Toro groundsmaster 455-D User manual

Part No. 93804SLRev. E
Service Manual
Groundsmaster® 455-D
This publication provides the service technician with
information for troubleshooting, testing, and repair of
major systems and components on the
Groundsmaster 455-D
REFER TO THE GROUNDSMASTER 455-D OPERA-
TOR’S MANUAL FOR OPERATING, MAINTENANCE
AND ADJUSTMENT INSTRUCTIONS. Space is pro-
vided at the end of Chapter 2 in this publication to insert
the Operator’s Manuals and Parts Catalogs for your
machine. Replacement Operator’s Manuals are avail-
able by sending complete Model and Serial Number of
traction unit and cutting unit to:
The Toro Company
8111 Lyndale Avenue South
Minneapolis, MN 55420
TheToroCompanyreservestherighttochange product
specifications or this publication without notice.
This safety symbol means DANGER, WARN-
ING, or CAUTION, PERSONAL SAFETY IN-
STRUCTION. When you see this symbol,
carefully read the instructions that follow.
Failure to obey the instructions may result in
personal injury.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing or re-
pair of the machine.
IMPORTANT: The IMPORTANT notice will give im-
portant instructions which must be followed to pre-
vent damage to systems or components on the
machine.
©The Toro Company - 1993, 1996, 1998, 2002, 2003

This page is blank.

Table Of Contents
Chapter 1 - Safety
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . .1 - 1
Chapter 2 - Product Records and Manuals
Product Records . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 1
Equivalents and Conversions . . . . . . . . . . . . . . . .2 - 2
Torque Specifications . . . . . . . . . . . . . . . . . . . . . .2 - 3
Maintenance Interval Charts . . . . . . . . . . . . . . . . .2 - 4
Equipment Operational and
Service Historical Report Record
Chapter 3 - Peugeot XUD9 Diesel Engine
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 2
Identification and Specifications . . . . . . . . . . . . . .3 - 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 11
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 17
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . .3 - 18
Testing and Inspection . . . . . . . . . . . . . . . . . . . .3 - 27
Fuel System Service . . . . . . . . . . . . . . . . . . . . . .3 - 33
Timing Belt Replacement . . . . . . . . . . . . . . . . . .3 - 36
Injection Pump Timing . . . . . . . . . . . . . . . . . . . .3 - 40
Preparation for Engine Repair . . . . . . . . . . . . . . 3 - 42
Engine Removal and Installation . . . . . . . . . . . .3 - 43
Engine Overhaul . . . . . . . . . . . . . . . . . . . . . . . . .3 - 45
Chapter 4 - Hydraulic System
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 2
General Information . . . . . . . . . . . . . . . . . . . . . . .4 - 3
Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . .4 - 5
Hydraulic Flow Diagrams . . . . . . . . . . . . . . . . . . .4 - 7
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 11
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . .4 - 13
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 19
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 26
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 27
Chapter 5 - Electrical System
Wiring Schematics and Diagrams . . . . . . . . . . . . .5 - 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 7
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 16
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 29
Chapter 6 - Axles and Brakes
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 2
General Information . . . . . . . . . . . . . . . . . . . . . . .6 - 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 4
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 6
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 8
Chapter 7 - PTO System
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 2
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 3
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 5
Chapter 8 - Cutting Unit
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 2
General Information . . . . . . . . . . . . . . . . . . . . . . .8 - 3
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 4
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 9
Rev. B
Groundsmaster®455-D
Engine Product Records
and Manuals
Hydraulic SystemElectrical SystemAxles and BrakesPTO SystemCutting Unit Safety

