter. OTC PN. OEM1428 or equivalent 2. Electrical “skin over grease” OTC PN. TOR50547 TORO GM 345 / 325-D Helpful Hints 1. Interlock switches Neutral switch closed with traction pedal in neutral PTO switch closed with PTO disengaged Seat switch open with no operator in the seat 2.
  • Page 71 TORO GM 345 / 325-D 1. How many interlock switches does the unit use? a. 1. b. 2. c. 3. d. 4. 2. The neutral switch is: a. Open when the traction pedal is depressed b. Closed when the neutral switch is depressed 3.
  • Page 72 Cutting Unit Drive TORO GM 345 / 235-D...
  • Page 73 TORO GM 345 / 325-D Attachment Drive (PTO) GM325/GM345 Pto Operation 1. The power take-off (PTO) system transmits power from the engine to the cutting deck or other implement attached to the front of the machine. 2. The PTO lever has two positions: ON (engage) and OFF (disengage). To engage the PTO shaft, slowly push the PTO lever fully forward to the ON position;...
  • Page 74 Cutting Unit Drive TORO GM 345 / 235-D...
  • Page 75 TORO GM 345 / 325-D Troubleshooting 1. Poor cutting unit performance: Drive belt slipping. Tighten the drive belt. Adjust PTO belt tension spring to 3 3/16 in.(80.96 mm). 2. Drive belt failure: Improper belt alignment. Align drive belt. NOTE: See the operators manual or the service manual for the complete adjustment procedure.
  • Page 76 Cutting Units TORO GM 345/325-D...

  • Page 77: Cutting Units

    TORO GM 345/325-D Cutting Units Cutting Units Maintenance and Service Spindle service If noisy operation of the cutting unit is encountered and the blade spindles need to be repaired, refer to the complete repair procedures in the service manual. The replacement bearing set consists of: 1.
  • Page 78 Cutting Units TORO GM 345/325-D...

  • Page 79: Quality Of Cut

    TORO GM 345/325-D Quality Of Cut Inspecting and Sharpening Rotary Mower Blades Rotary mowers cut grass by the blade’s cutting surface impacting against the grass stems at a high velocity. To assure good quality of cut, the cutting edge of the blade must be kept in a sharp condition. A dull blade will produce a ragged cut and will require an excessive amount of engine horsepower to rotate the blade through the grass.
  • Page 80 Cutting Units TORO GM 345/325-D...
  • Page 81 TORO GM 345/325-D Cutting Units Mismatch cut. When a mismatch condition occurs the blade tip height should be checked. It the blade tip height is different, the blades will cut at a different height and the grass will be uneven.
  • Page 82 2. Blade holding fixture OTC PN. TOR4030 or equivalent 3. Portable bench grinder OTC PN TOR4031 or equivalent TORO GM 345/325-D Helpful Hints 1. Fill the spindle bearing housing with grease when replacing the bearings. (This assures that the upper bearing gets grease when the spindle is greased).
  • Page 83 TORO GM 345/325-D 1. Bearings and spacers should be replaced as a a. True b. False 2. The drive belt engagement spring should be adjusted to a length of: a. 2 1/4 inches b. 3 3/16 inches c. 1 1/2 inches d.
  • Page 84 Commercial products FORM 96-904-SL The Toro Company - 1996 Printed in U.S.A...

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