Service Manual

ManualsBrandsToro ManualsRiding ProductsGroundsmaster 360 4-Wheel Drive Multi-Purpose Machine with Cab

Form No. 11184SL Rev B

Groundsmaster

360

(Models with Kubota Engine)

Original Instructions (EN)

Summary of content (395 pages)

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Form No.
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Revision History Revision Date Description -- 2011 Initial Issue. A 2016 Updated Hydraulic and Electrical chapters. B 03/2018 Added revision history. © THE TORO COMPANY 2018 This document and all information contained herein is the sole property of The Toro Company (and/or its affiliated companies). No intellectual property rights are granted by the delivery of this document or the disclosure of its content.
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Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail to servicemanuals@toro.
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NOTES _
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PART NO. 11184SL (Rev. B) Service Manual (Models with Kubota Engine) Groundsmaster 360 Preface The purpose of this publication is to provide the service technician with information for troubleshooting, testing and repair of major systems and components on the Groundsmaster 360 models with a Kubota diesel engine. REFER TO THE OPERATOR’S MANUAL FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS.
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Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equivalents and Conversions . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 2222- 1 1 2 3 Chapter 3 - Kubota Diesel Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2 General Information . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4 Adjustments . . . . . . . . . . . .
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Safety Table of Contents GENERAL SAFETY INSTRUCTIONS . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . SAFETY AND INSTRUCTION DECALS . . . . . . . . . .
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General Safety Instructions The Groundsmaster 360 has been tested and certified by TORO for compliance with existing safety standards and specifications. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance and storage of the machine.
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1. Sit on the seat when starting and operating the machine. 4. Do not touch engine, radiator or exhaust system while engine is running or soon after it is stopped. These areas could be hot enough to cause burns. 2. Before starting the engine: 5. Before getting off the seat: A. Engage the parking brake. A. Ensure that traction pedal is in NEUTRAL. B. Make sure the traction pedal is in NEUTRAL and the PTO switch is OFF (disengaged). B. Lower and disengage cutting deck and wait for all movement to stop.
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Maintenance and Service 1. Before servicing or making adjustments, position cutting deck to allow necessary service to be completed. Then, stop engine, set parking brake and remove key from the switch. 2. Make sure machine is in safe operating condition by routinely inspecting fasteners (nuts, bolts and screws) to make sure they are tight. 3. Never store the machine or fuel container inside where there is an open flame, such as near a water heater or furnace. 4.
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Safety Jacking Instructions CAUTION When changing attachments, tires or performing other service, use correct supports, hoists and jacks. Make sure machine is parked on a solid, level surface such as a concrete floor. Prior to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine. Always chock or block wheels. Use jack stands or other appropriate load holding devices to support the raised machine.
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Safety and Instruction Decals Numerous safety and instruction decals are affixed to your Groundsmaster. If any decal becomes illegible or damaged, install a new decal. Decal part numbers are listed in your Parts Catalog.
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Product Records and Maintenance Table of Contents PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . Fastener Identification . . . . . . . . . . . . . . . . . . . . . . .
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Equivalents and Conversions 0.
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Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual. These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Service Manual.
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Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) Thread Size Grade 1, 5 & 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in−lb in−lb N−cm 10 + 2 13 + 2 147 + 23 # 6 − 32 UNC # 6 − 40 UNF # 8 − 32 UNC 13 + 2 25 + 5 # 10 − 24 UNC 30 + 5 SAE Grade 8 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 5 or Stronger Nuts) in−lb N−cm in−lb N−cm 15 + 2 169 + 23 23 + 3 262 + 34
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Thread Size Class 8.8 Bolts, Screws and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 + 6 in−lb 644 + 68 N−cm 78 + 8 in−lb 881 + 90 N−cm M6 X 1.0 96 + 10 in−lb 1085 + 113 N−cm 133 + 14 in−lb 1503 + 158 N−cm M8 X 1.25 19 + 2 ft−lb 26 + 3 N−m 28 + 3 ft−lb 38 + 4 N−m M10 X 1.5 38 + 4 ft−lb 52 + 5 N−m 54 + 6 ft−lb 73 + 8 N−m M12 X 1.
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Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Thread Size Recommended Torque Recommended Torque** Thread Size Square Head Hex Socket 1/4 − 20 UNC 140 + 20 in−lb 73 + 12 in−lb 5/16 − 18 UNC 215 + 35 in−lb 145 + 20 in−lb 3/8 − 16 UNC 35 + 10 ft−lb 18 + 3 ft−lb 1/2 − 13 UNC 75 + 15 ft−lb 50 + 10 ft−lb 7/16 − 20 UNF Grade 5 65 + 10 ft−lb 88 + 14 N−m 1/2 − 20 UNF Grade 5 80 + 10 ft−lb 108 + 14 N−m M12 X 1.25 Class 8.
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Chapter 3 Kubota Diesel Engine Table of Contents Kubota Diesel Engine SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Machines with 4 Cylinder Engine . . . . . . . . . . . . . . 2 Machines with 3 Cylinder Engine . . . . . . . . . . . . . . 3 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Adjust Throttle Control . . . .
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Specifications (Machines with 4 Cylinder Engine) Item Description Make / Designation Kubota V1505−E3B, 4−stroke, Liquid Cooled, OHV Diesel Number of Cylinders 4 Bore x Stroke 3.07” x 3.09” (78 mm x 78.4 mm) 91.
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Specifications (Machines with 3 Cylinder Engine) Item Description Make / Designation Kubota V1105−E3B or E4B, 4−stroke, Liquid Cooled, OHV Diesel Number of Cylinders 3 Bore x Stroke 3.07” x 3.09” (78 mm x 78.
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General Information This Chapter gives information about specifications, troubleshooting, testing and repair of the Kubota diesel engine used in the Groundsmaster 360. Refer to the Operator’s Manual for engine maintenance information. Service and repair parts for Kubota engines are supplied through your Authorized Toro Distributor. If no parts list is available, be prepared to provide your distributor with the Toro equipment model and serial numbers as well as the Kubota engine model and serial numbers.
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Adjustments Adjust Throttle Control Proper throttle operation is dependent upon proper adjustment of throttle control. Make sure throttle control is operating properly. 1 2. Check position of speed control lever on engine fuel injection pump. Speed control lever should be contacting high speed screw when throttle control lever is in FAST (detent) position (Fig. 1). 3.
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Service and Repairs Air Cleaner Assembly 10 RIGHT FRONT 7 5 Vacuator Direction 12 1 8 11 9 13 4 6 14 4 4 4 2 5 3 Figure 2 1. 2. 3. 4. 5. Air cleaner housing Air intake hose Air inlet hose Hose clamp (4) Flange nut (4) Kubota Diesel Engine 6. 7. 8. 9. 10. Flange head screw (2) Air filter element Carriage screw (2) Air cleaner plate Air cleaner cover Page 3 − 6 11. 12. 13. 14.
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Removal (Fig. 2) Installation (Fig. 2) NOTE: See Operator’s Manual for air cleaner maintenance procedures and intervals. IMPORTANT: Any leaks in the air filter system will allow dirt into engine and will cause serious engine damage. Make sure that all air cleaner components are in good condition and are properly secured during assembly. 1. Park machine on a level surface, lower cutting unit, stop engine, engage parking brake and remove key from the ignition switch. 3.
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Exhaust System 27 to 33 ft−lb (37 to 44 N−m) 17 to 21 ft−lb (24 to 28 N−m) 4 3 1 5 2 5 7 6 RIGHT FRONT 7 Figure 3 1. Muffler assembly 2. Exhaust gasket 3. Flange nut (4) Kubota Diesel Engine 4. Cap screw (2) 5. Flange nut (5) Page 3 − 8 6. Muffler support 7.
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Removal (Fig. 3) 4. Tighten four (4) flange nuts to secure muffler flange to exhaust manifold. Torque flange nuts 17 to 21 ft−lb (24 to 28 N−m). CAUTION 1. Park machine on a level surface, lower cutting unit, stop engine, engage parking brake and remove key from the ignition switch. 6. Install and tighten flange head screw (item 7) and flange nut that secure the muffler to the muffler support (item 6). 2. Unlatch and raise hood. 7. Close and latch hood.
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Fuel System Antiseize Lubricant 20 to 30 in−lb (2.3 to 3.3 N−m) 11 5 16 13 12 10 2 3 7 8 4 6 17 20 18 18 23 19 9 22 22 21 15 23 1 14 RIGHT FRONT 14 14 Figure 5 1. 2. 3. 4. 5. 6. 7. 8. Fuel tank Cover plate Fuel gauge Fuel cap R−clamp Stand pipe (fuel supply) Elbow fitting (return) Elbow fitting (tank vent) Kubota Diesel Engine 9. 10. 11. 12. 13. 14. 15. 16. Bushing (3) Fuel hose Vent tube Hose clamp Screw (2) Flange nut (4) Cap screw Rivet Page 3 − 10 17. 18. 19. 20. 21. 22. 23.
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Use caution when storing or handling diesel fuel. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running or hot or when machine is in an enclosed area. Always fill fuel tank outside and clean up any spilled diesel fuel before starting the engine. Store fuel in a clean, safety−approved container and keep cap in place. Use diesel fuel for the engine only; not for any other purpose. 8. Lift fuel tank from machine. Fuel Tank Installation (Fig. 5) 1.
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Radiator 19 20 21 18 19 RIGHT FRONT 1 22 6 17 9 5 17 7 10 15 9 13 2 14 3 17 16 25 11 8 4 21 24 19 12 23 26 5 Figure 7 1. 2. 3. 4. 5. 6. 7. 8. 9. Radiator support Fan shroud Radiator/oil cooler assembly Bulb seal (2) Isolator mount (3) Bulb seal (2) Upper radiator hose Lower radiator hose Hose clamp (4) 10. 11. 12. 13. 14. 15. 16. 17. 18. Flange head screw (2) Flange nut (2) Bracket Cap screw (2) Spacer (2) Flange nut (2) Overflow bottle Hose (2) Hydraulic hose 19. 20. 21. 22. 23.
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4. Disconnect upper and lower radiator hoses from the radiator. Also, disconnect overflow bottle hose from the vent tube near the radiator cap. 5. Thoroughly clean hydraulic hose ends and oil cooler fittings to prevent hydraulic system contamination. Label hydraulic lines for assembly purposes. 6. Remove hydraulic lines from oil cooler fittings. Install clean plugs in hose and tube openings to prevent contamination. Remove and discard O−rings from oil cooler fittings. 7.
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Engine 4 70 to 86 in−lb (7.9 to 9.7 N−m) RIGHT FRONT 8 9 10 32 2 6 7 33 1 Antiseize Lubricant 5 34 to 42 ft−lb (47 to 56 N−m) 27 30 14 26 12 23 17 25 16 3 17 11 31 29 18 21 15 13 20 24 19 Loctite #271 19 ft−lb (26 N−m) 22 28 19 Figure 9 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Engine Thermo−switch Cable support Fan Fan pulley Flange head screw (4) Fan spacer Hex nut Lock washer Flat washer Engine mount (2) (yellow top) 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
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15.Support transmission to prevent it from moving during engine removal. Do not rely on hydraulic hoses to retain transmission position. 8. Remove rear steering cylinder to allow clearance for engine removal (see Steering Cylinder Removal in the Service and Repairs section of Chapter 4 − Hydraulic System). 9. Label and disconnect harness wires from engine: A. Negative battery cable, wire harness ground and fuel stop solenoid (Fig. 10). B. Glow plug bus (Fig. 11). C. Alternator connector and stud (Fig. 12).
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IMPORTANT: Make sure to not damage the engine, flywheel housing, fuel hoses, hydraulic lines, electrical harness or other parts while removing engine. Also, make sure that transmission does not shift location during engine removal. 3 2 1 CAUTION 4 One person should operate lift or hoist while a second person guides the engine assembly out of the machine. Figure 12 19.Move engine toward the rear of the machine to separate it from the transmission input shaft and flywheel housing.
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14.Secure wire harness to engine with cable ties at locations noted during engine removal. CAUTION One person should operate lift or hoist while a second person guides the engine assembly into the machine. 15.Install rear steering cylinder (see Steering Cylinder Installation in the Service and Repairs section of Chapter 4 − Hydraulic System). 16.Carefully position fan shroud around the engine fan. 8. Carefully lower engine assembly into the machine.
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Chapter 4 Hydraulic System SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Pushing Traction Unit . . . . . . . . . . . . . . . . . . . . . . . . 3 Relieving Hydraulic System Pressure . . . . . . . . . . 3 Traction Circuit (Closed Loop) Component Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic Hoses . . . .
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Specifications Item Description Transmission Kanzaki dual, variable displacement traction piston pumps with integral charge pump and multi−disc PTO clutch 1.1 in3 (18 cc) 4000 PSI (276 bar) 0.37 in3 (6 cc) 100 to 130 PSI (6.9 to 8.
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General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance procedures and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional information when servicing the machine. Pushing Traction Unit In case of emergency, your Groundsmaster can be pushed for a very short distance. However, Toro does not recommend this as a standard procedure. 1 2 Hydraulic System 1. Make sure that engine is not running. 2.
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Traction Circuit Component Failure The traction circuit on Groundsmaster 360 machines is a closed loop system that includes the dual piston (traction) pump and either two (2) or four (4) wheel motors. If a component in the traction circuit should fail, debris and contamination from the failed component will circulate throughout the traction circuit. This contamination can damage other components in the circuit so it must be removed to prevent additional component failure.
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Hydraulic Hoses Hard, cracked, cut, abraded, charred, leaking or otherwise damaged hose. Kinked, crushed, flattened or twisted hose. Blistered, soft, degraded or loose hose cover. Cracked, damaged or badly corroded hose fittings. When replacing a hydraulic hose, be sure that the hose is straight (not twisted) before tightening the fittings. This can be done by observing the imprint (layline) on the hose.
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Hydraulic Hose and Tube Installation (O−Ring Face Seal Fitting) C. Use a second wrench to tighten the nut to the correct Flats From Wrench Resistance (F.F.W.R.). The markings on the nut and fitting body will verify that the connection has been properly tightened. 1. Make sure threads and sealing surfaces of the hose/ tube and the fitting are free of burrs, nicks, scratches or any foreign material. 2.
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Hydraulic Fitting Installation (SAE Straight Thread O−Ring Fitting into Component Port) Non−Adjustable Fitting (Fig. 5) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 5. If a torque wrench is not available, or if space at the port prevents use of a torque wrench, an alternate method of assembly is the Flats From Finger Tight (F.F.F.T.) method. 2.
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Adjustable Fitting (Fig. 7) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 2. As a preventative measure against leakage, it is recommended that the O−ring be replaced any time the connection is opened. Lock Nut 3. Lightly lubricate the O−ring with clean hydraulic oil. Fitting threads should be clean with no lubricant applied. Back−up Washer 4. Turn back the lock nut as far as possible.
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Hydraulic Schematics Hydraulic System The hydraulic schematics for Groundsmaster 360 machines are located in Chapter 9 − Foldout Drawings.
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Hydraulic System 17.1 17.1 LH WHEEL MOTOR FORWARD 14.5 GPM RH WHEEL MOTOR FORWARD 14.5 GPM D BYPASS VALVE C B BYPASS VALVE A Working Pressure Low Pressure (Charge) Return or Suction Flow Page 4 - 10 3100 to 3150 RPM HIGH 0.031 0.031 1300 RPM LOW ENGINE PISTON PUMP L FLUSHING VALVE 4000 PSI (276 bar) FLUSHING VALVE 4000 PSI (276 bar) PISTON PUMP R Groundsmaster 360 Traction Circuits: 2WD Machines (Forward Shown) 1.10 CID 1.10 CID NOT ENGAGED 100 - 130 PSI 0.031 Rev. A 0.
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Traction Circuits: 2WD Machines The angle of the pump swash plates determines pump flow and ultimately traction speed. When the traction pedal is moved a small amount, a small swash plate rotation results in low pump output and lower traction speed. When the traction pedal is moved fully, the pump swash plates rotate fully to provide maximum pump output flow and traction speed.
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Hydraulic System Page 4 - 12 Rev. A RIGHT FRONT 17.1 FP1 PD2 .040 OR4 RR .090 OR2 RP1 PD1 450 PSI CV1 5 PSI 110 PSI CRV LR TRACTION RP2 MANIFOLD .040 OR3 CV2 5 PSI .090 OR1 FP2 RIGHT 17.1 REAR 17.1 LEFT FRONT LEFT 17.1 REAR Working Pressure Low Pressure (Charge) Return or Suction Flow A C REVERSE D BYPASS VALVE FORWARD 14.5 GPM B BYPASS VALVE REVERSE FORWARD 14.5 GPM 4000 PSI (276 bar) PISTON PUMP R 0.031 0.
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Traction Circuits: 4WD Machines NOTE: On Groundsmaster 360 4WD machines with serial numbers below 314999999, the Automatic Speed Control (ASC) system is only active when the machine is in the 4 wheel steering position. Forward For each of the transmission piston pumps, flow for the forward direction is routed to a rear wheel motor and then to the opposite front wheel motor (e.g. right rear and then to left front) to maximize traction.
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Hydraulic System P LEFT TURN R T Page 4 − 14 TO DECK LIFT MANIFOLD STEERING CONTROL VALVE P TO OIL COOLER E L FROM GEAR PUMP L REAR STEERING CONTROL VALVE PORTS E 6.1 CID FRONT Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 360 Steering Circuits: 2WD Machines T R Figure 12 Groundsmaster 360 L P FROM GEAR PUMP 6.
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Steering Circuits: 2WD Machines A single section gear pump is directly coupled to the transmission which is driven by the engine. This gear pump supplies hydraulic flow for both the steering and lift/lower circuits. Hydraulic pump flow from the gear pump is routed to the steering control valve first so the steering circuit has priority. The pump takes its suction from the hydraulic tank. Steering circuit pressure is limited to 1800 PSI (125 bar) by a relief valve located in the gear pump.
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Hydraulic System P Page 4 − 16 T R E STEERING CONTROL VALVE PORTS TO DECK LIFT MANIFOLD STEERING CONTROL VALVE TO OIL COOLER 4 WHEEL STEERING RIGHT TURN SHOWN 6.1 CID 1 3 P FROM GEAR PUMP L 2 L 4 REAR E STEER MODE SELECTOR VALVE (ENERGIZED) FRONT Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 360 Steering Circuits: 4WD Machines T R Figure 14 Groundsmaster 360 P 6.
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Steering Circuit: 4WD Machines The gear pump, steering control valve and steering cylinders used on 4WD machines are the same as the hydraulic components used on 2WD machines. The steering circuit on 4WD machines, therefore, operates basically the same as the steering circuit on 2WD machines. Refer to Steering Circuit: 2WD Machines in this section for information on steering system operation. In this switch position, the steering control manifold solenoid valve is not energized.
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Figure 15 Hydraulic System Page 4 − 18 Rev. A Groundsmaster 360 TRANSMISSION Working Pressure Low Pressure (Charge) Return or Suction Flow P IMPLEMENT RELIEF 1800 PSI 5.4 GPM L FRONT 6.1 CID SUCTION SCREEN GEAR PUMP 0.41 CID OIL COOLER Groundsmaster 360 Lift Circuit: Raise (2WD Machine Schematic Shown) T R E REAR STEERING CONTROL VALVE B 4 DECK LIFT MANIFOLD BOTH SOLENOIDS ENERGIZED 3 A 1 HYDRAULIC SCHEMATIC FOR MACHINE WITH SERIAL NUMBER BELOW 313999999 SHOWN 2 0.