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Chapter 1
Safety
Safety
Table of Contents
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . 1
Before Operating. . . . . . . . . . . . . . . . . . . . . . . . . 1
While Operating. . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Instructions
TheGROUNDSMASTER455-DconformstotheAmeri-
can National Standards Institute’s safety standards for
riding mowers when standard rear weight ballast is
installed. Although hazard control and accident preven-
tion partially are dependent upon the design and con-
figuration of the machine; these factors are also
dependent upon the awareness, concern, and proper
trainingofthepersonnelinvolvedintheoperation,trans-
port, maintenance, and storage of the machine. Im-
proper use or maintenance of the machine can result in
injury or death. To reduce the potential for injury or
death, comply with the following safety Instructions.
WARNING: Engine exhaust contains carbon monoxide
which is an odorless, deadly poison. Carbon monoxide
is also known by the State of California to cause birth
defects. Do not run engine indoors or in an enclosed
area.
While Doing Maintenance, Troubleshooting,
Testing, Adjustments or Repairs . . . . . . . . . . . . . 3
Obey the following safety instructions. Read
and understand these instructions before op-
erating the Groundsmaster 455-D or doing
maintenance, troubleshooting, testing, ad-
justments or repairs. Failure to comply with
the safety instructions may result in personal
injury.
CAUTION
Before Operating
1. Read and understand the Operator’s Manual before
starting, operating, maintaining or repairing the ma-
chine. Become familiar with the controls and know how
to stop the machine and engine quickly. Replacement
Operator’s Manuals are available by sending complete
Model and Serial Number of traction unit and cutting
units to: TheToroCompany
8
111LyndaleAvenueSouth
Minneapolis,MN 55420
UsetheModelandSerialNumberwhenreferringtoyour
machine. If you have questions about this Service Man-
ual, please contact:
TheToroCompany
Commercial Service Department
8111LyndaleAvenueSouth
Minneapolis,MN 55420
2. Never allow children to operate the machine. Do not
allow adults to operate machine without proper instruc-
tion. Only trained operators who have read this manual
should operate this machine.
3. Never operate the machine when under the influence
of drugs or alcohol.
4. Keep all shields, safety devices and decals in place.
If a shield, safety device or decal is defective, illegible
or damaged, repair or replace it before operating the
machine. Also tighten any loose nuts, bolts or screwsto
ensure machine is in safe operating condition.
5. Always wear substantial shoes. Do not operate ma-
chine while wearing sandals, tennis shoes, sneakers or
when barefoot. Do not wear loose fitting clothing that
could get caught in moving parts and possibly cause
personal injury. Wearing safety glasses, safety shoes,
Groundsmaster® 455-D Page 1 - 1 Safety Instructions

long pants and a helmet is advisable and required by
some local ordinances and insurance regulations.
6. Assure interlock switches are adjusted correctly so
engine cannot be started unless traction pedal is in
NEUTRAL and cutting unit is DISENGAGED.
7. Remove all debris or other objects that might be
picked up and thrown by the blades or fast moving
components from other attached implements. Keep all
bystanders away from operating area.
8. Since diesel fuel is highly flammable, handle it
carefully:
A. Use an approved fuel container.
B. Do not remove fuel tank cap while engine is hot
or running.
C. Do not smoke while handling fuel.
D. Fill fuel tank outdoors and only to within an inch
from the top of the tank, not the filler neck. Do not
overfill.
E. Wipe up any spilled fuel.
While Operating
9. Sit on the seat when starting and operating the
machine.
10. Before starting the engine:
A. Engage the parking brake.
B. Make sure traction pedal is in NEUTRAL and
cutting decks are DISENGAGED. Move axle shift to
HI or LO position.
C. After engine is started, release parking brake and
keepfoot offtractionpedal.Machinemust notmove.
If movement is evident, the neutral return mecha-
nism is adjusted incorrectly; therefore, shut engine
off and adjust until machine does not move when
traction pedal is released. Refer to Adjusting Trac-
tion Drive for Neutral in Chapter 4 - Hydraulic
System.
11. Seating capacity is one person. Therefore, never
carry passengers.
12. Do not run engine in a confined area without ade-
quate ventilation. Exhaust fumes are hazardous and
could possibly be deadly.
13. Check interlock switches daily for proper operation.
Do not rely entirely on safety switches – use common
sense. If a switch fails, replace it before operating the
machine. The interlock system is for your protection, so
do not bypass it. Replace all interlock switches every
two years.
14. Using the machine demands attention and to pre-
vent loss of control:
A. Operate only in daylight or when there is good
artificial light.
B. Drive slowly. Avoid sudden stops and starts.
C. Watch for holes or other hidden hazards.
D. Look behind machine before backing up.
E. Do not drive close to a sand trap, ditch, creek or
other hazard.
F Reduce speed when making sharp turns and
turning on a hillside.
15. Traverse slopes carefully. Do not start or stop sud-
denly when traveling uphill or downhill. Never shift axle
when moving. Machine must be on a flat surface and /
or brakes must be engaged to prevent freewheeling.
16. Operator must be skilled and trained in how to drive
onhillsides.Failuretousecautiononslopesorhillsmay
cause loss of control and vehicle to tip or roll possibly
resulting in personal injury or death.
17. When operating 4 wheel drive machine, always use
the seat belt and ROPS together and have seat pivot
retaining pin installed.
18. If engine stalls or loses headway and cannot make
it to the top of a slope, do not turn machine around.
Always back slowly straight down the slope.
19. Raise cutting decks and latch securely in transport
position before driving from one work area to another.
20. DON’TTAKE AN INJURY RISK! When a person or
pet appears unexpectedly in or near the mowing area,
STOP MOWING. Careless operation, combined with
terrain angles, ricochets, or improperly positioned
guardscanleadtothrownobjectinjuries.Donotresume
mowing until area is cleared.
21. Do not touch engine, muffler or exhaust pipe while
engineisrunningorsoonafteritisstopped.Theseareas
could be hot enough to cause burns.
22. If cutting deck strikes a solid object or vibrates
abnormally, stop immediately, turn engine off, set park-
ing brake and wait for all motion to stop. Inspect for
damage.Ifdamaged,repairorreplaceanycomponents
before operating.
Safety Instructions Page 1 - 2 Groundsmaster® 455-D