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Lift Circuit: Raise A single section gear pump is directly coupled to the transmission which is driven by the engine. This gear pump supplies hydraulic flow for both the steering and lift/lower circuits. Gear pump flow is routed to the steering control valve first so the steering circuit has priority. The pump takes its suction from the hydraulic tank.
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Figure 16 Hydraulic System Page 4 − 20 Rev. A Groundsmaster 360 TRANSMISSION Working Pressure Low Pressure (Charge) Return or Suction Flow P IMPLEMENT RELIEF 1800 PSI 5.4 GPM L FRONT 6.1 CID SUCTION SCREEN GEAR PUMP 0.41 CID OIL COOLER Groundsmaster 360 Lift Circuit: Lower (2WD Machine Schematic Shown) T R REAR E STEERING CONTROL VALVE 3 A 1 4 DECK LIFT MANIFOLD SOLENOID A ENERGIZED B HYDRAULIC SCHEMATIC FOR MACHINE WITH SERIAL NUMBER BELOW 313999999 SHOWN 2 0.
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Lift Circuit: Lower When the deck lift switch is in its neutral state, flow from the gear pump bypasses the lift cylinder and is routed through the deck lift manifold directly to the oil cooler and then to the transmission. The transmission case drain allows oil to return to the hydraulic tank. NOTE: The engine must be running to allow the cutting deck to be lowered. When the front of the deck lift switch is depressed, the deck will lower fully and enter the float position.
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Figure 17 Hydraulic System Page 4 - 22 Rev. A Groundsmaster 360 17.1 17.1 LH WHEEL MOTOR FORWARD 14.5 GPM RH WHEEL MOTOR FORWARD 14.5 GPM D BYPASS VALVE C B BYPASS VALVE A Working Pressure Low Pressure (Charge) Return or Suction Flow 0.031 0.031 1300 RPM LOW 3100 to 3150 RPM HIGH ENGINE PISTON PUMP L FLUSHING VALVE 4000 PSI (276 bar) FLUSHING VALVE 4000 PSI (276 bar) PISTON PUMP R Groundsmaster 360 PTO Circuit (2WD Machine Schematic Shown) 1.10 CID 1.
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PTO Circuit The transmission used on Groundsmaster 360 machines includes a hydraulic, multi−plate clutch that is used to engage the PTO. Hydraulic flow for PTO clutch engagement is provided by the transmission charge pump. When the PTO switch is turned off (pushed down), the transmission solenoid valve is de−energized and the PTO clutch is disengaged. The integral PTO brake is applied to control the stopping rate of the drive shaft and cutting deck.
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Special Tools Order special tools from your Toro Distributor. Hydraulic Pressure Test Kit Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings. Contains one each: 1000 PSI (70 bar), 5000 PSI (350 bar) and 10000 PSI (700 bar) gauges. Use gauges as recommended in the Testing section of this chapter.
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40 GPM Hydraulic Tester (Pressure and Flow) Use to test hydraulic circuits and components for flow and pressure capacities as recommended in the Testing section of this chapter. This tester includes the following: 1. LOAD VALVE: A simulated working load is created in the circuit by turning the valve to restrict flow. 2. PRESSURE GAUGE: Glycerine filled 0 to 5000 PSI gauge to provide operating circuit pressure. 3.
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High Flow Hydraulic Filter Kit The high flow hydraulic filter kit is designed with large flow (40 GPM/150 LPM) and high pressure (5000 PSI/345 bar) capabilities. This kit provides for bi−directional filtration which prevents filtered debris from being allowed back into the circuit regardless of flow direction. If a component failure occurs in the closed loop traction circuit, contamination from the failed part will remain in the circuit until removed.
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Troubleshooting The chart that follows contains suggestions that can be used to assist in diagnosing hydraulic system performance issues. The suggestions are not all−inclusive. Also, consider that there may be more than one cause for a machine problem. Refer to the Testing section of this Chapter for precautions and specific hydraulic test procedures.
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Traction Circuit Problems Problem Possible Causes Traction response is sluggish. Transmission bypass valve(s) is open or defective. Brake is dragging or binding. Hydraulic oil is very cold. Transmission check valve, relief valve and/or flushing valve is leaking. Charge pressure is low. Transmission or wheel motor(s) is worn or damaged.
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Traction Circuit Problems (Continued) Problem Possible Causes Wheel motor will not hold load in neutral. Make up fluid from charge pump is not available. NOTE: Machine may not be completely stationary if parked on an incline without the parking brake engaged. Check valves in transmission are damaged. On 4WD machine, PD1 or PD2 cartridge in CrossTraxTM AWD control manifold is leaking or is damaged. Valve plate(s) in transmission is worn or damaged.
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PTO Circuit Problems Problem Possible Causes Cutting deck blades will not turn. Cutting deck problem exists (see Chapter 7 − Cutting Deck). An electrical problem exists that prevents PTO from engaging (see Chapter 5 − Electrical System). The engine coolant temperature is excessive. Transmission solenoid valve is stuck. Transmission charge pump is damaged (traction charge circuit also affected). Transmission pressure valve is faulty. Cutting deck blade(s) turn too slowly. Engine speed is too low.
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Steering and Lift/Lower Circuit Problems Problem Possible Causes Gear pump is noisy (cavitation). Hydraulic tank oil level is low. Hydraulic oil is very cold. Suction line is restricted. Suction line has an air leak. Steering inoperative or sluggish. Steering components (e.g. steering forks, steering arms, tie rods, steering cylinder ends) are binding and need to be greased. Steering components (e.g. steering forks, steering arms, tie rods, steering cylinder ends) are worn or damaged.
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Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks (see the Special Tools section in this Chapter). 1. Clean machine thoroughly before disconnecting or disassembling any hydraulic components. Always keep in mind the need for cleanliness when working on hydraulic equipment. Contamination can cause excessive wear or binding of hydraulic components.
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2. If a PTO circuit problem exists, consider performing the PTO Pressure Valve Test. Which Hydraulic Tests Are Necessary? Before beginning any hydraulic test, identify if the problem is related to the traction circuit, PTO circuit, lift/lower circuit or steering circuit. Once the faulty system has been identified, perform tests that relate to that circuit. 1.
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Hydraulic System LH WHEEL MOTOR A Page 4 - 34 PISTON PUMP L 4000 PSI (276 bar) 0.031 0.031 ENGINE 1300 RPM LOW 3100 to 3150 RPM HIGH FLUSHING VALVE FLUSHING VALVE 1.10 CID 1.10 CID 100 - 130 PSI PRESSURE GAUGE D BYPASS VALVE C B BYPASS VALVE 4000 PSI (276 bar) 0.031 Rev. A 0.37 CID 78 PSI TRANSMISSION 313 PSI 0.41 CID HYDRAULIC SCHEMATIC FOR 2WD MACHINE SHOWN HYDRAULIC SCHEMATIC FOR MACHINE WITH SERIAL NUMBER BELOW 313999999 SHOWN 17.1 FORWARD 17.
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The Charge Relief Valve Pressure Test should be performed if a traction circuit problem is identified. This test will determine if the traction charge circuit is functioning correctly. 10.Next, determine charge pressure under traction load by operating the machine in a direct forward and reverse direction. Make sure that engine is running at full speed (3100 to 3150 RPM). Procedure for Charge Relief Valve Pressure Test: NOTE: When applying brakes, make sure that parking brake latch is not depressed.
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RIGHT SIDE FORWARD TRACTION RELIEF VALVE TESTING SHOWN Hydraulic System 17.1 LH WHEEL MOTOR PLUG FORWARD FORWARD 4000 PSI (276 bar) Page 4 - 36 0.031 0.031 ENGINE 1300 RPM LOW 3100 to 3150 RPM HIGH PISTON PUMP L FLUSHING VALVE FLUSHING VALVE 4000 PSI (276 bar) 1.10 CID 1.10 CID 100 - 130 PSI 0.031 Rev. A 0.37 CID 78 PSI Port B Port A 0.41 CID 1800 PSI 5.
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The Traction Relief Valve Pressure Test should be performed if a traction circuit problem is identified. This test will determine if a transmission relief valve is operating correctly. Procedure for Traction Relief Valve Pressure Test: 1. Make sure hydraulic oil is at normal operating temperature. Also, make sure that traction drive is correctly adjusted for the neutral position. 4WD Machine Balancing Hose Port D Port C Port B Port A WARNING Balancing Hose Figure 29 10.
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13.If traction relief valve pressure is not met, relieve hydraulic system pressure (see Relieving Hydraulic System Pressure in the General Information section). Remove and inspect relief valve(s) from transmission (see Transmission Service in the Service and Repairs section of this chapter). Clean or replace relief valve(s). Traction relief valves are not adjustable. 1 14.
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PAGE 78
HYDRAULIC TESTER Hydraulic System 17.1 LH WHEEL MOTOR FORWARD 4000 PSI (276 bar) Page 4 - 40 0.031 0.031 ENGINE 1300 RPM LOW 3100 to 3150 RPM HIGH PISTON PUMP L FLUSHING VALVE FLUSHING VALVE 4000 PSI (276 bar) 1.10 CID 1.10 CID 100 - 130 PSI 0.031 Rev. A 0.37 CID 78 PSI Port B Port A 0.41 CID 1800 PSI 5.
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The Transmission Piston Pump Flow Test should be performed if a traction circuit problem is identified. This test will determine if hydraulic flow from a transmission piston pump is correct. Procedure for Transmission Piston Pump Flow Test: 4WD Machine Balancing Hose Port D Port C Port B Port A 1. Make sure hydraulic oil is at normal operating temperature. Also, make sure that traction drive is correctly adjusted for the neutral position and that the hydraulic tank is full.
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B. The traction control assembly may need adjustment (e.g. traction pedal not rotating pump swash plate fully). C. If the engine speed drops excessively as the tester flow control valve is closed, engine performance should be evaluated. D. If engine speed does not drop and pressure and flow specifications are not met, the tested transmission piston pump needs to be inspected, repaired or replaced as necessary. Hydraulic System 16.
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PAGE 82
HYDRAULIC TESTER Hydraulic System 17.1 LH WHEEL MOTOR PLUG FORWARD FORWARD Page 4 - 44 4000 PSI (276 bar) 0.031 0.031 ENGINE 1300 RPM LOW 3100 to 3150 RPM HIGH PISTON PUMP L FLUSHING VALVE FLUSHING VALVE 4000 PSI (276 bar) 1.10 CID 1.10 CID 100 - 130 PSI 0.031 Rev. A 0.37 CID 78 PSI Port B Port A 0.41 CID 1800 PSI 5.
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NOTE: Over a period of time, a wheel motor can wear internally. A worn motor may bypass oil internally causing the motor to be less efficient. Eventually, enough oil loss will cause the wheel motor to stall under heavy load conditions. Continued operation with a worn, inefficient motor can generate excessive heat, cause damage to seals and other components in the hydraulic system and affect overall machine performance.
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14.Rear wheel motor internal leakage will be shown on the tester flow meter in GPM (LPM). 15.Return traction pedal to the neutral position. Release brakes, shut off engine and record test results. Rotate wheel and retest. Testing of wheel motor leakage in three (3) different wheel positions will provide the most accurate test results. 17.Relieve hydraulic system pressure (see Relieving Hydraulic System Pressure in the General Information section).
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PAGE 86
Hydraulic System Page 4 - 48 Rev. A D BYPASS VALVE C B 4000 PSI (276 bar) 0.031 0.031 ENGINE 1300 RPM LOW 3100 to 3150 RPM HIGH PISTON PUMP L FLUSHING VALVE FLUSHING VALVE HYDRAULIC SCHEMATIC FOR MACHINE WITH SERIAL NUMBER BELOW 313999999 SHOWN LH WHEEL MOTOR FORWARD A BYPASS VALVE 4000 PSI (276 bar) 1.10 CID 1.10 CID 100 - 130 PSI 0.031 0.37 CID 78 PSI PRESSURE GAUGE TRANSMISSION 313 PSI HYDRAULIC SCHEMATIC FOR 2WD MACHINE SHOWN 17.1 17.
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The PTO Pressure Valve Test should be performed if a PTO engagement problem is identified. This test will determine if the PTO pressure valve in the transmission is operating correctly. Pressure Valve Test Port FRONT Procedure for PTO Pressure Valve Test: 1. Make sure hydraulic oil is at normal operating temperature. WARNING Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved.
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Hydraulic System Page 4 − 50 TRANSMISSION HYDRAULIC SCHEMATIC FOR 2WD MACHINE SHOWN Rev. A P IMPLEMENT RELIEF 1800 PSI 5.4 GPM SUCTION SCREEN GEAR PUMP 0.41 CID OIL COOLER 6.1 CID L FRONT T R STEERING CONTROL VALVE 2 0.
PAGE 89
Procedure for Implement Relief Pressure Test: 1. Make sure hydraulic oil is at normal operating temperature. 2. Make sure that traction drive is correctly adjusted for the neutral position. WARNING Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved. See Relieving Hydraulic System Pressure in the General Information section. 3. Park machine on a level surface with the cutting deck lowered and off.
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Hydraulic System Page 4 − 52 TRANSMISSION HYDRAULIC SCHEMATIC FOR 2WD MACHINE SHOWN Rev. A P IMPLEMENT RELIEF 1800 PSI 5.4 GPM HYDRAULIC TESTER SUCTION SCREEN GEAR PUMP 0.41 CID OIL COOLER 6.1 CID L FRONT T R STEERING CONTROL VALVE 2 0.
PAGE 91
Procedure for Gear Pump Flow Test: NOTE: Over a period of time, the gears and wear plates in the gear pump can wear. A worn pump will bypass oil and make the pump less efficient. Eventually, enough oil loss will occur to cause the cutting unit motors to stall under heavy cutting conditions. Continued operation with a worn, inefficient pump can generate excessive heat and cause damage to seals and other components in the hydraulic system. 1. Make sure hydraulic oil is at normal operating temperature. 2.
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Hydraulic System Page 4 − 54 Rev. A TRANSMISSION P IMPLEMENT RELIEF 1800 PSI 5.4 GPM SUCTION SCREEN GEAR PUMP 0.41 CID OIL COOLER 6.1 CID L FRONT T R E REAR CHECK FOR CYLINDER RETRACTING CAP 2 PLUG B 3 DECK LIFT MANIFOLD A 1 4 HYDRAULIC SCHEMATIC FOR MACHINE WITH SERIAL NUMBER BELOW 313999999 SHOWN STEERING CONTROL VALVE 0.
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NOTE: Raise/lower circuit operation will be affected by lift cylinder binding, extra weight on the cutting deck and/ or binding of lift components. Make sure that these items are checked before proceeding with the lift cylinder internal leakage test. Procedure for Lift Cylinder Internal Leakage Test: 1. Park machine on a level surface with the PTO switch OFF. Position the cutting deck in a partially raised position and turn the engine off. Apply the parking brake. 2.
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Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components 1. Before removing any parts from the hydraulic system, park machine on a level surface, engage parking brake, lower cutting deck and stop engine. Remove key from the ignition switch. 6. Put clean caps or plugs on any hydraulic lines, hydraulic fittings and components left open or exposed to prevent contamination. Cap the opening as soon as line or port is exposed.
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Flush Hydraulic System IMPORTANT: Flush the hydraulic system any time there is a severe component failure or if the system is contaminated (oil appears milky, black or contains metal particles). IMPORTANT: Use only hydraulic fluids specified in Operator’s Manual. Other fluids may cause system damage. Use of biodegradable hydraulic fluid in Groundsmaster 360 machines is not recommended.
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Filtering Closed−Loop Traction Circuit Filtering of a closed−loop hydraulic system after a major component failure (e.g. transmission piston pump or wheel motor) is a requirement to prevent debris from transmitting throughout the system. If a closed−loop hydraulic system filtering tool is not used to ensure system cleanliness, repeat failures, as well as subsequent damage to other hydraulic components in the affected system, will occur.
PAGE 97
IMPORTANT: While engaging the traction circuit, monitor the indicator on the high flow hydraulic filter. If the indicator should show red, either reduce pressure on the traction pedal or reduce engine speed to decrease hydraulic flow through the filter. IMPORTANT: If using a filter that is not the bi−directional Toro high flow filter, do not press the traction pedal in the reverse direction.
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Charge Hydraulic System NOTE: When initially starting the hydraulic system with new or rebuilt components such as wheel motors, gear pump or lift cylinder, it is important that the hydraulic system be charged properly. Air must be purged from the system and its components to reduce the chance of damage. IMPORTANT: Change hydraulic oil filter whenever hydraulic components are repaired or replaced. 1. Park machine on a level surface with engine off. 2.
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PAGE 100
Hydraulic Tank 16 RIGHT FRONT 15 14 13 11 81 to 99 ft−lb (110 to 134 N−m) 12 121 to 149 ft−lb (165 to 202 N−m) 17 10 1 10 18 9 2 3 8 81 to 99 ft−lb (110 to 134 N−m) 7 17 4 19 20 to 26 ft−lb (28 to 35 N−m) 5 6 Figure 46 1. 2. 3. 4. 5. 6. 7. Hydraulic tank O−ring Suction strainer Hose clamp Suction hose Flange head screw (4) Plug Hydraulic System 8. 9. 10. 11. 12. 13. O−ring Barbed fitting O−ring 90o hydraulic fitting O−ring Tank cap Page 4 − 62 14. 15. 16. 17. 18. 19.
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Hydraulic Tank Removal (Fig. 46) Hydraulic Tank Installation (Fig. 46) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Raise and support operator seat. 1. Attach removed suction strainer and fittings with new, lubricated O−rings to hydraulic tank using Figure 46 as a guide (see Hydraulic Fitting Installation in the General Information section of this chapter). Torque fittings to values identified in Figure 46. 3.
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Rear Wheel Motors 15 8 5 27 9 26 13 7 25 28 11 300 to 400 ft−lb (407 to 542 N−m) 14 12 16 17 18 10 19 6 1 20 4 2 26 21 Loctite #271 3 22 RIGHT 23 FRONT 94 to 116 ft−lb (128 to 157 N−m) 75 to 85 ft−lb (102 to 115 N−m) 24 Figure 48 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Rear wheel assembly (LH shown) Hydraulic tube Brake assembly (LH shown) Hydraulic tube Brake cable Cap screw (2 per bracket) Clevis pin Brake cable bracket (LH shown) Cap screw (2 per bracket) Return spring bracket 11. 12.
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3. Position rear wheel motor to steering fork. Make sure that ports in wheel motor are facing forward. Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 − Safety. 3. Jack up machine enough to allow the removal of the rear wheel. Support machine with jack stands. 4. Remove wheel assembly (item 1), brake drum (item 23), wheel hub (item 22) and brake assembly (item 3) from the machine (see Brake Service in the Service and Repairs section of Chapter 6 − Chassis). 5.
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Front Wheel Motors (4WD Machines) 16 300 to 400 ft−lb (407 to 542 N−m) 11 12 75 to 85 ft−lb (102 to 115 N−m) 14 16 9 8 2 7 13 15 1 6 Loctite #271 5 3 RIGHT FRONT 10 4 94 to 116 ft−lb (128 to 157 N−m) Figure 50 1. 2. 3. 4. 5. 6. Front wheel motor (LH shown) O−ring Wheel hub Wheel spacer Wheel stud (5 per wheel) Cap screw (4 per motor) 7. 8. 9. 10. 11. Square key 45o fitting (2 per motor) Cap screw (2 per bracket) Lug nut (5 per wheel) Hydraulic tube 12. 13. 14. 15. 16.
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IMPORTANT: DO NOT hit wheel hub, puller or wheel motor with a hammer during wheel hub removal or installation. Hammering may cause damage to the wheel motor. 5. Make sure that lock nut on wheel motor shaft is loosened at least two (2) turns. Use hub puller (see Special Tools in this chapter) to loosen wheel hub from wheel motor. 2. Clean threads in steering fork and on cap screws used to secure wheel motor to machine. 3. Position front wheel motor to steering fork.
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Wheel Motor Service 14 15 16 17 18 12 13 19 4 1 2 10 3 5 45 to 55 ft−lb (61 to 75 N−m) 6 3 7 3 8 9 3 3 11 Figure 51 1. 2. 3. 4. 5. 6. 7. Cap screw (7) End cover Body seal (5) Commutator ring Commutator Commutator ring Manifold 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Stator Vane (7) Rotor Wear plate Drive link Thrust bearing NOTE: The wheel motors used on the Groundsmaster 360 have the same basic construction. The left wheel motor(s) has a yellow sticker on the port side of the stator.
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PAGE 108
Traction Linkage Assembly (Serial Number Below 313999999) 21 10 12 11 7 3 6 20 14 2 5 13 1 15 19 9 4 22 RIGHT FRONT 16 9 21 8 17 19 20 18 Figure 52 1. 2. 3. 4. 5. 6. 7. 8. Speed control shaft Flange bearing (2) Rear axle ASC control arm Neutral sensor Damper Transmission assembly Traction rod assembly 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
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When servicing the traction linkage on your Grounds− master 360, use the following information: 1 NOTE: Refer to the Operator’s Manual for information on adjusting traction pedal stops, mow speed limiter lever and traction pedal neutral position. 3 1. Rod ends on traction rod assembly should be installed equally into traction rod so that distance between center of rod ends is 28.520” (724.4 mm) (Fig. 54).
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5. For correct operation of Automatic Speed Control (ASC), adjust the ASC control arm as follows (Fig. 59): 1 NOTE: Before adjusting the ASC control arm, make sure that traction pedal stop is correctly adjusted. A. With the rear wheels in the straight forward position (not turned), fully depress and hold the traction pedal in the full forward direction. 3 B.
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PAGE 112
Traction Linkage Assembly (Serial Number Above 314000000) 20 19 24 21 15 4 18 2 17 16 10 12 14 22 14 13 3 5 25 23 8 9 1 13 6 14 2 13 7 12 14 RIGHT 3 4 11 FRONT 9 8 Figure 60 1. 2. 3. 4. 5. 6. 7. 8. 9. Speed control shaft Flange bearing (2) Carriage screw (2 per bearing) Lock nut (2 per bearing) Spacer RH end plate LH end plate Cap screw (2 per plate) Lock washer (2 per plate) 10. 11. 12. 13. 14. 15. 16. 17. The Groundsmaster 360 transmission includes two (2) piston pumps.
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When servicing the traction linkage on your Grounds− master 360, use the following information: 4. Adjust the link assemblies (item 12 in Fig. 60) as follows: A. Align transmission control arm with transmission side cover with a 3/8” alignment pin (Fig. 63). This ensures that transmission is in the neutral position. 11 12 13 6 19 9 5 4 3 18 15 2 1 3 8 7 FRONT Figure 61 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. B. Adjust length of link assembly (Fig.
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6. The rod end on the traction rod assembly is used to adjust the orientation of the traction pedal. With the traction pedal in the neutral position (shown in Figure 65), the standard height from the front platform (footrest) to the rear of the pedal is 1.760” to 1.890” (44.7 to 48.0 mm). If your Groundsmaster is equipped with an operator cab which has a layer of padding on the footrest, the standard height is 1.340” to 1.460” (34.3 to 37.0 mm).
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PAGE 116
Transmission 7 Antiseize Lubricant RIGHT FRONT 8 400 in−lb (45 N−m) 6 5 3 5 4 16 14 17 19 18 9 2 1 10 15 13 12 11 12 10 Figure 66 1. 2. 3. 4. 5. 6. 7. Transmission assembly Dowel pin (2) Cap screw (50 mm long) (6) Cap screw (35 mm long) Lock washer (7) Bracket Engine 8. 9. 10. 11. 12. 13. Flywheel housing Cap screw (2) Cap screw (4) Shield Lock nut (4) Driveshaft assembly 14. 15. 16. 17. 18. 19. O−ring Roll pin (2) Coupler Gear pump assembly Lock washer (2) Cap screw (2) 2.
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4. On both sides of machine, remove cap screw and flange nut that secures the pump control arm to the speed control shaft (Fig. 67). Note that cap screw is installed toward the right side of the machine. Locate and retrieve lock washer from between control arm and control shaft. SERIAL NUMBER BELOW 313999999 SHOWN 5. Unplug wire harness electrical connector from transmission solenoid valve coil. Position wire harness away from transmission. 10 6. Drain oil from hydraulic tank and transmission.
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58 to 72 ft−lb (79 to 97 N−m) RIGHT FRONT 60 to 74 ft−lb (82 to 100 N−m) 10 3 13 9 24 6 9 to 11 ft−lb (13 to 15 N−m) 18 11 3 2 3 16 19 8 14 26 16 21 20 35 to 43 ft−lb (48 to 58 N−m) 12 25 17 21 22 60 to 74 ft−lb (82 to 100 N−m) 35 to 43 ft−lb (48 to 58 N−m) 81 to 99 ft−lb (110 to 134 N−m) 9 to 11 ft−lb (13 to 15 N−m) 5 9 16 16 2 23 15 20 to 26 ft−lb (28 to 35 N−m) 15 7 19 4 20 1 Figure 69 1. 2. 3. 4. 5. 6. 7. 8. 9.
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1. Make sure that flywheel coupler and flywheel housing are secure on engine (see Engine Installation in the Service and Repairs section of Chapter 3 − Kubota Diesel Engine). 2. If hydraulic fittings were removed from transmission, lubricate and install new O−rings to fittings. Install fittings into transmission ports (see Hydraulic Fitting Installation in the General Information section of this chapter). Tighten fittings to torque values identified in Figure 69. 3.
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Transmission Service 3 4 5 8 7 6 11 10 9 12 13 14 2 RIGHT FRONT 15 1 19 21 23 18 17 16 26 27 28 22 29 30 24 25 58 59 31 32 57 33 56 55 54 41 40 51 52 37 53 34 50 49 26 48 47 46 47 46 44 43 39 20 42 77 38 35 36 45 67 66 63 64 57 57 68 69 40 41 26 30 65 63 62 44 61 43 60 70 78 37 75 37 74 73 72 71 41 40 38 39 31 76 Figure 70 Hydraulic System Page 4 − 82 Groundsmaster 360
PAGE 121
Figure 70 (continued) Solenoid assembly Solenoid valve assembly Bolt (3) Bolt (2) Hex plug (2) O−ring Pump body Pin (2) O−ring Charge pump assembly Key O−ring (5) Piston Spring Collar Bolt and washer (2) Accumulator cover Gasket Filter bypass valve assembly Hex drain plug Charge relief valve assembly Pressure valve assembly Socket head plug (4) Filter adapter Oil filter Retaining ring (4) 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52.
PAGE 122
5. Remove filter bypass plug, spring and valve from transmission pump body. Remove and discard O−ring from plug. 2 1 Figure 72 1. Filter bypass plug 2. Bypass valve 6. Remove pressure valve plug, spring and valve from transmission pump body. Remove and discard O−ring from plug. 7. Remove charge relief plug, spring and valve from transmission pump body. Remove and discard O−ring from plug. 1 2 Figure 73 1. Pressure valve plug 2. Charge relief plug 8.
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12.Remove three (3) shorter (45 mm) and two (2) longer (95 mm) flange head screws that secure pump body to center case. Remove pump body from center case. 1 2 Figure 76 1. Pump body 2. Center case 2 1 1 Figure 77 1. Pin 14.Slide outer and inner charge pump rotors from RH pump shaft. Remove key from key slot in pump shaft. 2. Pump body 2 3 1 Figure 78 1. RH pump shaft 2. Outer pump rotor Groundsmaster 360 Page 4 − 85 3. Inner pump rotor Hydraulic System Hydraulic System 13.
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15.Remove eight (8) socket head screws that secure center case to transmission pump housing. 16.Carefully remove center case assembly from transmission pump housing. 1 17.Remove two (2) pins from transmission pump housing bores. Remove and discard gasket. 3 2 Figure 79 1. Center case 2. Pump housing 18.Remove bypass valves from center case. Remove and discard O−rings and backup rings from bypass valves. 3. Pin (2) 1 5 IMPORTANT: The forward and reverse relief cartridges are different.
PAGE 125
21.Remove six (6) hex plugs from center case. Remove and discard O−rings from plugs. 2 3 22.Remove RH and LH flushing valve plugs, springs and valves from center case. Note differences in flushing valves and their locations for assembly purposes. Remove and discard O−rings from plugs. 4 1 Figure 82 1. Hex plug (6) 2. RH flushing valve 3. LH flushing valve 4. Center case 23.Taking care to not drop pistons from cylinder block, slide both cylinder block assemblies from pump shafts.
PAGE 126
28.Remove two (2) hex plugs and one (1) socket head plug from gear case housing. Remove and discard O− rings from plugs. 1 2 1 Figure 85 1. Hex plug 2. Socket head plug 29.Remove fifteen (15) flange head screws that secure gear case housing to transmission pump housing. 30.Carefully remove gear case housing from pump housing. 1 31.Locate and retrieve two (2) pins from gear case housing holes. Remove and discard gasket. 3 32.
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33.Remove input shaft, RH pump shaft and LH pump shaft assemblies from transmission pump housing. 1 34.Slide pipe assembly from bore of pump housing. Remove and discard two (2) O−rings from grooves in pipe. 3 2 4 Figure 87 3. LH pump shaft 4. Pipe Hydraulic System 1. Input shaft 2. RH pump shaft 35.If pump shaft bearing replacement is necessary, remove and discard seal ring from RH and LH pump shafts. Remove bearings from pump shaft using a bearing puller. Discard removed bearings.
PAGE 128
37.Remove PTO shaft assembly from transmission pump housing. 2 1 Figure 89 1. PTO shaft assembly 38.Remove final friction plate from transmission pump housing. 2. Pump housing 2 1 NOTE: This friction plate may have been removed with PTO shaft assembly. Figure 90 1. Friction plate Hydraulic System Page 4 − 90 2.
PAGE 129
39.Disassemble PTO shaft assembly: 5 6 2 A. Using a bearing puller, remove bearing from PTO shaft. Discard bearing. 1 4 B. Remove spacer from PTO shaft. C. Slide gear and clutch assembly from PTO shaft. D. Remove key from PTO shaft slot. 3 E. Remove two (2) seal rings from PTO shaft grooves. Discard seal rings. F. Remove B−plate, C−plate, three (3) A−plates and three (3) friction plates from PTO shaft. Figure 91 1. Bearing 2. PTO shaft 3. Spacer 4. Gear 5. Clutch assembly 6. Key G.
PAGE 130
42.If necessary, remove two (2) bearings from PTO gear. Discard removed bearings. Remove retaining ring from groove in PTO gear bore. 1 3 2 1 Figure 94 1. Bearing 2. PTO gear 3. Retaining ring 43.Remove two (2) plugs from transmission pump housing. Remove and discard O−rings from plugs. 2 3 1 Figure 95 1. Socket head plug 2. Hex plug 3. Pump housing 44.Remove three (3) socket head screws that secure both side covers to transmission pump housing. 45.
PAGE 131
47.Carefully remove swash plates from transmission pump housing. Remove washer from each swash plate. 1 2 48.Thoroughly clean and inspect all transmission components. 3 Figure 97 3. Pump housing Hydraulic System 1. Swash plate (2) 2.
PAGE 132
Transmission Assembly (Fig. 70) 1 IMPORTANT: When assembling the transmission, lubricate all transmission components with clean hydraulic oil. 2 3 1. Make sure that all transmission components are thoroughly clean before assembling the transmission. 2. Apply clean hydraulic oil to washers and swash plate surfaces. Install washer onto each swash plate and carefully install swash plates into transmission pump housing. Figure 98 1. Swash plate (2) 2. Washer 3. Pump housing 3.
PAGE 133
6. Install retaining ring into groove in bore of PTO gear. Press two (2) bearings into PTO gear until each bearing contacts the installed retaining ring. 1 3 2 1 Figure 101 1. Bearing 2. PTO gear 3. Retaining ring 7. Slide three (3) rods into holes in clutch assembly. Hydraulic System 8. Slide PTO gear assembly into clutch assembly. 3 2 1 Figure 102 1. Rod (3) 2. Clutch assembly 3. PTO gear 9. Assemble PTO shaft: 5 7 A. Press new bearing onto PTO shaft so that bearing is flush with shaft shoulder.
PAGE 134
10.Install clutch assembly and gear onto PTO shaft: 5 6 2 A. Install key into PTO shaft slot making sure that rounded ends of key align with rounded ends of shaft slot. 1 4 B. Slide clutch assembly and gear onto PTO shaft making sure to align slot in clutch with key in shaft. Also, align rods in clutch with holes in B−plate. 3 C. Place spacer onto PTO shaft. D. Press bearing onto PTO shaft so bearing is flush with shaft shoulder. Figure 104 1. Bearing 2. PTO shaft 3. Spacer 11.
PAGE 135
13.If shafts were disassembled, install gear and two (2) bearings onto input shaft, RH pump shaft and/or LH pump shaft. Make sure that bearings are pressed fully to the shaft shoulder. 1 4 3 4 2 Figure 107 1. RH pump shaft 2. LH pump shaft 15.Install RH and LH pump shaft assemblies into transmission pump housing. Then, install input shaft into pump housing making sure to align input shaft gear teeth with gears on PTO and pump shafts. 3. Input shaft 4. Seal ring 1 3 16.
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17.Place two (2) pins into transmission pump housing holes. Position new gasket to housing. 18.Carefully place gear case housing onto pump housing making sure to align pins, pipe and shaft bearings. 1 19.Secure gear case housing to pump housing with fifteen (15) flange head screws. Tighten screws evenly in a crossing pattern and then torque screws from 17 to 19 ft−lb (22 to 27 N−m). 3 2 20.Taking care to not damage input shaft oil seal, install oil seal into gear case housing bore.
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22.Taking care to not damage PTO oil seal, install oil seal into pump housing bore at PTO shaft. Place spacer on oil seal and secure with retaining ring. 2 3 23.Lubricate both sides of thrust plates with clean hydraulic oil. Place thrust plate onto each swash plate making sure to position the beveled side of the thrust plates against the swash plate surface. 1 24.Slide control arm onto each trunnion shaft and secure with socket head screw and nut. Torque nut from 20 to 23 ft−lb (27 to 32 N−m).
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30.Lubricate O−rings and backup rings for bypass valves. Position rings on bypass valves and install valves into center case. Torque valves from 62 to 79 in− lb (7 to 9 N−m). 1 5 31.Lubricate sealing washers and install onto forward and reverse relief valve cartridges. 2 IMPORTANT: The forward and reverse relief cartridges are different. Use labels made during disassembly to make sure the relief cartridges are properly installed. 32.
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37.Install key into key slot in RH pump shaft. Lubricate inner and outer charge pump rotors with clean hydraulic oil. Slide inner rotor onto pump shaft and align with key. Place outer rotor onto inner rotor. 2 3 1 Figure 117 1. RH pump shaft 2. Outer pump rotor 3. Inner pump rotor 39.Apply clean grease to pump body O−rings to hold them in position during assembly. Place O−rings in pump body locations. 2 1 1 Figure 118 1. Pin 2. Pump body 40.
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41.Lubricate new O−rings and install O−rings onto two (2) hex plugs. Install plugs into pump body. Torque plugs from 14 to 15 ft−lb (18 to 21 N−m). 42.Apply sealant to threads of four (4) socket head plugs and install into pump body. Torque plugs from 78 to 95 in−lb (8.8 to 10.8 N−m). 1 2 Figure 120 1. Hex plug (2) 2. Socket plug (4) 43.Lubricate accumulator components with clean hydraulic oil. Install piston, spring and collar into pump body.
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50.Lubricate solenoid valve spring, sleeve and spool with clean hydraulic oil and install into pump body. Make sure that sleeve is installed so that holes are closest to the spring location and that step in spool is toward spring location as well. Place pin in spool. 7 6 5 51.Install solenoid valve stem into pump body and torque from 186 to 195 in−lb (21 to 22 N−m). 2 52.Place O−ring, solenoid coil, O−ring, washer, lock washer and nut onto solenoid valve stem.
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CrossTraxTM AWD Control Manifold (4WD Machines) 14 6 9 7 13 11 5 6 4 10 6 3 7 8 2 5 1 RIGHT FRONT 12 Figure 126 1. 2. 3. 4. 5. Cap screw (2) Flange nut (2) 90o hydraulic fitting Mount (2) Washer (4) 6. 7. 8. 9. 10. O−ring O−ring Washer (2) 45o hydraulic fitting (2) Mount plate Removal (Fig. 126) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch.
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5. Disconnect hydraulic hoses from control manifold. The hoses at control manifold ports LR and RR need to be disconnected at hydraulic tubes before removal from manifold (Fig. 127). 2 6. Install clean caps or plugs on disconnected hoses and fittings to prevent contamination. 7. Support manifold to prevent it from falling. 8. Remove two (2) cap screws (item 1) and washers (item 5) that secure manifold to mount plate. Remove manifold from machine. 10.
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CrossTraxTM AWD Control Manifold Service (4WD Machines) 6 30 to 35 ft−lb (41 to 47 N−m) 1 1 25 to 30 ft−lb (34 to 41 N−m) 30 to 35 ft−lb (41 to 47 N−m) 5 7 7 ft−lb (9.5 N−m) 2 2 4 3 Figure 128 1. Pilot directional valve − PD1 & PD2 (2) 2. Orifice 0.040 − OR3 and OR4 (2) 3. Orifice 0.090 − OR1 and OR2 (2) 4. Hex plug 5. Check valve − CV1 and CV2 (2) 6. Relief valve (CRV) 7.
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Cartridge Valve Service CAUTION Before opening hydraulic system, operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the General Information section of this chapter. IMPORTANT: An orifice is threaded into control manifold ports OR1, OR2, OR3 and OR4. If any orifice is removed from manifold, make sure to label its position for assembly purposes.
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Control Manifold Cartridge Valve Service CAUTION CAUTION Before opening hydraulic system, operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the General Information section of this chapter. 1. Make sure the control manifold is clean before removing the cartridge valve from the control manifold. 2. If cartridge valve is solenoid operated, remove nut securing solenoid coil to the cartridge valve.
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PAGE 148
Gear Pump RIGHT FRONT 20 19 12 14 6 13 5 15 4 11 2 18 10 8 3 1 10 9 16 15 17 7 Figure 129 1. 2. 3. 4. 5. 6. 7. Transmission assembly Coupler O−ring O−ring Hydraulic fitting O−ring Hydraulic hose (output) Hydraulic System 8. 9. 10. 11. 12. 13. 14. Cap screw (2) Lock washer (2) O−ring Hydraulic tee fitting Hose clamp Hydraulic hose Hydraulic hose (suction) Page 4 − 110 15. 16. 17. 18. 19. 20.