23. Before getting off the seat: D. Stop engine and remove key from switch.
E. Do not park on slopes unless wheels are chocked
A. Set parking brake. or blocked.
B. Move traction pedal to neutral and axle shift to Hi
or LO position. 24. Use only a rigid tow bar if it becomes necessary to
C. Disengage cutting decks and wait for blades tow machine. Use trailer for normal transport.
to stop.
Safety
While Doing Maintenance, Troubleshooting, Testing, Adjustments or Repairs
25. Before servicing or making adjustments, stop en-
gine and remove key from the switch.
26. When changing attachments, tires or performing
other service, use the correct blocks, hoists and jacks.
Always chock or block the wheels and use jack stands
or solid wood blocks to support the raised machine. If
the traction unit is not properly supported by blocks or
jack stands, the unit may move or fall resulting in injury.
27. Make sure machine is in safe operating condition by
keeping all nuts, bolts and screws tight.
28.Makesureallhydrauliclineconnectorsaretight,and
all hydraulic hoses and lines are in good condition
before applying pressure to the system.
29. Keep body and hands away from pin hole leaks or
nozzles that eject high pressure hydraulic fluid. Use
cardboard or paper to find hydraulic leaks. Hydraulic
fluid escaping under pressure can penetrate skin and
cause injury. Fluid accidentally injected into the skin
must be surgically removed within a few hours by a
doctor familiar with this form of injury or gangrene may
result.
30. Before disconnecting or performing any work on the
hydraulic system, all pressure in system must be
relieved by lowering cutting units to the ground and
stopping engine.
31. If major repairs are ever needed or assistance is
desired, contact an Authorized Toro Distributor.
32. To reduce potential fire hazard, keep engine area
free of excessive grease, grass, leaves and dirt. Clean
protective screen on back of machine frequently.
33. If engine must be running to perform maintenance
or an adjustment, keep hands, feet, clothing and other
parts of the body away from cutting units and other
moving parts. Keep all bystanders away.
34. Do not overspeed the engine by changing governor
setting. To assure safety and accuracy, have an Author-
ized Toro Distributor check maximum engine speed.
35. Shut engine off before checking or adding oil to the
crankcase.
36. Disconnect battery before servicing the machine. If
battery voltage is required for troubleshooting or test
procedures, temporarily connect the battery.
37. At the time of manufacture, the machine conformed
to the safety standards for riding mowers. Ballast
weight, mounted to rear of traction unit, is required for
machine to conform to safety standard. DO NOT re-
move ballast weight at any time. To assure optimum
performance and continued safety certification of the
machine, use genuine Toro replacement parts and ac-
cessories. Replacement parts and accessories made
by other manufacturers may result in non-conformance
with the safety standards, and the warranty may be
voided.
Groundsmaster® 455-D Page 1 - 3 Rev. C Safety Instructions