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Removal (Fig. 129) Installation (Fig. 129) 1. If hydraulic fittings were removed from pump, lubricate and install new O−rings to fitting. Install fittings into gear pump ports (see Hydraulic Fitting Installation in the General Information section of this chapter). Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved. See Relieving Hydraulic System Pressure in the General Information section. 1.
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Gear Pump Service 220 in−lb (25 N−m) 8 7 5 6 4 3 2 10 1 9 11 7 12 220 in−lb (25 N−m) 13 14 15 16 17 18 Figure 130 1. 2. 3. 4. 5. 6. Shaft seal Front back−up seal Front pressure seal Drive gear Rear pressure ring Rear back−up seal 7. 8. 9. 10. 11. 12. O−ring Implement relief valve Socket head screw (4) Lock washer (4) Back plate Body Disassembly (Fig. 130) 13. 14. 15. 16. 17. 18. Dowel pin Rear bearing block Idler gear Front bearing block Front plate Retaining ring MARKER LINES 1.
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6. Remove front plate from the body, then remove back plate. Locate and remove dowel pins from body. IMPORTANT: Mark the relative positions of the gear teeth and bearing blocks so they can be assembled in the same position. Do not touch the gear surfaces as residue on hands may be corrosive to gear finish. 7. Place pump on its side and push on the rear bearing block to remove bearing blocks and gear set from the pump body. NOTE: Pressure seals and back−up rings fit in grooves machined into bearing blocks.
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Assembly (Fig. 130) NOTE: When assembling the pump, check the V− shaped marker line made during disassembly to make sure components are properly aligned. 1. Lubricate new O−rings, pressure seals and back−up gaskets with a thin coat of petroleum jelly. Lubricate all internal pump parts freely with clean hydraulic oil. 2. Install new shaft seal in front plate. Note orientation of seal lips during installation (Fig. 132). Seal should be pressed into place until it reaches the bottom of the bore. 3.
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PAGE 154
Steering Control Valve 14 2 3 1 Antiseize Lubricant 5 34 to 42 ft−lb (47 to 56 N−m) 20 to 26 ft−lb (28 to 35 N−m) 13 11 10 7 34 to 42 ft−lb (47 to 56 N−m) 12 9 4 RIGHT 8 FRONT 6 Figure 134 1. 2. 3. 4. 5. Steering wheel Lock nut Flat washer Alignment bushing Steering column assembly 6. 7. 8. 9. 10. Steering control valve Steering plate Carriage screw (4) Mount (4) Washer (4) Flange nut (4) Flange head screw (3) Socket head screw Steering wheel cover 2.
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5. Put caps or plugs on disconnected lines and fittings to prevent contamination. 7. Remove caps and plugs from disconnected hydraulic lines and fittings. 6. While supporting steering column to prevent it from falling, loosen and remove four (4) carriage screws (item 8) and flange nuts (item 11) that secure steering column assembly to machine. Locate and retrieve four (4) washers (item 10) and mounts (item 9). 8.
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Steering Control Valve Service 26 1 27 5 4 8 28 3 24 2 7 19 30 20 19 6 25 23 22 29 21 150 in−lb (17 N−m) 9 10 13 12 11 14 140 to 160 in−lb (16 to 18 N−m) 15 16 17 18 Figure 137 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Steering valve housing Dust seal O−ring Spool Spring retaining ring Pin Sleeve Centering springs/spacers Cap screw (7) End cap 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Disassembly (Fig. 137) 1. Remove the seven (7) cap screws from the steering valve assembly. 2.
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8. Put the thrust bearing and races into the housing. The thrust bearing goes between the two races (Fig. 138). The centering springs are under tension. Remove the retaining ring carefully. IMPORTANT: Do not damage the dust or quad seals when installing the spool and sleeve assembly. 10.Remove the spring retaining ring and centering springs from the spool. 9. Apply a light coating of clean hydraulic fluid to the spool and sleeve assembly and slide carefully the assembly into the housing. Assembly (Fig.
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Steering Cylinder (Serial Number Below 314999999) FRONT AXLE 83 to 101 ft−lb (113 to 136 N−m) REAR AXLE 8 9 8 11 83 to 101 ft−lb (113 to 136 N−m) 9 7 10 12 6 10 5 18 4 4 17 3 5 6 19 13 2 13 2 11 12 1 16 14 14 14 15 16 RIGHT FRONT RIGHT FRONT 14 57 to 75 ft−lb (78 to 101 N−m) 80 to 90 ft−lb (109 to 122 N−m) 15 80 to 90 ft−lb (109 to 122 N−m) Figure 139 1. 2. 3. 4. 5. 6. 7.
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3. If rear steering cylinder is to be removed from machine, the storage compartment behind operator seat needs to be removed to allow clearance for cylinder removal. To remove storage compartment, see Storage Compartment Removal in the Service and Repairs section of Chapter 6 − Chassis or, if machine is equipped with operator cab, see Storage Compartment Removal in the Service and Repairs section of Chapter 8 − Operator Cab. 4.
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10.Lubricate steering cylinder ball joint grease fittings. 13.If removed, secure front cover to front axle (Fig. 140). 11. Follow Hydraulic System Start−up procedures (see Hydraulic System Start−up in this section). 14.
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PAGE 162
Steering Cylinder (Serial Number Above 315000000) 6 FRONT AXLE 5 18 REAR AXLE 6 4 5 4 3 9 8 83 to 101 ft−lb (113 to 136 N−m) 19 9 8 10 10 13 13 7 11 2 83 to 101 ft−lb (113 to 136 N−m) 11 2 9 9 12 12 1 17 14 16 RIGHT FRONT 14 14 15 RIGHT FRONT 14 80 to 90 ft−lb (109 to 122 N−m) 16 80 to 90 ft−lb (109 to 122 N−m) 15 Figure 142 1. 2. 3. 4. 5. 6. 7.
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3. If rear steering cylinder is to be removed from machine, the storage compartment behind operator seat needs to be removed to allow clearance for cylinder removal. To remove storage compartment, see Storage Compartment Removal in the Service and Repairs section of Chapter 6 − Chassis or, if machine is equipped with operator cab, see Storage Compartment Removal in the Service and Repairs section of Chapter 8 − Operator Cab. 4.
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11. Follow Hydraulic System Start−up procedures (see Hydraulic System Start−up in this section). 12.Check that steering cylinder does not contact the axle or frame as cylinder moves from fully retracted to fully extended. Also, check that distance between the drag links and steering stops are equal on both sides of the machine. If necessary, adjust location of rod end on cylinder shaft. Hydraulic System 13.If removed, secure front cover to front axle (Fig. 7). 14.
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PAGE 166
Steering Cylinder Service 8 9 10 11 1 15 2 14 13 3 12 11 4 10 9 8 5 6 7 1 Figure 145 1. 2. 3. 4. 5. Collar (2) Front head Barrel Front rod Piston assembly 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Rear rod Rear head Dust seal (2) Head seal (2) Back−up ring (2) O−ring (2) O−ring Piston seal Wear ring Roll pin NOTE: Front and rear steering cylinders used on the Groundsmaster 360 are the same and use the same service procedures. 2.
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IMPORTANT: When removing roll pin from front and rear rods, make sure that rod surfaces are not damaged. 7. Remove and discard roll pin (item 15) that secures front rod to rear rod. Then remove rear rod (item 6), piston (item 5) and front head (item 2) from front rod. 8. Remove and discard seals, O−rings and wear ring from piston and heads. Assembly (Fig. 145) 1. Use a new seal kit to replace all seals, O−rings and wear ring to piston and heads.
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Steering Control Manifold (4WD Machines) 12 3 1 13 2 4 9 2 6 3 9 8 7 3 11 5 10 RIGHT FRONT Figure 146 1. 2. 3. 4. 5. Steering control manifold O−ring (4) 90o hydraulic fitting (3) Mount (2) Washer (2) 6. 7. 8. 9. Straight hydraulic fitting Flange nut (2) Washer (2) O−ring (4) 10. 11. 12. 13.
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Manifold Removal (Fig. 146) Manifold Installation (Fig. 146) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 1. If hydraulic fittings were removed from steering control manifold, lubricate new O−rings with clean hydraulic oil, position O−rings to fittings and install fittings into manifold ports (see Hydraulic Fitting Installation in the General Information section of this chapter). WARNING 2.
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Steering Control Manifold Service (4WD Machines) NOTE: The ports on the steering control manifold are marked for easy identification of components. See Hydraulic Schematic in Chapter 9 − Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each manifold port. 4 3 60 in−lb (6.7 N−m) CAUTION 2 Before opening hydraulic system, operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil.
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PAGE 172
Deck Lift Manifold 7 11 8 9 7 12 13 SERIAL NUMBER BELOW 313999999 SHOWN 10 7 14 1 6 15 5 16 17 2 3 4 RIGHT FRONT Figure 148 1. 2. 3. 4. 5. 6. Steering control manifold Flat washer (2) Cap screw (2) AWD control manifold O−ring 90o hydraulic fitting 7. 8. 9. 10. 11. 12. O−ring (7) O−ring Straight hydraulic fitting Deck lift manifold Flange nut (2) Hydraulic adapter NOTE: On machines with serial number below 313999999, the deck lift manifold mount plate is secured to the frame (Fig. 148).
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3. Thoroughly clean hydraulic hose ends and fittings on deck lift manifold to prevent hydraulic system contamination. SERIAL NUMBER ABOVE 314000000 SHOWN 4. Label all hydraulic and electrical connections for assembly purposes. 12 1 11 2 16 15 5. Disconnect hydraulic hoses connected to the hydraulic fittings on the deck lift manifold. Allow hoses to drain into a suitable container. Install clean caps or plugs on disconnected hoses and fittings to prevent contamination. 14 10 13 6 6.
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Deck Lift Manifold Service SERIAL NUMBER BELOW 314999999 SERIAL NUMBER ABOVE 315000000 7 60 in−lb (6.7 N−m) 7 8 6 60 in−lb (6.7 N−m) 8 10 5 20 ft−lb (27 N−m) 5 5 20 ft−lb (27 N−m) 4 20 ft−lb (27 N−m) 4 3 3 20 ft−lb (27 N−m) 1 2 25 ft−lb (34 N−m) 25 ft−lb (34 N−m) 1 9 2 Figure 150 1. 2. 3. 4. Lift control manifold Zero leak plug with O−ring Solenoid valve (raise) Solenoid valve (lower) 5. Solenoid coil 6. Coil spacer 7.
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Deck Lift Manifold Service CAUTION Before opening hydraulic system, operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the General Information section of this chapter. WARNING Hydraulic System If lift manifold is attached to machine, make sure that cutting deck is fully lowered and supported before loosening hydraulic lines, cartridge valves or plugs from lift manifold.
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Lift Cylinder 6 7 8 1 2 3 4 5 RIGHT FRONT Figure 151 1. Lift cylinder 2. Pivot pin 3. Grease fitting Hydraulic System 4. Shoulder bolt 5. Lift shaft assembly 6. Cylinder shaft Page 4 − 138 7. Washer (2) 8.
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Installation (Fig. 151) WARNING Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved. See Relieving Hydraulic System Pressure in the General Information section. 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. WARNING Make sure that cutting deck is fully lowered and supported before loosening hydraulic lines from lift cylinder.
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Lift Cylinder Service 13 12 11 1 10 9 8 2 3 7 4 40 ft−lb (54 N−m) 5 6 1 3 13 4 12 7 2 5 11 10 9 8 6 Figure 153 1. 2. 3. 4. 5. Grease fitting Barrel Nut O−ring Head Hydraulic System 6. 7. 8. 9. Collar Shaft Dust seal Rod seal Page 4 − 140 10. 11. 12. 13.
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Disassembly (Fig. 153) Assembly (Fig. 153) 1. Remove oil from lift cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder. 1. Make sure all parts are clean before reassembly. 2. Mount lift cylinder in a vise. Use of a vise with soft jaws is recommended. A. Install piston seal and O−ring to the piston. B. Install dust seal, O−ring, back−up ring and dust seal to the head. 3. Carefully remove collar with a pipe wrench.
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Quick Attach System (QAS) Control Manifolds (Optional Kit for 4WD Machines) 9 13 11 5 9 10 1 8 3 5 6 2 7 5 10 5 RIGHT 9 7 12 FRONT 3 4 Figure 154 1. 2. 3. 4. 5. QAS frame assembly Angle control manifold Flange head screw (5) Guard plate O−ring (5) Hydraulic System 6. 7. 8. 9. Straight fitting O−ring Cap screw (2) Straight hydraulic fitting (4) Page 4 − 142 10. 11. 12. 13.
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Manifold Removal (Fig. 154) 7. Disconnect hydraulic lines from control manifold. 1. Remove attachment from QAS frame. 8. Install clean caps or plugs on disconnected hydraulic lines and fittings to prevent contamination. 2. Park machine on a level surface and make sure that QAS frame is fully lowered. Stop engine, engage parking brake and remove key from the ignition switch. 9. Disconnect wire harness connector from solenoid coil(s) on manifold. 10.Support manifold to prevent it from falling.
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Quick Attach System (QAS) Control Manifold Service (Optional Kit for 4WD Machines) UP UP 60 in−lb (6.8 N−m) 13 10 10 25 ft−lb (34 N−m) 11 11 10 4 25 ft−lb (34 N−m) 3 10 9 75 ft−lb (101 N−m) 20 ft−lb (27 N−m) 8 60 in−lb (6.8 N−m) 13 12 3 6 20 ft−lb (27 N−m) 7 20 ft−lb (27 N−m) 6 2 1 5 14 Figure 155 1. 2. 3. 4. 5. QAS angle control manifold Orifice 0.080 − port C3 Check valve − ports CV1 and CV2 (2) Plug 90o hydraulic fitting (2) Hydraulic System 6. 7. 8. 9. 10.
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NOTE: The ports on the QAS control manifolds are marked for easy identification of components. See Hydraulic Schematic for Groundsmaster 360 with 4WD in Chapter 9 − Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each manifold port. 4 3 QAS Control Manifold Cartridge Valve Service 20 ft−lb (27 N−m) 60 in−lb (6.
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Oil Cooler 19 20 21 18 19 RIGHT FRONT 1 22 6 17 9 5 17 7 10 15 9 13 2 14 3 17 16 25 11 8 4 21 24 19 12 23 26 5 Figure 158 1. 2. 3. 4. 5. 6. 7. 8. 9. Radiator support Fan shroud Radiator/oil cooler assembly Bulb seal (2) Isolator mount (3) Bulb seal (2) Upper radiator hose Lower radiator hose Hose clamp (4) Hydraulic System 10. 11. 12. 13. 14. 15. 16. 17. 18.
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Removal (Fig. 158) Installation (Fig. 158) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 1. If hydraulic fittings were removed from oil cooler, lubricate and install new O−rings to fittings. Install fittings into oil cooler ports. 2. Raise hood and secure it in the raised position. 2. Secure oil cooler to radiator (Fig. 159). 3. Check that gap between oil cooler and radiator is less than 0.090” (2.3 mm).
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PAGE 187
Chapter 5 Electrical System Table of Contents Groundsmaster 360 PTO Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deck Lift Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Selector Switch (4WD Machines) . . . . . Air Conditioning Switch (4WD Machines with Operator Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . Windshield Washer/Wiper Switch (4WD Machines with Operator Cab) . . . . . . . . . . . . . . Seat Switch . . . . . . . . . . . . . . . . .
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General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional information when servicing the machine. Electrical Drawings The electrical schematic and wire harness drawings for the Groundsmaster 360 are located in Chapter 9 − Foldout Drawings.
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Standard Control Module (SCM) (2WD Machines) Electrical System Groundsmaster 360 machines with 2WD are equipped with a Standard Control Module (SCM) to monitor and control electrical components required for safe operation. The SCM can be used to check operation of machine switches by monitoring the SCM LED’s. Information on the Standard Control Module is included in the Component Testing section of this chapter. Groundsmaster 360 Page 5 - 3 (Rev.
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Special Tools Order special tools from your Toro Distributor. Some tools may also be available from a local tool supplier. Multimeter The multimeter can test electrical components and circuits for current, resistance or voltage. Obtain this tool locally. NOTE: Toro recommends the use of a DIGITAL Volt− Ohm−Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital meter in the voltage mode will make sure that excess current is not allowed through the meter.
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Battery Terminal Protector Aerosol spray that should be used on battery terminals, ring terminals and fork terminals to reduce corrosion problems. Apply terminal protector to the connection after the battery cable, ring terminal or fork terminal has been secured. Toro Part Number: 107−0392 Figure 4 Dielectric Gel Do not use dielectric gel on sealed connection terminals as the gel can unseat connector seals during assembly.
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Troubleshooting Make sure that all machine interlock switches are functioning correctly for proper troubleshooting and safety. CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the battery cables unless the test requires battery voltage. For effective troubleshooting and repairs, there must be a good understanding of the electrical circuits and components used on this machine.
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Retrieving Fault Codes All machine fault codes are retained in the TEC controller memory. The three (3) most recent fault codes that have occurred within the last forty (40) hours of operation can be retrieved using the diagnostic light. To retrieve these fault codes from the controller memory, perform the following steps: 2. Place machine in fault retrieval mode (see above). The diagnostic light should be displaying the fault codes. 3. Press the steering selector switch to the 4 wheel steering position.
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Fault Code (Lamp Flashes) Fault Description 1−1 High engine temp warning occurred (PTO was shutdown by controller) 1−2 High engine temp shutdown occurred (engine was shutdown by controller) 1−3 Low engine oil pressure occurred 1−4 Engine alternator fault occurred 1−5 Charging voltage was out of acceptable range 2−1 Upper fuse 3 (7.5 amp) for TEC outputs is faulty 2−2 Upper fuse 2 (7.5 amp) for TEC outputs is faulty 2−3 Upper fuse 1 (7.
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Diagnostic Display (4WD Machines) Groundsmaster 360 machines with 4WD are equipped with a Toro Electronic Controller (TEC) which controls machine electrical functions. The controller monitors various input switches (e.g. ignition switch, seat switch, etc.) and energizes outputs to actuate solenoids or relays for the requested machine function. 2 For the controller to properly control the machine, each of the input switches, output solenoids and relays must be connected and functioning properly.
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5. The “INPUTS DISPLAYED” LED, on lower right column of the Diagnostic Display, should be illuminated. If the green “OUTPUTS DISPLAYED” LED is illuminated, press the toggle button on the Diagnostic Display to change to “INPUTS DISPLAYED” LED. 6. The Diagnostic Display will illuminate the LED associated with each of the inputs when that input is in the position identified on the Diagnostic Display overlay. Individually, change the position of each of the inputs (i.e. sit on seat, press traction pedal, etc.
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Diagnostic Display LED Operation ASSY PRESENT Optional kit with second TEC controller installed: LED ON Optional kit with second TEC controller NOT installed: LED OFF STEERING OFF CTR RH front wheel turned (not aimed straight ahead): LED ON RH front wheel NOT turned (aimed straight ahead): LED OFF 4 WHEEL STEER Steering selector switch in 4 wheel steering position: LED ON Steering selector switch in 2 wheel steering position: LED OFF TEMP WARNING Engine coolant temperature has exceeded 220oF (105oC)
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Verify Diagnostic Display Output Functions The Diagnostic Display has the ability to detect which output solenoids or relays are turned on by the TEC controller. This is a quick way to determine if a machine malfunction is electrical or hydraulic. NOTE: If the “DIAG. LAMP” output LED is blinking, this indicates that the TEC controller has detected a fault during machine operation. Refer to Diagnostic Light in this section for information on retrieval and clearing of controller faults. A.
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Diagnostic Display LED Operation STARTER TEC output exists to energize starter relay: LED ON No TEC output to starter relay: LED OFF ETR TEC output exists to energize fuel stop solenoid and fuel pump: LED ON No TEC output to fuel stop solenoid and fuel pump: LED OFF PREHEAT TEC output exists to energize glow plug relay: LED ON No TEC output to glow plug relay: LED OFF DIAG LAMP Diagnostic lamp is ON or FLASHING: LED ON or FLASHING Diagnostic lamp is not ON or FLASHING: LED OFF MOW CLUTCH TEC outpu
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Standard Control Module Logic Chart (2WD Machines) Engine Run (Operator in Seat) − Engine Run (No Operator in Seat) − Mow − High Temperature Warning − High Temperature Shutdown − − − − − − − + + NA − − NA − − NA − NA − NA − NA − PTO − Engine Start + Engine Run − OUTPUTS Engine Start (No Operator in Seat) − Backlap − High Temperature Shutdown − High Temperature Warning + In Seat Parking Brake Off − MACHINE FUNCTION PTO Switch Neutral Engine Start (Operator in
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TEC Logic Chart (Machines with 4WD) X X X X X Lower Cutting Deck (or Implement) X X X X X X PTO Solenoid Energized Lift Manifold SV2 Energized (Deck Float) Lift Manifold SV1 Energized (Deck Lift) Engine Start (Run Solenoid and Start Solenoid Energized) Fuel Pump and Engine Run Solenoid Hold Coil Energized Engine Glow Plugs Energized P P P X P P P X X P X X P X P X P P X P P P P X X Raise Cutting Deck (or Implement) X Diagnostic Light Fault Retrieval X X Clearing F
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Starting Problems Problem Possible Causes Nothing happens when start attempt is made. The traction pedal is not in the neutral position. NOTE: On 4WD machines, if excessive engine coolant temperature causes the engine to stop, the engine can be restarted for ten (10) seconds to allow the machine to be moved. After ten seconds in this condition, the engine will again shutdown. The traction neutral sensor is out of adjustment or is faulty.
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Starting Problems (continued) Problem Possible Causes The engine cranks, but does not start. The fuel tank is empty. Wiring in the engine crank circuit is loose, corroded or damaged (see electrical schematic in Chapter 9 − Foldout Drawings). The fuel filter is plugged. The engine and/or fuel may be too cold. The wire harness fusible link to the engine run solenoid is faulty. The engine run solenoid or circuit wiring is faulty. The engine fuel pump or circuit wiring is faulty.
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General Run and Transport Problems Problem Possible Causes Engine stops during operation (operator sitting on seat). Operator not in center of seat (seat switch is not depressed). Fuel tank is empty. Machine is being operated on a slope with a low fuel level. The parking brake was engaged or the parking brake sensor is faulty. Fuse(s) is (are) faulty (other electrical components most likely affected as well). The engine temperature is excessive (above 240oF / 115oC). The seat switch is faulty.
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Cutting Deck Operating Problems Problem Possible Causes With a running engine, the cutting deck will not run with The operator seat is unoccupied. the PTO switch in the ON (up) position. The seat switch or circuit wiring is faulty. Wiring to the transmission PTO solenoid valve coil is loose, corroded or damaged (see electrical schematic in Chapter 9 − Foldout Drawings). The transmission PTO solenoid valve coil is faulty. The PTO switch is faulty. Upper fuse 2 for TEC outputs (7.
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4 Wheel Steer Operating Problems (4WD Machines) Problem Possible Causes Cannot change between 2 and 4 wheel steer. Wheels are not directed straight ahead when steering selector switch is pressed (switch light should be flashing). Upper fuse 1 for TEC outputs (7.5 amp) is faulty. The steering home sensor is out of adjustment. The steering home sensor bracket is loose or damaged. The steering selector switch or circuit wiring is faulty. The steering manifold solenoid valve coil is faulty.
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Electrical System Quick Checks Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the battery terminals. Set multimeter to the DC volts setting. The battery should be at a temperature of 60o to 100oF (16o to 38oC). The ignition key should be off and all accessories turned off. Connect the positive (+) meter lead to the positive battery post and the negative (−) meter lead to the negative battery post. Measure and record the battery voltage.
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Check Operation of Interlock Switches 1. Make sure all bystanders are away from the area of operation. Keep hands and feet away from cutting deck. CAUTION 2. With the operator in the seat, the engine must not start with either the PTO switch in the ON position or the traction control pedal moved from the neutral position. Diagnose and correct problem if machine does not operate properly. Check the operation of the interlock switches daily for proper operation.
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Adjustments Traction Neutral Sensor The traction neutral sensor is a normally open proximity sensor that closes when the traction pedal is in the neutral position. The sensor mounts to a bracket on the right side of the traction speed control shaft (Fig. 14 or 15). SERIAL NUMBER BELOW 315000000 5 On machines with serial number below 315000000 (Fig.
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Parking Brake Sensor The parking brake sensor acts as an input for the TEC controller to determine when the parking brake is applied (brake latch engaged). The brake sensor is a normally open proximity sensor that is attached to the bottom of the brake pedal (Fig. 16). 6 4 5 When the parking brake is not applied (brake latch not engaged), the parking brake detent is positioned near the target end of the parking brake sensor so the sensor is closed.
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Steering Home Sensor (4WD Machines) 3. After adjustment to the steering home sensor, use the Diagnostic Display to verify that the steering home sensor and circuit wiring are functioning correctly (see Steering Home Sensor in the Component Testing section of this chapter). The steering home sensor is a normally open proximity sensor. The sensor mounts to a bracket that is secured to the bottom of the front axle near the left side front steering fork (Fig. 18).
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Component Testing For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before doing a continuity check on the switch). CAUTION When testing electrical components for continuity with a multimeter (ohms setting), make sure that power to the circuit has been disconnected.
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Ignition Switch (Serial Number Above 312000300) The ignition (key) switch is located on the control panel and has three positions: OFF, RUN and START (Fig. 20). On 2WD machines, the Standard Control Module (SCM) monitors the operation of the ignition switch. When the ignition switch is in the RUN or START position, the SCM power input LED should be illuminated. If the ignition switch is in the START position, the SCM start input LED should be illuminated. 6.
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Indicator Lights Charge Indicator Light 4 The charge indicator light should come on when the ignition switch is in the RUN position with the engine not running. Also, it should illuminate with an improperly operating charging circuit while the engine is running. 3 Engine Oil Pressure Light The engine oil pressure light should come on when the ignition switch is in the RUN position with the engine not running.
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Hour Meter 1. Park machine on a level surface, lower cutting deck, engage parking brake and stop engine. 2. Remove control panel to gain access to hour meter (see Control Console Disassembly in the Service and Repairs section of Chapter 6 − Chassis). 2 1 3. Make sure ignition switch is in the OFF position. Disconnect machine wire harness electrical connector from the hour meter. 4. Connect the positive (+) terminal of a 12 VDC source to the positive terminal of the hour meter. 5.
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Fuses (2WD Machines) The fuse block is attached to the seat support under the operator seat. Fuse Identification and Function Use Figure 28 to identify each individual fuse and its correct amperage. Fuses for the Groundsmaster 360 with 2WD have the following function: Upper Fuse 1 (10 Amp): Protects power supply for ignition switch circuits. Upper Fuse 2 (15 Amp): Protects power supply for power point and optional light kit.
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Fuses (4WD Machines) The fuse block is attached to the seat support under the operator seat. In addition to the fuses in the fuse blocks, an in−line fuse is included in the wire harness near the battery (Fig. 30). Fuse Identification and Function Use Figure 29 to identify each individual fuse and its correct amperage. Fuses for the Groundsmaster 360 with 4WD have the following function: Upper Fuse 1 (10 Amp): Protects power supply for operator cab power relay circuit 7.5A 7.
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Operator Cab Fuses (4WD Machines with Operator Cab) The operator cab fuse blocks are located in the cab headliner (Fig. 31). 1 2 On machines with a serial number below 314999999 that include an operator cab, a 50 amp maxi−fuse is included in the operator cab wire harness. This fuse protects the cab power circuits and resides in a fuse holder attached to the air cleaner bracket near the rear steering cylinder.
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PTO Switch The PTO switch is located on the control panel (Fig. 33). The PTO switch is pulled up to engage the PTO (cutting deck). On 2WD machines, the Standard Control Module (SCM) monitors the operation of the PTO switch. If the ignition switch is in the RUN position and the PTO switch is engaged, the SCM PTO switch input LED should be illuminated. On 4WD machines, the Toro Electronic Controller (TEC) monitors the operation of the PTO switch. 6. Replace PTO switch if testing determines that it is faulty.
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Deck Lift Switch The deck lift switch is used to raise or lower the cutting deck. The deck lift switch is located on the control panel (Fig. 36). The engine must be running to allow the cutting deck to be raised or lowered. When the front of the lift switch is depressed, the deck will lower fully. When the rear of the lift switch is depressed and held, the deck will raise. When raising the deck, the deck will remain in position if the switch is released. 6.
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Steering Selector Switch (4WD Machines) The steering selector switch on 4WD machines is used to control 4 wheel steer operation. The steering selector switch is located on the control panel (Fig. 39). When the front of the steering selector switch is depressed with the wheels directed straight ahead, steering will only be active on the front wheels. This position is recommended for transporting the machine.
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Air Conditioning Switch (4WD Machines with Operator Cab) The air conditioning switch is used to turn the air conditioning on and off. When the front of the switch is depressed, air conditioning will be on. When the rear of the switch is depressed, air conditioning will be off. The air conditioning switch is located on the cab control panel (Fig. 42). 1 Testing 1. Park machine on a level surface, lower cutting deck, engage parking brake and stop engine. 2 Figure 42 2.
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Windshield Washer/Wiper Switch (4WD Machines with Operator Cab) The windshield washer/wiper switch is used to control the windshield washer and wiper. When the front of the switch is depressed, both the wiper and the washer will be off. When the switch is in the center position, the wiper will be on. Both the washer and wiper will be on when the rear of the switch is depressed and held. The washer/wiper switch is located on the cab control panel (Fig. 45). 2 1 Testing 1.
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Seat Switch B. Press directly onto the seat switch through the seat cushion. There should be continuity between the seat switch harness terminals as the seat cushion approaches the bottom of its travel indicating that the seat switch is functioning. The seat switch is normally open and closes when the operator is on the seat. If the traction system or PTO switch is engaged when the operator raises out of the seat, the engine will stop. The seat switch and its electrical connector (Fig.
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Traction Neutral Sensor The traction neutral sensor is a normally open proximity sensor that closes when the traction pedal is in the neutral position. The sensor mounts to a bracket on the traction control shaft (Fig. 49 or 50). SERIAL NUMBER BELOW 315000000 2 1 On machines with serial number below 315000000 (Fig. 49), the sensing plate for the traction neutral sensor is the head of the socket head screw that secures the ball bearings to the neutral centering arm assembly.
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6. If the neutral sensor LED did not function correctly: A. Make sure that neutral sensor is properly adjusted (see Traction Neutral Sensor in the Adjustments section of this chapter). If necessary, adjust sensor and return to step 4 above. 7. After testing is complete, make sure that sensor connector is plugged into machine wire harness. 8. Lower operator seat. B. Make sure ignition switch is OFF and disconnect the traction neutral sensor connector from the machine wire harness. C.
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Parking Brake Sensor 6. If the brake sensor LED did not function correctly: A. Make sure that parking brake sensor is properly adjusted (see Parking Brake Sensor in the Adjustments section of this chapter). If necessary, adjust sensor and return to step 4 above. When the parking brake is not applied (brake latch not engaged), the parking brake detent is positioned near the target end of the parking brake sensor so the sensor is closed.
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Steering Home Sensor (4WD Machines) The steering home sensor is used on Groundsmaster 360 machines with 4WD to determine when the wheels are directed straight ahead. The sensor acts as an input for the Toro Electronic Controller (TEC) to determine when steering can be changed from 4 wheel steering to 2 wheel steering. 6. If the steering sensor LED did not function correctly: The steering home sensor is a normally open proximity sensor.
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Standard Control Module (2WD Machines) Groundsmaster 360 machines with 2WD are equipped with a Standard Control Module (SCM) to monitor and control electrical components required for safe operation. The SCM is attached to the frame under the operator seat (Fig. 53). Inputs from the ignition, neutral, parking brake, PTO, seat, high temperature warning and high temperature shutdown switches are monitored by the SCM.
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Toro Electronic Controller (TEC) (4WD Machines) Groundsmaster 360 machines with 4WD use a Toro Electronic Controller (TEC) to monitor the condition of various switches (inputs) and then direct electrical power output to allow certain machine functions. The controller is attached to the frame under the operator seat (Fig. 55).
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Fusible Links The Groundsmaster 360 uses four (4) fusible links for circuit protection. Two (2) of these fusible links are included in a three (3) wire harness that connects the starter B+ terminal to the wire harness (Fig. 56 and 57). An additional fusible link is used that connects the starter B+ terminal to the alternator B+ terminal (Fig. 56 and 58). The remaining fusible link is included in the wire harness and connects the starter G terminal to the engine run solenoid pull coil.
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PTO Solenoid Valve Coil The Groundsmaster 360 transmission includes a solenoid valve coil that is used to engage the PTO drive (Fig. 44). When the solenoid valve coil is energized, hydraulic flow is directed to operate the PTO system. On 2WD machines, the Standard Control Module (SCM) provides current to the PTO solenoid valve coil based on the position of several input switches. The PTO LED on the SCM will be illuminated when the solenoid valve coil is energized.
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Hydraulic Solenoid Valve Coils The Groundsmaster 360 hydraulic control manifolds use several hydraulic solenoid valve coils for system control. The deck lift manifold includes two (2) solenoid valves and the steering control manifold on 4WD machines includes a single solenoid valve. When the solenoid coils are energized, hydraulic valve shift occurs to control hydraulic circuit flow. Testing of the coils can be done with the coil installed on the hydraulic valve.
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Main Power, Glow, Start (4WD Machines) and Cab Power (4WD Machines with Operator Cab) Relays The Groundsmaster 360 electrical system includes identical relays for current control. The main power, glow, start (4WD machines) and cab power (4WD machines with operator cab) relays are attached to the air cleaner bracket near the rear steering cylinder (Fig. 63). The wire harness is attached to these relays with four (4) wire connectors. Relays can be identified by a tag on the wire harness. 4.
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Deck Lift Relay (2WD Machines) The deck lift relay is used to prevent cutting deck raising or lowering when the engine is not running. The deck lift relay is attached to the air cleaner bracket near the rear steering cylinder (Fig. 65). The relay can be identified by a tag on the wire harness. When the engine is not running, the lack of engine oil pressure closes the engine oil pressure switch. This closed switch allows a grounding path to energize the deck lift relay.
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High Temperature Warning Switch (Machines without Operator Cab) The high temperature warning switch is attached to the water pump housing on the engine (Fig. 67). This switch is normally open and closes when engine coolant temperature reaches approximately 220oF (105oC). If high engine coolant temperature causes the warning switch to close, the high temperature warning light on the console will illuminate and also the cutting deck will shut down.
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High Temperature Shutdown Switch (Machines without Operator Cab) The high temperature shutdown switch is located on the water pump housing (Fig. 69). The high temperature shutdown switch is normally open and closes when engine coolant temperature reaches approximately 240oF (115oC). If excessive engine coolant temperature causes the shutdown switch to close, the engine shuts down. There is a red wire attached to the shutdown switch. 4.
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Dual Temperature Switch (Machines with Operator Cab) On Groundsmaster 360 machines equipped with an operator cab, the dual temperature switch includes two (2) normally open circuits used to monitor engine coolant temperature. These switch circuits are the high temperature warning circuit and the high temperature shutdown circuit. The dual temperature switch is attached to the engine water pump housing (Fig. 71).
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Oil Pressure Switch The engine oil pressure switch is located on the engine near the oil filter (Fig.73). The oil pressure switch is a normally closed switch that opens with pressure. The oil pressure switch should open at approximately 8 PSI (0.56 kg/cm2). 2 On machines with 4WD, the TEC controller monitors the operation of the oil pressure switch.
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Fuel Pump The fuel pump is attached to the frame near the fuel filter (Fig. 74). Electrical current is available for the fuel pump when the ignition switch is in either the RUN or START position. On 2WD machines, the Standard Control Module run output LED will be illuminated when the fuel pump is energized. 6. Collect fuel in the graduated cylinder by turning ignition switch to the RUN position. Allow pump to run for fifteen (15) seconds, then turn ignition switch to OFF. 7.
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Fuel Stop Solenoid The fuel stop solenoid used on the Groundsmaster 360 must be energized for the diesel engine to run. The solenoid is mounted to the injection pump on the engine (Fig. 75). The fuel stop solenoid includes two (2) coils for operation: the pull coil and the hold coil. When the ignition switch is turned to START, the fuel stop solenoid is initially energized and the pull coil retracts the solenoid plunger.
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Glow Controller (2WD Machines) On Groundsmaster 360 machines with 2WD, the glow controller is attached to the air cleaner bracket near the rear steering cylinder (Fig. 77). 5. If any of the conditions in Step 3 are not met or electrical power to terminal 1 exists and any of the other conditions in Step 4 are not met: NOTE: When troubleshooting the glow controller, refer to electrical drawings in Chapter 9 − Foldout Drawings. A.
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Service and Repairs NOTE: For engine electrical component repair information, see the Kubota Workshop Manual, Diesel Engine, 05−E3B Series that is included after Chapter 3 − Kubota Diesel Engine. PTO Solenoid Valve Coil The PTO solenoid valve coil on the transmission (Fig. 79) can be replaced without opening the hydraulic system. Removal 1. Park machine on a level surface, lower cutting deck, engage parking brake, stop engine and remove key from the ignition switch. 2.
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Hydraulic Manifold Solenoid Valve Coils A hydraulic solenoid valve coil on the deck lift manifold (Fig. 81) or steering control manifold (machines with 4WD) (Fig. 82) can be replaced without opening the hydraulic system. 4 60 in−lb (6.7 N−m) 3 5 NOTE: The deck lift manifold solenoid valve coils on machines with serial number below 315000000 are identical (shown in Fig. 81). The coils on machines with serial number above 315000000 are different.
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Battery Storage If the machine will be stored for more than thirty (30) days: 3. Leave cables disconnected if the battery is stored on the machine. 1. Make sure ignition switch is in the OFF position. Remove the battery and charge it fully (see Battery Service in this section). 4. Store battery in a cool atmosphere to avoid quick deterioration of the battery charge. 5. To help prevent the battery from freezing during storage, make sure it is fully charged (see Battery Service in this section). 2.
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Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally, battery and electrical component failure can be prevented. 7 CAUTION 4 When working with batteries, use extreme caution to avoid splashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes. Always wear safety goggles and a face shield when working with batteries.
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Battery Testing B. Make sure battery terminals are free of corrosion. 1. Conduct a hydrometer test of the battery electrolyte. C. Measure the electrolyte temperature of the center battery cell. IMPORTANT: Make sure the area around the cells is clean before opening the battery caps. D. Connect a battery load tester to the battery terminals following the manufacturer’s instructions. Connect a digital multimeter to the battery terminals. A. Measure the specific gravity of each cell with a hydrometer.
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Battery Charging CAUTION To minimize possible damage to the battery and allow the battery to be fully charged, the slow charging method is presented here. This charging method can be accomplished with a constant current battery charger which should be available locally. Do not charge a frozen battery because it can explode and cause injury. Let the battery warm to 60F (15.5C) before connecting to a charger. Charge the battery in a well−ventilated place to dissipate gases produced from charging.
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Chapter 6 Chassis Table of Contents Groundsmaster 360 Page 6 − 1 Chassis SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Specifications Item Description Rear tire pressure (all Groundsmaster 360 machines) 25 PSI (172 kPa) Front tire pressure (machines without operator cab) 15 PSI (103 kPa) Front tire pressure (machines with operator cab) 25 PSI (172 kPa) Wheel lug nut torque 75 to 85 ft−lb (102 to 115 N−m) Wheel hub lock nut torque 300 to 400 ft−lb (407 to 542 N−m) General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance procedures and maintenanc
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Special Tools Order special tools from your Toro Distributor. Wheel Hub Puller The wheel hub puller allows safe removal of the wheel hub from the wheel motor shaft. Toro Part Number: TOR6004 Figure 1 Steering Alignment Tools The steering alignment tools are used to ensure that the front and rear steering assemblies are properly centered for steering assembly service. These tools are required for adjustment of wheel alignment or when replacing tie rods.
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Adjustments Brake Adjustment 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 1 2 2 NOTE: Adjustments to brake cables can be performed at two (2) places on the machine: under the footrest platform near the brake pedal assembly (Fig. 3) and also at the rear wheel (Fig. 4). Final brake cable adjustment is easiest to complete at rear wheel end of cable. 2.
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Steering Stop Adjustment Proper adjustment of the steering stop bolts is necessary to allow full rotation of the wheels when steering your Groundsmaster 360. SERIAL NUMBER BELOW 314999999 SHOWN 2 1. Park machine on a level surface, lower cutting deck and engage parking brake. Make sure that the PTO switch is OFF. 2. Lubricate all grease fittings in front and rear steering assemblies. 3.
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Wheel Alignment 1. Park machine on a level surface with the wheels directed straight ahead. Lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 1 2 3 2. Make sure that all tire pressures (front and rear) are properly adjusted before checking or adjusting wheel alignment (see Specifications in this chapter). 4 6 3. Remove front cover from front axle to allow access to front steering components (Fig. 7). 4.
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8. Secure front alignment tool (see Special Tools in this chapter) to front axle and center link (Fig. 9). If necessary to align front steering components with alignment tool, loosen hydraulic hoses on front steering cylinder to allow front cylinder movement independent of the rear steering cylinder. Then, use a large adjustable wrench to rotate front steering arm so that front steering components are aligned with alignment tool. 9. With both alignment tools installed, place a rigid straight edge (e.g.
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Service and Repairs Wheels 2 1 3 RIGHT FRONT 3 4 75 to 85 ft−lb (102 to 115 N−m) Figure 13 1. Front wheel 2. Rear wheel Chassis 3. Lug nuts (5 used per wheel) Page 6 − 8 4.
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Removal (Fig. 13) Installation (Fig. 13) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 1. If front wheel was removed, position front wheel spacer to wheel hub. 2. Install wheel and secure with five (5) lug nuts. 2. Chock wheels to prevent machine from shifting. 3. Lower machine to ground. 3. Loosen wheel lug nuts. WARNING CAUTION Before raising the machine, review and follow Jacking Instructions in Chapter 1 − Safety.
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Brake Service 300 to 400 ft−lb (407 to 542 N−m) 5 14 13 11 7 18 3 75 to 85 ft−lb (102 to 115 N−m) 6 16 10 17 1 15 2 9 12 8 Loctite #271 RIGHT FRONT 4 94 to 116 ft−lb (128 to 157 N−m) Figure 14 1. 2. 3. 4. 5. 6. Rear tire (LH shown) Brake support Brake assembly (LH shown) Brake drum Brake cable (2) Lock washer (4 per side) Chassis 7. 8. 9. 10. 11. 12. Clevis pin Lug nut (5 per wheel) Cap screw (4 per side) Return spring bracket Brake return spring Wheel hub Page 6 − 10 13. 14. 15. 16.
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Brake Disassembly (Fig. 14) 14 1. Park machine on a level surface, lower cutting deck, stop engine and remove key from the ignition switch. 12 10 9 2. Chock front wheels to prevent machine from shifting. 3. Loosen, but do not remove, wheel lug nuts and lock nut (item 17) from rear wheel motor shaft. 6 2 4 7 5 11 4. Jack up rear of machine and remove rear wheel assembly (see Wheel Removal in this section). Make sure to support machine with jack stands. 8 13 5 5.
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4. Position one brake shoe to the backing plate. Install brake hold down pin and secure with hold down spring and cup. Repeat for second brake shoe. WARNING 5. Install both shoe springs to brake shoes. Make sure that brake shoes are properly positioned to pivot and actuator points. Failure to properly torque wheel lug nuts and wheel hub lock nut could result in failure or loss of wheel and may result in personal injury.
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Brake Cables 15 5 8 9 13 2 11 7 3 1 10 12 4 14 6 RIGHT FRONT Figure 17 1. 2. 3. 4. 5. Rear tire (LH shown) Operator platform bracket Brake assembly (LH shown) Cable yoke Brake cable (2) Chassis 6. 7. 8. 9. 10. Cap screw (2 per bracket) Clevis pin Brake bracket (LH shown) Cap screw (2 per bracket) Return spring bracket Page 6 − 14 11. 12. 13. 14. 15.
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Brake Cable Removal (Fig. 17) 5. Check and adjust brakes (see Brake Adjustment in the Adjustments section of this chapter). 1. Park machine on a level surface, lower cutting deck, stop engine and remove key from the ignition switch. Make sure that parking brake is not applied. CAUTION 2. Chock front wheels to prevent machine from moving. 3. Disconnect brake cable from front of machine: A. Loosen one of the jam nuts that secures brake cable to operator platform bracket.
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Front Spindle Assembly (2WD Machines) 1 See text for tightening procedure 2 4 5 13 9 10 Loctite #271 11 3 6 7 6 5 94 to 116 ft−lb (128 to 157 N−m) 8 12 Figure 20 1. 2. 3. 4. 5. Steering fork assembly Spindle Cap screw (4) Seal Bearing cone Chassis 6. 7. 8. 9. Bearing cup Wheel hub Spindle washer Jam nut Page 6 − 16 10. 11. 12. 13. Rev.
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5. Install one greased bearing into the bearing cup on inboard side of the wheel hub. Disassembly (Fig. 20) 1. Chock rear wheels to prevent machine from shifting. 3. Remove the dust cap from the wheel hub. 4. Remove the cotter pin, nut retainer, jam nut and spindle washer. Slide the wheel hub from the spindle shaft. 5. Pull the seal (item 4) out of the wheel hub. Discard seal. 6. Remove the bearing cones from both sides of the wheel hub. Clean the bearings in solvent.
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Rear Steering Fork 22 21 20 19 11 7 3 5 8 14 1 300 to 400 ft−lb 13 (407 to 542 N−m) 4 18 2 17 16 15 12 23 10 9 RIGHT 6 FRONT Loctite #271 94 to 116 ft−lb (128 to 157 N−m) Figure 21 1. 2. 3. 4. 5. 6. 7. 8. Cap screw (2 per bulkhead) Brake support Bulkhead nut (2 per bulkhead) Wheel motor Bulkhead bracket Cap screw (4 per motor) Thrust washer (0.250” thick) Rear steering fork assembly 9. 10. 11. 12. 13. 14. 15. 16. Cap screw (2 per bracket) Spring bracket Thrust washer (0.
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Removal (Fig. 21) 1. Park machine on a level surface, lower cutting deck, stop engine and remove key from the ignition switch. 13.Clean and inspect flange bushings in axle. If bushings are worn or damaged, replace bushings (see Steering Assembly Bushing Service in this section). 2. Chock wheels to prevent machine from shifting. LH REAR FORK SHOWN 3. Loosen, but do not remove, wheel lug nuts and wheel motor shaft lock nut (item 23) at rear steering fork to be removed.
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Installation (Fig. 21) 1. Apply a light coating of grease to steering fork spindle. 2. Install thrust washer (item 7) onto the steering fork spindle and slide the spindle up through the axle tube. Hold the steering fork in place and install the upper thrust washer (item 11) and retaining ring (item 19) onto the end of the spindle. Make sure that retaining ring is fully seated in spindle groove. 3.
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Front Steering Fork 21 1 20 19 11 7 15 3 9 17 5 18 16 25 24 26 4WD FRONT AXLE SHOWN 13 5 14 5 8 300 to 400 ft−lb (407 to 542 N−m) 23 12 6 4 10 RIGHT 2 FRONT 22 94 to 116 ft−lb (128 to 157 N−m) Loctite #271 Figure 25 1. 2. 3. 4. 5. 6. 7. 8. 9. Front axle Square key Washer head screw Wheel motor Washer (3) Flange nut Thrust washer (0.250” thick) Steering fork assembly Cap screw 10. 11. 12. 13. 14. 15. 16. 17. 18. Lock nut Thrust washer (0.
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Removal (Fig. 25) 1. Park machine on a level surface, lower cutting deck, stop engine and remove key from the ignition switch. 1 5 6 2. Chock wheels to prevent machine from shifting. 7 3. Loosen, but do not remove, wheel lug nuts on front wheel at steering fork to be removed. 4. Jack up machine and remove front wheel assembly (see Wheel Removal in this section). Make sure to support machine with jack stands. 8 5. Remove cotter pin and slotted hex nut that secure tie rod end to the steering fork (Fig.
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Installation (Fig. 25) 1. Apply a light coating of grease to steering fork spindle. 2. Install thrust washer (item 7) onto the steering fork spindle and slide the spindle up through the axle tube. Hold the steering fork in place and install the upper thrust washer (item 11) and retaining ring (item 19) onto the end of the spindle. Make sure that retaining ring is fully seated in spindle groove. 1 94 to 116 ft−lb (128 to 157 N−m) 3.
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Front Steering Assembly SERIAL NUMBER BELOW 314999999 SHOWN 33 20 24 16 17 14 25 15 12 80 to 90 ft−lb (109 to 122 N−m) 13 18 23 21 28 17 32 22 4 26 31 57 to 75 ft−lb (78 to 101 N−m) 1 14 29 35 18 10 16 28 34 5 70 to 80 ft−lb (95 to 108 N−m) Loctite #271 19 27 5 35 to 40 ft−lb (48 to 54 N−m) 11 30 6 28 7 5 3 80 to 90 ft−lb (109 to 122 N−m) 37 36 RIGHT 2 FRONT 8 28 67 to 83 ft−lb (91 to 112 N−m) 9 11 35 to 40 ft−lb (48 to 54 N−m) Figure 29 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
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NOTE: The front axle steering cylinder on machines with serial numbers above 315000000 is installed in the reverse direction of machines with lower serial numbers. Figure 30 shows the cylinder orientation for machines with the higher serial number. Use the following procedure and torque specifications identified in Figure 29 when servicing the front axle on all Groundsmaster 360 machines. SERIAL NUMBER ABOVE 315000000 SHOWN 1 Disassembly (Fig. 29) 2 3 1.
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Assembly (Fig. 29) 1. Install all removed front steering components using Figure 29 as a guide. Note torque specifications identified in Figure 29 during assembly. If front axle was removed from frame, use washers (item 37) so axle has less than 0.030” (0.76 mm) free play between frame and axle support. If ball joints were removed from center link (item 26), press new ball joints into center link from the side of the link that has a notch at ball joint bore (Fig. 33).
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Rear Steering Assembly SERIAL NUMBER BELOW 314999999 SHOWN 25 26 14 13 23 15 5 8 11 80 to 90 ft−lb (109 to 122 N−m) 3 12 4 9 22 31 18 6 17 7 19 10 32 18 30 9 28 21 8 27 24 80 to 90 ft−lb (109 to 122 N−m) 10 16 5 1 20 RIGHT 18 35 to 40 ft−lb (48 to 54 N−m) FRONT 70 to 80 ft−lb (95 to 108 N−m) Loctite #271 2 29 Figure 34 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
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NOTE: The rear axle steering cylinder on machines with serial numbers above 315000000 is installed differently than the cylinder on machines with lower serial numbers. Figure 35 shows the cylinder orientation for machines with the higher serial number. Use the following procedure and torque specifications identified in Figure 34 when servicing the rear axle on all Groundsmaster 360 machines. SERIAL NUMBER ABOVE 315000000 SHOWN 2 5 Disassembly (Fig. 34) 1 1.
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Assembly (Fig. 34) 6. If rear wheel was removed, install wheel (see Wheel Installation in this section). 1. Install all removed rear steering components using Figure 34 as a guide. Note torque specifications identified in Figure 34 during assembly. If ball joints were removed from center link (item 16), press new ball joints into center link from the side of the link that has a notch at ball joint bore (Fig. 37). 2. To install tie rod (item 20) to vehicle: A.
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Steering Assembly Bushing Service Bushings in the front axle (Fig. 38) or rear axle (Fig. 39) assembly can be replaced using the following procedure. FRONT AXLE 6 NOTE: Bushings in steering arms (item 6 in Fig. 38 and item 5 in Fig. 39) may require reaming after installation. If reaming tools are not available, replace arm assembly which has bushings installed and properly sized. 6 5 4 1. Use a bushing removal tool to extract both flange bushings from the component.
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Frame Assembly 94 to 116 ft−lb (128 to 157 N−m) RIGHT FRONT 67 to 83 ft−lb (91 to 112 N−m) 11 3 9 10 4 5 2 6 7 8 8 1 8 Figure 40 1. 2. 3. 4. Front frame Rear axle Rear frame Flange head screw (4) 5. 6. 7. 8. Cap screw Cap screw Flange head screw (3) Flange nut (9) 9. Seat channel 10. Flange head screw (2) 11. Carriage screw (2) The Groundsmaster 360 frame assembly is illustrated in Figure 40.
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Steering Column 14 20 to 26 ft−lb (28 to 35 N−m) 2 3 1 34 to 42 ft−lb (47 to 56 N−m) Antiseize Lubricant 5 12 11 34 to 42 ft−lb (47 to 56 N−m) 10 7 9 13 4 RIGHT FRONT 8 6 Figure 41 1. 2. 3. 4. 5. Steering wheel Lock nut Flat washer Alignment bushing Steering column assembly Chassis 6. 7. 8. 9. 10. Steering control valve Steering plate Carriage screw (4) Mount (4) Washer (4) Page 6 − 36 11. 12. 13. 14.
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Removal (Fig. 41) 4. Slide rubber bellows to bottom of steering column. 1. Park the machine on a level surface, engage the parking brake, lower the cutting deck and stop the engine. Remove the key from the ignition switch. 5. Thoroughly clean tapered surfaces of steering wheel and steering column. 2. Remove cover from steering wheel by carefully prying up on one of the cover spokes. 3. Remove lock nut and flat washer that secure steering wheel to steering column. 4.
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PTO Drive Shaft 175 to 225 in−lb (20 to 25 N−m) RIGHT 7 8 FRONT 4 3 175 to 225 in−lb (20 to 25 N−m) 2 5 1 2 4 2 4 6 2 175 to 225 in−lb (20 to 25 N−m) 3 4 175 to 225 in−lb (20 to 25 N−m) Figure 43 1. 2. 3. Transmission assembly Cap screw (4) Roll pin (2) 4. 5. 6. Lock nut (4) PTO drive shaft Cutting deck gearbox Removal (Fig. 43) NOTE: PTO drive shaft removal is easier if machine is positioned on a hoist. 1.
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Installation (Fig. 43) 1. Position PTO drive shaft to machine. Make sure that drive shaft yoke and slip tube (item 6 in Fig. 46) is toward cutting deck gearbox shaft. 2. Align splines and roll pin holes of drive shaft yokes with transmission and gearbox shafts. 3. Slide PTO drive shaft end yokes onto transmission PTO shaft and gearbox shaft. 2 4. Secure end yokes of PTO drive shaft. 1 3 A. Install roll pins in end yokes and shafts. B. Install cap screws in driveshaft end yokes.
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PTO Drive Shaft Cross and Bearing Service 1. Remove PTO drive shaft from vehicle (see PTO Drive Shaft Removal in this section). D. Hold cross in alignment and press bearing in until it hits the yoke. IMPORTANT: When placing yoke in vise, clamp lightly on the solid part of the yoke to prevent yoke damage. Also, the use of a vise with soft jaws is recommended. E. Carefully place second bearing into yoke bore and onto cross shaft. Press bearing into yoke. 2. Lightly clamp yoke in vise.
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Cutting Deck Lift Assembly 24 26 23 25 50 ft−lb (68 N−m) 10 11 12 14 8 13 5 21 3 4 6 20 2 9 14 50 ft−lb (68 N−m) 16 12 19 18 17 8 1 13 7 RIGHT FRONT 3 22 12 50 ft−lb (68 N−m) 15 Figure 48 1. 2. 3. 4. 5. 6. 7. 8. 9. LH lift arm Retainer pin HOC chain (4) Flange head screw Spacer Flange bushing (2) Grease fitting Lock nut Cap screw Chassis 10. 11. 12. 13. 14. 15. 16. 17. 18.
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Disassembly (Fig. 48) 1. Park machine on a level surface and fully lower cutting deck. Stop engine, engage parking brake and remove key from the ignition switch. 2 1 NOTE: If cutting deck is to removed from machine, see Cutting Deck Removal and Installation in the Service and Repairs section of Chapter 7 − Cutting Deck. 2. Remove lift arm components as necessary using Figures 48 and 50 as guides.
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Control Console 15 14 13 12 16 17 18 11 19 10 9 1 8 2 3 4 5 4 6 7 RIGHT FRONT Figure 52 1. 2. 3. 4. 5. 6. 7. Control panel Ignition switch Washer head screw Flat washer (4) Hydraulic tank cover Flange head screw (3) Tinnerman nut (3) Chassis 8. 9. 10. 11. 12. 13. Lock nut (2) Throttle control lever Knob Cap Screw (2) Lock washer Page 6 − 44 14. 15. 16. 17. 18. 19.
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Disassembly (Fig. 52) 1 1. Park machine on a level surface, lower cutting deck, engage parking brake, stop engine and remove key from the ignition switch. 2 2. Disconnect battery. Make sure to remove negative battery cable first and then positive cable (see Battery Service in this section). 1 3. Remove five (5) screws that secure control panel to hydraulic tank cover (Fig. 53). Carefully lift and support control panel to allow access to electrical connections. 3 4.
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Storage Compartment (Machines without Operator Cab) 2 8 4 9 1 5 10 6 3 6 7 RIGHT FRONT Figure 55 1. 2. 3. 4. Storage compartment Cover Lower panel Hinge (2) Chassis 5. Magnetic catch 6. Flange nut (6) 7. Flange head screw (4) Page 6 − 46 8. Support 9. Flange head screw (2) 10.
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Removal (Fig. 55) Installation (Fig. 55) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 1. Secure all removed components to storage compartment using Figure 55 as a guide. 2. Align notches in storage compartment with two (2) shoulder bolts in machine frame and slide compartment onto bolts. 2. Unlatch and raise operator seat. 3. Remove two (2) flange head screws (item 9) that secure storage compartment to frame. 4.
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Operator Seat 20 4 1 14 21 27 5 Permatex Blue Gel Threadlocker 13 23 2 18 19 3 3 26 6 4 24 12 11 17 7 5 9 22 15 8 16 25 Permatex Blue Gel Threadlocker 10 RIGHT FRONT Figure 56 1. 2. 3. 4. 5. 6. 7. 8. 9. Operator seat (non−cab shown) Seat belt latch Flat washer (2) Flat washer (2) Cap screw (2) Seat belt Torsion spring Clevis pin Seat latch Chassis 10. 11. 12. 13. 14. 15. 16. 17. 18.
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Removal (Fig. 56) 3 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 1 2. Unlatch and raise operator seat. 3 WARNING 2 1 If seat switch service is necessary, remove seat from seat plate to access switch. To prevent injury, DO NOT attempt to reach switch through openings in seat plate. 2 Figure 57 3. Disconnect machine wire harness electrical connector from the seat wire harness connector (Fig. 57).
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Operator Seat Service (Machines without Operator Cab) 4 5 3 6 3 7 2 23 22 8 1 9 24 10 12 11 27 21 20 26 19 14 13 18 15 25 17 16 Figure 58 1. 2. 3. 4. 5. 6. 7. 8. 9. Bottom cushion Back cushion Armrest RH armrest mount assembly Back panel LH armrest mount assembly Seat frame assembly Lumbar support knob Label Chassis 10. 11. 12. 13. 14. 15. 16. 17. 18.
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Removal (Fig. 58) 5. Position seat frame to suspension base. 1. Remove operator seat from machine (see Operator Seat Removal in this section). 6. Align bearing blocks on frame with receivers on suspension base and guide frame into place. Insert two (2) bearing shafts and split nylon bushings to suspension base and frame. Secure bearing shafts with two (2) roll pins. 2. Remove armrest assemblies and then back panel from back of seat. 3. Carefully peel label from back rest knob (Fig. 59).
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Operator Seat Service (Machines with Operator Cab) 1 2 17 62 18 64 3 16 13 7 8 14 6 5 9 4 10 20 25 18 11 12 21 22 59 26 27 15 24 30 28 34 19 13 23 33 63 65 31 60 42 43 29 57 58 16 61 56 27 32 33 44 41 26 40 45 39 37 36 55 46 54 35 53 38 50 47 49 48 52 51 Figure 60 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
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NOTE: Refer to your parts catalog for operator seat components that are available. Assembly (Fig. 60) 1. Assemble operator seat using Figure 60 as a guide. Disassembly (Fig. 60) 1. Remove operator seat from machine if desired (see Operator Seat Removal in this section). 2. If operator seat was removed from machine, secure seat to machine (see Operator Seat Installation in this section). Chassis 2. Disassemble operator seat as necessary using Figure 60 as a guide.
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Hood 6 4 22 9 1 9 19 7 21 10 16 11 12 5 10 7 15 17 8 14 20 3 18 2 RIGHT 13 FRONT Figure 61 1. 2. 3. 4. 5. 6. 7. 8. Hood Hood mount Bulb seal Screen Hood seal Plug (29) Flange nut (11) Carriage screw (3) Chassis 9. 10. 11. 12. 13. 14. 15. Flange head screw (8) Foam seal (2) Latch (2) Lock nut (2 per latch) Screw (2 per latch) Prop rod Cotter pin Page 6 − 54 16. 17. 18. 19. 20. 21. 22.
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Removal (Fig. 61) Installation (Fig. 61) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Unlatch and raise hood. 1. Install all removed hood components using Figure 61 as a guide. If intake screen was removed from hood, make sure that hood seal (item 5) and hood mount (item 2) are attached to hood before installing screen. Secure screen to hood with plugs. 3.
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PAGE 305
Chapter 7 Cutting Deck Table of Contents Cutting Deck GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Cutting Deck Specifications . . . . . . . . . . . . . . . . . . 2 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2 FACTORS THAT CAN AFFECT CUTTING PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 5 Blade Stopping Time . . . . . . . . . . . . . . . . . . . . . . . .
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General Information Cutting Deck Specifications Several cutting decks are available for the Groundsmaster 360. Refer to the Operator’s Manual for specifications and optional accessories for the cutting deck used on your Groundsmaster. Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for the cutting deck on your Groundsmaster machine. Refer to that publication for additional information when servicing the cutting deck.
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Factors That Can Affect Cutting Performance There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf conditions. Turf conditions such as excessive thatch, “sponginess” or attempting to cut off too much grass height may not always be overcome by adjusting the machine. It is important to remember that the lower the height−of−cut, the more critical these factors are.
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PAGE 309
Service and Repairs CAUTION WARNING Do not start the engine and engage the PTO switch when the PTO drive shaft is disconnected from the cutting deck. If the engine is started and the PTO shaft is allowed to rotate, serious personal injury and machine damage could result. If the PTO drive shaft is disconnected from the cutting deck, disconnect PTO solenoid coil connector from wire harness to prevent unintentional engagement of the PTO clutch. Never work on the cutting deck with the engine running.
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Cutting Deck Removal and Installation Deck Removal 4 5 1. Park machine on a level surface with the cutting deck in the fully raised position. Stop engine, engage parking brake and remove key from the ignition switch. 2 NOTE: When the cutting deck is in the raised position, pull link torsion spring tension is reduced making it much easier to disconnect pull links from machine. 6 2. Disconnect pull link from each side of machine (Fig.
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6. Disconnect end yoke of PTO drive shaft from cutting deck gearbox shaft (see PTO Drive Shaft Removal in the Service and Repairs section of Chapter 6 − Chassis). Position and support drive shaft end away from deck gearbox. 7. Remove four (4) ring pins and clevis pins that secure deck lift chains to adjustment clevises on cutting deck (Fig. 1). 4. Start engine and fully raise cutting deck. Stop engine and remove key from the ignition switch.
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Idler Assembly 9 5 16 6 17 7 19 8 14 10 22 21 15 12 13 18 2 9 11 4 3 15 5 6 7 19 8 16 20 1 RIGHT FRONT Figure 4 1. 2. 3. 4. 5. 6. 7. 8. Cutting deck Flat washer LH spindle assembly Drive belt Snap ring Flange bushing (2 per idler) Torsion spring Washer Cutting Deck 9. 10. 11. 12. 13. 14. 15. Grease fitting Drive belt Idler pulley Idler pulley Center spindle assembly RH spindle assembly Socket head screw Page 7 − 8 16. 17. 18. 19. 20. 21. 22.
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Removal (Fig. 4) 4. Install drive belts to pulleys. 1. Park machine on a level surface with cutting deck lowered. Stop engine, engage parking brake and remove key from the ignition switch. 5. If idler arm on right side of cutting deck was removed, check that clearance between idler arm and stop bolt is from 0.100” to 0.160” (2.5 to 4.0 mm) (Fig. 5). If necessary, adjust jam nut location on stop bolt to allow proper clearance. 2. Lift the footrest, exposing the top of the cutting deck.
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Blade Spindle 1 2 3 5 4 9 6 7 8 RIGHT FRONT Figure 6 1. 2. 3. RH spindle assembly Drive belt Idler pulley 4. 5. 6. Center spindle assembly Idler pulley Drive belt 7. 8. 9. LH spindle assembly Cutting deck Drive pulley Removal (Fig. 6) 1. Park machine on a level surface with cutting deck raised. Stop engine, engage parking brake and remove key from the ignition switch. Support the cutting deck so it cannot fall accidentally. 1 2. Lift the footrest, exposing the top of the cutting deck.
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6. Remove spindle assembly from deck (Fig. 8). A. On decks before serial number 314000000, remove eight (8) flange head screws and flange nuts that secure spindle assembly to deck. Remove spindle assembly. 2 7 2 B. On decks after serial number 314000000, remove eight (8) flange nuts that secure spindle assembly to deck. Ribbed neck bolts are pressed into spindle housing. Remove spindle assembly and doubler ring. 7.
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Blade Spindle Service Disassembly (Fig. 10) 1 2 1. Remove lock nut from top of spindle shaft. 2. Remove special hardened washer and pulley from shaft. 3 130 to 150 ft−lb (176 to 203 N−m) 3. Remove the spindle shaft from the spindle housing which may require the use of an arbor press. The spindle shaft spacer should remain on the spindle shaft as the shaft is being removed. 4 5 7 4. Remove oil seals from spindle housing. 6 5.
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3. Using an arbor press, push the bearing cups into the top and bottom of the spindle housing. The top bearing cup must contact the outer spacer previously installed, and the bottom bearing cup must contact the snap ring. Make sure that the assembly is correct by supporting the first bearing cup and pressing the second cup against it (Fig 12). PRESS 4 4. Pack the bearing cones with grease. Apply a film of grease on lips of oil seals and O−ring. 5.
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Gearbox 1 2 6 9 4 3 11 12 14 10 7 13 8 17 15 16 7 5 RIGHT FRONT 18 Figure 15 1. 2. 3. 4. 5. 6. Flange nut (3) Washer (3) LH gearbox bracket Mount (3) Carriage screw (3) Gearbox 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Grommet (5) Taper−lock bushing RH gearbox bracket Cap screw (4) Lock washer (4) Woodruff key Deck drive pulley RH deck cover LH deck cover Knob (2) Set screw (2) Retainer nut (2) Removal (Fig. 15) 1.
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5. Disconnect end yoke of PTO drive shaft from cutting deck gearbox shaft (see PTO Drive Shaft Removal in the Service and Repairs section of Chapter 6 − Chassis). Position and support drive shaft end away from deck gearbox. 8. Connect PTO drive shaft to gearbox (see PTO Drive Shaft Installation in the Service and Repairs section of Chapter 6 − Chassis). Make sure that wire harness is connected to PTO solenoid coil after drive shaft installation. 6.
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Cutting Deck Pull Links 5 4 2 6 8 9 1 10 16 7 12 15 6 17 14 13 3 21 11 18 20 8 RIGHT FRONT 19 Figure 18 1. 2. 3. 4. 5. 6. 7. LH lift arm Retainer pin Clevis pin Flange head screw Spacer Flange bushing (2) Grease fitting Cutting Deck 8. 9. 10. 11. 12. 13. 14. Lock nut Cap screw Pivot pin Ring pin Grease fitting Spacer Torsion spring Page 7 − 16 15. 16. 17. 18. 19. 20. 21.
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Disassembly (Figs. 18 and 19) 3. Slide pivot pin (item 10) through cutting deck, pull link and spacer. 1. Remove cutting deck from machine (see Cutting Deck Removal and Installation in this section). CAUTION 4. Insert cap screw (item 17) through pivot pin and holes in deck. Make sure that torsion spring end is below screw. Secure cap screw with lock nut. 5. Install adjustment clevis to deck and secure with flange nut. Be careful when removing the pull links from the cutting deck.
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PAGE 323
Chapter 8 (Serial Number Below 315000000) Operator Cab Table of Contents Operator Cab GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Electrical Components and Schematic . . . . . . . . . 2 Air Conditioning System . . . . . . . . . . . . . . . . . . . . . 2 Cab Heater System . . . . . . . . . . . . . . . . . . . . . . . . . 2 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . .
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General Information The information in this chapter pertains to Groundsmaster 360 machines with serial number below 314999999 that are equipped with an operator cab. Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster. Refer to the Operator’s Manual for additional information when servicing the machine.
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Service and Repairs General Precautions for Removing and Installing Air Conditioning System Components 5. Put labels on disconnected lines and hoses for proper installation after repairs are completed. The air conditioning system is under high pressure. Do not loosen any system fitting or component until after the system has been completely discharged by a certified A/C service technician. WARNING Always wear safety goggles or a face shield when working with air conditioning system components.
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Air Conditioning Compressor 5 RIGHT FRONT 2 6 13 15 2 14 7 1 12 9 4 11 16 17 8 26 to 31 ft−lb (36 to 42 N−m) 3 10 24 to 29 ft−lbs (33 to 39 N−m) Figure 1 1. 2. 3. 4. 5. 6. A/C compressor mount bracket Flange nut (4) Air conditioning compressor Flange nut Pulley Cap screw (3) 7. 8. 9. 10. 11. 12. Removal (Fig. 1) V−belt Reservoir bracket Windshield washer reservoir A/C hose (from evaporator) A/C hose (to condenser) 4. Inspect compressor drive belt for glazing or damage.
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CAUTION The air conditioning system is under high pressure. Do not loosen any system fitting or component until after the system has been completely discharged by a certified A/C service technician. 7. Have refrigerant evacuated from air conditioning system by a certified A/C service technician. 8. Label and remove hoses from compressor. Immediately cap hoses and fittings to prevent moisture and contaminants from entering the system. 9. Support compressor to prevent it from shifting or falling.
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Roof Assembly 1 2 3 16 4 3 4 15 14 8 5 7 13 4 6 3 9 2 12 4 11 10 9 RIGHT FRONT 17 Figure 3 1. 2. 3. 4. 5. 6. Roof panel Screw (2) Flat washer (6) Bushing (10) Rear fastener (2) Rear spacer (2) Operator Cab 7. 8. 9. 10. 11. 12. Panel nut Roof mount Flange nut (2) Flange nut (4) Headliner Front spacer (2) Page 8 − 6 13. 14. 15. 16. 17.
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To gain access to the heater core and air conditioning components that are located under the cab roof, the roof panel can be loosened, raised and supported. NOTE: When following this procedure, the air conditioning hoses will remain connected. 4 3 5 6 7 Removal (Fig. 3) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2 1 9 8 10 2.
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Air Conditioning Condenser Assembly 10 1 3 11 2 6 8 12 2 4 6 8 RIGHT 6 7 FRONT 5 9 Figure 5 1. 2. 3. 4. Condenser cover Lock nut (4) Condenser fan Condenser coil assembly 5. 6. 7. 8. Carriage screw (2) Flat washer (8) Roof Bushing (4) Removal (Fig. 5) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove fasteners that secure roof in place.
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8. Label and remove hoses from condenser coil. Immediately cap hoses and fittings to prevent moisture and contaminants from entering the system. 18 11 13 17 19 1 9. Remove condenser coil from roof using Figure 6 as a guide. 2 12 NOTE: The replacement of the drier−receiver is recommended whenever the air conditioning system is opened (see Heater/Evaporator Assembly in this section). 3 Installation (Fig. 5) 15 1. Install condenser coil to roof using Figure 6 as a guide. 2.
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Heater/Evaporator Assembly 2 18 19 17 10 14 16 15 1 23 21 20 22 9 6 13 3 4 8 11 12 7 5 Figure 7 1. 2. 3. 4. 5. 6. 7. 8. Heater/evaporator assembly Top cover Flange head screw (2) Drier−receiver mount Bottom cover Hose clamp (2) Panel nut (8) Panel nut (4) 9. 10. 11. 12. 13. 14. 15. 16. Drier−receiver assembly Screw (8) Screw (4) Seal Seal Air duct hose Binary switch Blower fan assembly Screw (2) Resistor Screw (12) Expansion valve Screw (2) Freeze switch Clamp 3.
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6. Connect wire harness connectors to fan motor and binary switch on drier−receiver. CAUTION The air conditioning system is under high pressure. Do not loosen any system fitting or component until after the system has been completely discharged by a certified A/C service technician. 5. Have refrigerant evacuated from air conditioning system by a certified A/C service technician. 6. Label and remove hoses from heater core, evaporator and drier−receiver.
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Windshield Wiper 8 1 7 9 2 3 4 10 5 6 11 12 13 Figure 9 1. 2. 3. 4. 5. Wiper motor Gasket Linkage bracket Lock washer Cap screw Operator Cab 6. 7. 8. 9. Cap (2) Washer Nut Flange nut (2) Page 8 − 12 10. 11. 12. 13.
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Disassembly (Fig. 9) Assembly (Fig. 9) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 1. Assemble windshield wiper components using Figure 9 as a guide. 2. If access to wiper motor is necessary, remove fasteners that secure roof in place. Raise and support roof to allow access to condenser assembly (see Roof Assembly Removal in this section). 2.
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Storage Compartment 11 5 3 10 12 2 8 7 9 6 4 RIGHT 1 FRONT Figure 10 1. 2. 3. 4. Cab platform Storage compartment Flange head screw (4) Bulb seal 5. 6. 7. 8. RH foam LH foam Foam Foam 9. 10. 11. 12. LH foam RH foam Foam Tinnerman nut (4) Removal (Fig. 10) Installation (Fig. 10) 1. Park machine on a level surface, lower cutting deck (or implement), stop engine, engage parking brake and remove key from the ignition switch. 1. Position storage compartment assembly to cab platform.
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Chapter 8.1 (Serial Number Above 315000000) Operator Cab Table of Contents Operator Cab GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Electrical Components, Schematics and Wire Harness Drawings . . . . . . . . . . . . . . . . . . . . . . . . . 2 Air Conditioning System . . . . . . . . . . . . . . . . . . . . . 2 Cab Heater System . . . . . . . . . . . . . . . . . . . . . . . . .
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General Information The information in this chapter pertains to Groundsmaster 360 machines with serial number above 315000000 that are equipped with an operator cab. Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster. Refer to the Operator’s Manual for additional information when servicing the machine.
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Air Conditioning System Performance There are a number of factors that can affect the performance of the Groundsmaster 360 air conditioning system. To ensure the best system operation, inspect the following components. 1. Make sure that the heater control fully closes the heater valve in the cab headliner. 2. Make sure that the condenser and evaporator fins are clean. 3. Verify that refrigerant charge quantity and system operating pressures are correct. 4.
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Service and Repairs General Precautions for Removing and Installing Air Conditioning System Components 5. Put labels on disconnected lines and hoses for proper installation after repairs are completed. The air conditioning system is under high pressure. Do not loosen any system fitting or component until after the system has been completely discharged by a certified A/C service technician. WARNING Always wear safety goggles or a face shield when working with air conditioning system components.
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Air Conditioning Compressor 30 to 35 in−lb (3.4 to 3.9 N−m) FRONT RIGHT 26 21 24 19 22 20 19 23 13 25 26 5 14 6 27 2 15 25 16 17 12 9 30 7 18 29 4 11 1 8 10 3 28 Figure 1 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Compressor mount bracket Straight fitting AC compressor Flange nut Pulley Cap screw (3) Idler pulley Carriage bolt Spacer Cap screw (2) Operator Cab 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
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Removal (Fig. 1) Installation (Fig. 1) 1. Park machine on a level surface, lower cutting decks and stop engine. Remove key from the ignition switch. 1. Position compressor to compressor mount on machine frame. 2. Raise and support hood to allow access to engine and air conditioning compressor. 2. The clearance between the compressor mounting flanges and the compressor mount must be less than 0.004” (0.10 mm).
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Roof Assembly 5 3 4 6 8 1 10 7 11 9 14 13 12 2 RIGHT FRONT 14 13 Figure 2 1. 2. 3. 4. 5. Roof panel Headliner assembly Condenser screen Flange head screw (16) RH condenser seal Operator Cab 6. 7. 8. 9. 10. Front condenser seal LH condenser seal Rear condenser seal Condenser assembly Shoulder screw (22) Page 8.1 − 8 (Rev. A) 11. 12. 13. 14.
PAGE 345
To gain access to heater and air conditioning components, the roof panel needs to be removed. Installation (Fig. 2) Removal (Fig. 2) 1. Make sure that all components in headliner are installed and secure. 1. Park machine on a level surface, lower cutting deck or implement and stop engine. Remove key from the ignition switch. 2. Position roof onto headliner. Make sure that all roof mounting holes are properly aligned with headliner and A/C condenser assembly. 2.
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Heating and Air Conditioning Components 1 8 7 2 6 3 4 5 RIGHT FRONT Figure 3 1. 2. 3. A/C binary switch A/C drier−receiver RH intake air filter Operator Cab 4. 5. 6. A/C condenser assembly LH intake air filter A/C expansion valve Page 8.1 − 10 (Rev. A) 7. 8.
PAGE 347
Access to cab heating and air conditioning components can be obtained by removing the cab roof. Once the cab roof is removed, the illustrations in Figures 3 and 4 can be used to identify the components used for heating and cooling the operator cab. 2 1 NOTE: Figure 4 shows the heat and A/C mixing box assembly with the mixing box cover removed. NOTE: A/C system capacity is 3.44 pounds of R134a refrigerant. 4 FRONT 3 Figure 4 3. Air diverter assembly 4. A/C freeze switch Operator Cab 1.
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A/C Condenser Fan Assembly 3 RIGHT FRONT 2 1 5 4 Figure 5 1. 2. Cab frame Cab headliner assembly Operator Cab 3. 4. A/C condenser assembly Knob (2) Page 8.1 − 12 (Rev. A) 5.
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Removal (Fig. 5) 1 3 1. Park machine on a level surface, lower cutting deck or implement and stop engine. Remove key from the ignition switch. 2. Locate A/C condenser fan assembly which is secured to the frame under the rear of the cab headliner. 3. Disconnect the two (2) condenser fan plugs from the wire harness connectors attached to the cab frame (Fig. 6). 4. Support the condenser fan assembly to prevent it from falling. 2 5. Remove two (2) knobs that secure condenser fan assembly to machine (Fig.
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A/C Condenser Assembly 11 9 RIGHT FRONT 10 to 15 ft−lb (14 to 20 N−m) 12 3 10 10 to 15 ft−lb (14 to 20 N−m) 2 7 6 8 1 5 4 Figure 8 1. 2. 3. 4. Cab frame Cab headliner assembly A/C condenser assembly Knob (2) Operator Cab 5. 6. 7. 8. Condenser fan assembly Flange nut (4) Strip seal (2) Edge seal (2) Page 8.1 − 14 (Rev. A) 9. 10. 11. 12.
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2. Carefully lower the A/C condenser assembly through headliner and onto cab frame. Removal (Fig. 8) 1. Park machine on a level surface, lower lower cutting deck or implement and stop engine. Remove key from the ignition switch. 2. To access A/C condenser assembly, remove roof panel from top of cab (see Roof Assembly in this section). 3. Remove condenser fan assembly from machine (see A/C Condenser Fan Assembly in this section). 4.
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Mixing Box Assembly 2 4 3 5 14 13 10 12 23 11 9 7 6 1 8 15 32 16 21 22 25 16 24 25 30 20 22 23 26 33 29 21 21 31 21 27 28 19 RIGHT 17 FRONT 18 Figure 10 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Mixing box Mixing box cover Cover insulation Rivet (19) Heater core/AC evaporator/fan assy Expansion valve O−ring (2) A/C drier−receiver Binary switch Air diverter assembly Control cable Operator Cab 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
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Removal (Fig. 10) 4 3 1. Park machine on a level surface, lower cutting deck or implement and stop engine. Remove key from the ignition switch. 2 1 2. To access mixing box assembly, remove roof panel from top of cab (see Roof Assembly in this section). 3. Remove cover from mixing box assembly: A. Carefully use a small pry bar to raise head of pin in center of each rivet that secures mixing box cover. 7 B. Lift rivets from cover and mixing box. C. Remove mixing box cover.
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2. Make sure that condensation hoses are secured to the drain fittings on the bottom of mixing box assembly. Also, route hoses to cab frame for proper draining of condensate. 3. Make sure to connect electrical connectors from mixing box wire harness and binary switch on A/C drier−receiver. 4. If any A/C system components were removed from cab headliner, make sure that all machine air conditioning components are installed and secure.
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Operator Cab This page is intentionally blank. Groundsmaster 360 Page 8.1 − 19 (Rev.
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Heater and A/C Evaporator Cores 3 2 RIGHT FRONT 5 6 9 8 7 4 18 21 22 16 13 20 17 10 15 1 16 16 19 11 12 15 14 16 15 to 20 ft−lb (21 to 27 N−m) Figure 13 1. 2. 3. 4. 5. 6. 7. 8. Mixing box Rivet (19) Mixing box cover Cover insulation Screw (5) Mount bracket cover Cover gasket Screw (2) 9. 10. 11. 12. 13. 14. 15. Freeze switch Mount bracket (shown with fan) Expansion valve O−ring (2) A/C evaporator core Heater core Double sided tape (2) 16. 17. 18. 19. 20. 21. 22.
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Removal (Fig. 13) 1. Park machine on a level surface, lower cutting deck and stop engine. Remove key from the ignition switch. 12.Inspect seals, gaskets and insulation in mixing box assembly for tears or other damage. Replace all damaged sealing components. Installation (Fig. 13) 2. To access heater and A/C evaporator cores, remove roof panel from top of cab (see Roof Assembly in this section). 3.
PAGE 358
Blower Fan 3 2 RIGHT FRONT 4 8 12 9 15 5 11 10 16 6 13 14 7 15 to 20 ft−lb (21 to 27 N−m) 1 Figure 14 1. 2. 3. 4. 5. 6. Mixing box Rivet (19) Mixing box cover Cover insulation Heater core/AC evaporator assembly O−ring (2) 7. 8. 9. 10. 11. Expansion valve Blower fan Screw (6) Freeze switch Screw (2) NOTE: The blower fan can be removed and installed with the mixing box (item 1 in Figure 14) attached to the cab headliner. 12. 13. 14. 15. 16.
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4. Have refrigerant evacuated from air conditioning system by a certified A/C service technician. 5. Disconnect both evaporator core swivel fittings from front ports of expansion valve. Immediately cap tubes and expansion valve ports to prevent moisture and contaminants from entering the system. Position expansion valve with attached hoses away from the mixing box. 6. Label heater hoses for assembly purposes. Loosen hose clamps and disconnect both heater hoses from tubes on heater core. 5.
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Windshield Wiper Assembly 12 11 8 100 in−lb (11.3 N−m) 18 17 RIGHT FRONT 16 15 10 14 13 6 16 to 18 ft−lb (23 to 25 N−m) 5 1 7 9 4 2 Medium Strength Thread Locker 3 Figure 16 1. 2. 3. 4. 5. 6. Wiper blade Cap screw (2) Lock washer (2) Wiper arm assembly Flange nut (2) Cab headliner Operator Cab 7. 8. 9. 10. 11. 12. Washer plate Wiper bracket Washer head screw (4) Flange nut (4) Washer head screw (3) Wiper motor Page 8.1 − 24 (Rev. A) 13. 14. 15. 16. 17. 18.
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Disassembly (Fig. 16) 3. If wiper arm assembly was removed: 1. Park machine on a level surface, lower cutting deck or implement and stop engine. Remove key from the ignition switch. 2. To remove wiper blade, remove two (2) cap screws and lock washers that secure wiper blade to wiper arm assembly. 3. If necessary, remove wiper arm assembly: A. Disconnect washer hose from wiper assembly. B. Lift caps at top of wiper arms and remove flange nuts that secure wiper arms to wiper motor. A.
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PAGE 363
Chapter 9 Foldout Drawings Table of Contents Foldout Drawings ELECTRICAL DRAWING DESIGNATIONS . . . . . . . 2 Wire Color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Wire Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 HYDRAULIC SCHEMATICS Groundsmaster 360 with 2WD Serial Number Below 313999999 . . . . . . . . . . . . 3 Serial Number Above 314000000 . . . . . . . . . . . . 4 Groundsmaster 360 with 4WD Serial Number Below 313999999 . . . . . . . . . . . .
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Electrical Drawing Designations NOTE: A splice used in a wire harness will be identified on the wire harness diagram by SP. The manufacturing number of the splice is also identified on the wire harness diagram (e.g. SP01 is splice number 1). Wire Color The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter.
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6 5 4 3 2 1.50” X 3.68” STROKE 0.75” ROD 2.00” X 5.50” STROKE 1.00” ROD FRONT D 115- 0392 REV. A 1 0.052 REAR D 1 STEERING CYLINDER RE- PHASING CHECK VALVES SHOWN (BOTH STEERING CYLINDERS) A B 4 2 L R 6.1 CID X 3 DECK LIFT MANIFOLD PISTON PUMP R 14.5 GPM 4000 PSI (276 bar) FORWARD A C RH WHEEL MOTOR STEERING CONTROL VALVE 1.10 CID P T C E BYPASS 17.1 VALVE B FLUSHING VALVE DIFF LOCK OPTION 14.5 GPM 0.060 4000 PSI (276 bar) FORWARD LH WHEEL MOTOR 0.031 C 1.
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6 5 4 3 2 1 115- 0392 REV. C D D STEERING CYLINDER RE- PHASING CHECK VALVES SHOWN (BOTH STEERING CYLINDERS) C C PISTON PUMP R A BYPASS VALVE B B B C BYPASS VALVE PISTON PUMP L D Groundsmaster 360 with 2WD (Serial Number Above 314000000) Shown With Optional Kits Installed Hydraulic Schematic A AUX POWER SUPPLY All solenoids are shown as de- energized. 6 Page 9 - 4 5 4 3 (Rev.
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6 5 4 3 2 1 2.00” X 5.50” STROKE 1.00” ROD REAR FRONT 1.50” X 3.68” STROKE 0.75” ROD D 4 2 3 1 0.052 D 1 STEER MODE SELECTOR VALVE A STEERING CYLINDER RE- PHASING CHECK VALVES SHOWN (BOTH STEERING CYLINDERS) B 4 2 L R 6.1 CID X3 DECK LIFT MANIFOLD PISTON PUMP R 4000 PSI (276 bar) 14.5 GPM FORWARD C A STEERING CONTROL VALVE 1.10 CID P T E C BYPASS VALVE B REVERSE 0.031 FLUSHING VALVE FORWARD 14.5 GPM RIGHT REAR 17.1 LEFT 17.1 REAR 4000 PSI (276 bar) C 1.
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6 5 4 3 2 C1 2.00” X 5.50” STROKE 1.00” ROD FRONT C2 2500 PSI REAR QUICK ATTACH SYSTEM (QAS) (OPTIONAL KIT) 2.25” X 3.50” STROKE 1.125” ROD CYLINDER IS DEPENDENT ON ATTACHMENT D 117- 2228 REV.C 1 C3 C4 1.50” X 3.68” STROKE 0.75” ROD 2500 PSI 0.080 0.046 D 0.052 S3 STEERING CYLINDER RE- PHASING CHECK VALVES SHOWN (BOTH STEERING CYLINDERS) 4 2 3 1 L RV1 STEER MODE SELECTOR VALVE RV2 4 CV1 PSI 3:1 piston ratio CV2 1 4 PSI 3:1 piston ratio A B S2 R 6.
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6 5 4 3 2 2.250” BORE 3.500” STROKE 1.125” ROD BORE 2.25” STROKE 3.50” ROD 1.13” CYLINDER IS DEPENDENT ON ATTACHMENT 132- 6560 REV. B 1 TILT CYLINDER LIFT CYLINDER COVER CYLINDER C1 C2 2500 psi 2500 psi D C3 .080” FRONT STEERING CYLINDER 2.00” BORE 5.50” STROKE 1.00” ROD STEERING CYLINDER RE- PHASING CHECK VALVES SHOWN (BOTH STEERING CYLINDERS) 4 psi 3:1 PISTON RATIO REAR STEERING CYLINDER 2.00” BORE 5.50” STROKE 1.00” ROD .
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6 5 4 3 2 1 D 119−5779 REV. C D C C PTO CLUTCH PTO SWITCH B (LIFT) A (FLOAT) (OPTIONAL) B B (OPTIONAL) (UPPER) (OPTIONAL) A A Groundsmaster 360 with 2WD (Serial Number Below 312000300) Electrical Schematic (OPTIONAL) All relays and solenoids are shown as de−energized. (LOWER) All ground wires are black. 6 Page 9 − 8 5 4 3 (Rev.
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6 5 4 3 2 1 121−6567 REV. A D D C C NOTE: ON MACHINES WITH SERIAL NUMBERS ABOVE 315000000, THE LIFT MANIFOLD SOLENOIDS ARE IDENTIFIED WITH S1 (FLOAT) AND S2 (LIFT) B (LIFT) A (FLOAT) B B (OPTIONAL) (OPTIONAL) A Groundsmaster 360 with 2WD (Serial Number Above 312000300) Electrical Schematic (OPTIONAL) A All relays and solenoids are shown as de−energized. All ground wires are black. 6 5 4 3 (Rev.
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6 5 4 3 2 1 119−5780 REV. A PTO CLUTCH D B STEERING SELECTOR SWITCH D A C C PTO SWITCH B B (OPTIONAL) MACHINES WITH OPERATOR CAB (UPPER) OPERATOR CAB INTERCONNECT WIRE HARNESS A Groundsmaster 360 with 4WD (Serial Number Below 312000300) Electrical Schematic All relays and solenoids are shown as de−energized. (OPTIONAL) All ground wires are black. (LOWER) 6 Page 9 − 10 5 4 3 (Rev.
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6 5 4 3 2 1 121−0171 REV. B D D C C B B A Groundsmaster 360 with 4WD (Serial Number Above 312000300) Electrical Schematic A All relays and solenoids are shown as de−energized. All ground wires are black. 6 5 4 3 (Rev.
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6 D 5 4 3 2 1 D F1−3 F1−2 OPERATOR CAB INTERCONNECT WIRE HARNESS F2−1 C C F2−2 F1−1 OPERATOR CAB INTERCONNECT WIRE HARNESS F1−4 F2−3 (OPTIONAL LIGHT KIT) F2−4 B A B Groundsmaster 360 Operator Cab (Serial Number Below 314999999) Electrical Schematic A All relays and solenoids are shown as de−energized. All ground wires are black. 6 Page 9 − 12 5 4 3 (Rev.
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6 5 4 3 2 1 122−0426 REV. A D D C C B B A A All relays and solenoids are shown as de−energized. All ground wires are black. 6 5 4 3 (Rev.
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6 5 4 3 2 1 122−0426 REV. A D D C C B B A Groundsmaster 360 Operator Cab (Sheet 2 of 2) (Serial Number Above 315000000) Electrical Schematic A All relays and solenoids are shown as de−energized. All ground wires are black. 6 Page 9 − 14 5 4 3 (Rev.
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6 5 4 3 2 1 119−5781 REV. A D D C C B B A A All relays and solenoids are shown as de−energized. All ground wires are black. 6 5 4 3 (Rev.
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6 5 4 3 2 1 119−5782 REV. D D D C C B B A A Groundsmaster 360 with 2WD (Serial Number Below 312000300) Wire Harness Drawing 6 Page 9 − 16 5 4 3 (Rev.
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D PINK PINK PINK 119−5782 REV.
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6 5 4 3 2 1 121−6566 REV. A D D C C B B A A Groundsmaster 360 with 2WD (Serial Number Above 312000300) Wire Harness Drawing 6 Page 9 − 18 5 4 3 (Rev.
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6 5 4 3 2 1 121−6566 REV. A D D C C B B A A Groundsmaster 360 with 2WD (Serial Number Above 312000300) Wire Harness Diagram 6 5 4 3 (Rev.
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6 5 4 3 2 1 119−5783 REV. C D D C C B B A A Groundsmaster 360 with 4WD (Serial Number Below 312000300) Wire Harness Drawing 6 Page 9 − 20 5 4 3 (Rev.
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6 5 4 (Rev.
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6 5 4 3 2 1 121−6553 REV. E D D C C B B A A Groundsmaster 360 with 4WD (Serial Number From 312000301 to 313999999) Wire Harness Drawing 6 Page 9 − 22 5 4 3 (Rev.
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6 5 4 3 2 1 121−6553 REV. E D D C C B B A A Groundsmaster 360 with 4WD (Serial Number From 312000301 to 313999999) Wire Harness Diagram 6 5 4 3 (Rev.
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6 5 4 3 2 1 122−0170 REV. B D D C C B B A A Groundsmaster 360 with 4WD (Serial Number Above 314000000) Wire Harness Drawing 6 Page 9 − 24 5 4 3 (Rev.
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6 5 4 3 2 1 122−0170 REV. B D D C C B B A A Groundsmaster 360 with 4WD (Serial Number Above 314000000) Wire Harness Diagram 6 5 4 3 (Rev.
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6 5 4 3 2 1 D D C C B B A A Operator Cab (Serial Number Below 314999999) Wire Harness Drawing 6 Page 9 − 26 5 4 3 (Rev.
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4 2 YELLOW GRAY 1 BLACK/WHITE ORANGE RED D 3 ORANGE/BLACK 5 YELLOW 6 D BROWN ORANGE VIOLET ORANGE/BLACK PINK BLACK BLACK BLUE ORANGE ORANGE ORANGE BLACK BLACK YELLOW RED ORANGE/BLACK RED/WHITE RED C BLACK VIOLET RED BLUE C BLACK GREEN YELLOW RED BLACK BLACK RED BLACK BLACK BLACK B BLACK BLACK BLACK BLACK RED BLACK BLACK B WHITE VIOLET VIOLET ORANGE VIOLET GRAY BROWN BROWN BLUE VIOLET BLUE VIOLET BLACK VIOLET BLUE VIOLET BROWN VIOLET BLACK BLACK VIOLET
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6 5 4 3 2 1 122−0723 REV. A D D C C B B A A Operator Cab (Serial Number Above 315000000) Wire Harness Drawing 6 Page 9 − 28 5 4 3 (Rev.
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6 5 4 3 2 1 122−0723 REV. A D D C C B B A A Operator Cab (Serial Number Above 315000000) Wire Harness Diagram 6 5 4 3 (Rev.
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6 5 4 3 2 1 D D C C RED RED BLACK B B BLACK BLUE BLACK A GREEN YELLOW BLACK WHITE A Operator Cab Interconnect (Serial Number Below 314999999) Wire Harness Drawing and Diagram 6 Page 9 − 30 5 4 3 (Rev.
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6 5 4 3 2 1 119−4384 REV. A D D C C B B A A Operator Cab Interconnect (Serial Number Above 315000000) Wire Harness Drawing and Diagram 6 5 4 3 (Rev.
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6 5 4 3 2 1 119−5784 REV. C D D C C B B A A Groundsmaster 360 Electrical Accessories Kit (Optional) Wire Harness Drawing 6 Page 9 − 32 5 4 3 (Rev.
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6 5 A 4 (Rev. A) 3 GRAY BLACK/WHITE GRAY B RED/WHITE BLACK/WHITE PINK GRAY ORANGE BLACK BLACK WHITE GREEN BLACK 4 RED/WHITE BLACK/WHITE RED/WHITE BLACK/WHITE RED/WHITE BLACK/WHITE RED/WHITE RED/BLACK ORANGE WHITE TAN BLACK GRAY BLACK BLACK GREEN BLACK PINK GREEN BLACK 5 BLUE GRAY YELLOW GREEN VIOLET RED VIOLET BLACK YELLOW BLACK PINK BLUE BLACK GRAY BLUE ORANGE BROWN RED BLACK GREEN RED GRAY 6 3 2 BLACK 2 1 BLACK 119−5784 REV.