Safety Instructions Page 1 - 4 Groundsmaster® 455-D

Chapter 2
Product Records and Manuals
Table of Contents
PRODUCT RECORDS. . . . . . . . . . . . . . . . . . . . . . . 1
EQUIVALENTS AND CONVERSIONS . . . . . . . . . . 2
Decimal and Millimeter Equivalents . . . . . . . . . . 2
U.S. to Metric Conversions . . . . . . . . . . . . . . . . . 2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . 3
Capscrew Markings and Torque Values - U.S. . . 3
Capscrew Markings and Torque Values - Metric. 3
Product Records
Record information about your Groundsmaster 455-D
ontheEquipmentOperationandServiceHistoryReport
Form. Use this information when referring to your ma-
chine.
MAINTENANCE CHARTS . . . . . . . . . . . . . . . . . . . . 4
2 Wheel Drive Quick Reference Aid . . . . . . . . . . 4
4 Wheel Drive Quick Reference Aid . . . . . . . . . . 6
EQUIPMENT OPERATION
AND SERVICE HISTORY REPORT
Insert the Operator’s Manuals and Parts Catalogs for
your Groundsmaster 455-D at the end of this section.
and Manuals
Product Records
Groundsmaster® 455-D Page 2 - 1 Rev. B Product Records

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Equivalents and Conversions
Decimal and Millimeter Equivalents
Fractions Decimals mm Fractions Decimals mm
1/64 0.015625 — 0.397 33/64 0.515625 — 13.097
1/32 ––––– 0.03125 — 0.794 17/32 –––– 0.53125 — 13.494
3/64 0.046875 — 1.191 35/64 0.546875 — 13.891
1/16–––––––––––– 0.0625 — 1.588 9/16–––––––––––– 0.5625 — 14.288
5/64 0.078125 — 1.984 37/64 0.578125 — 14.684
3/32 ––––– 0.9375 — 2.381 19/32 –––– 0.59375 — 15.081
7/64 0.109275 — 2.778 39/64 0.609375 — 15.478
1/8––––––––––––– 0.1250 — 3.175 5/8––––––––––––– 0.6250 — 15.875
9/64 0.140625 — 3.572 41/64 0.640625 — 16.272
5/32 ––––– 0.15625 — 3.969 21/32 –––– 0.65625 — 16.669
11/64 0.171875 — 4.366 43/64 0.671875 — 17.066
3/16–––––––––––– 0.1875 — 4.762 11/16 ––––––––––– 0.6875 — 17.462
13/64 0.203125 — 5.159 45/64 0.703125 — 17.859
7/32 ––––– 0.21875 — 5.556 23/32 –––– 0.71875 — 18.256
15/64 0.234375 — 5.953 47/64 0.734375 — 18.653
1/4––––––––––––– 0.2500 — 6.350 3/4––––––––––––– 0.7500 — 19.050
17/64 0.265625 — 6.747 49/64 0.765625 — 19.447
9/32 ––––– 0.28125 — 7.144 25/32 –––– 0.78125 — 19.844
19/64 0.296875 — 7.541 51/64 0.796875 — 20.241
5/16–––––––––––– 0.3125 — 7.541 13/16––––––––––– 0.8125 — 20.638
21/64 0.328125 — 8.334 53/64 0.828125 — 21.034
11/32 –––– 0.34375 — 8.731 27/32 –––– 0.84375 — 21.431
23/64 0.359375 — 9.128 55/64 0.859375 — 21.828
3/8––––––––––––– 0.3750 — 9.525 7/8––––––––––––– 0.8750 — 22.225
25/64 0.390625 — 9.922 57/64 0.890625 — 22.622
13/32 –––– 0.40625 — 10.319 29/32 –––– 0.90625 — 23.019
27/64 0.421875 — 10.716 59/64 0.921875 — 23.416
7/16–––––––––––– 0.4375 — 11.112 15/16––––––––––– 0.9375 — 23.812
29/64 0.453125 — 11.509 61/64 0.953125 — 24.209
15/32 –––– 0.46875 — 11.906 31/32 –––– 0.96875 — 24.606
31/64 0.484375 — 12.303 63/64 0.984375 — 25.003
1/2––––––––––––– 0.5000 — 12.700 1 –––––––––––––– 1.000 — 25.400
1 mm = 0.03937 in. 0.001 in. = 0.0254 mm
U.S to Metric Conversions
To Convert Into Multiply By
Linear Miles Kilometers 1.609
Measurement Yards Meters 0.9144
Feet Meters 0.3048
Feet Centimeters 30.48
Inches Meters 0.0254
Inches Centimeters 2.54
Inches Millimeters 25.4
Area Square Miles
Square Feet
Square Inches
Acre
Square Kilometers 2.59
Square Meters 0.0929
Square Centimeters 6.452
Hectare 0.4047
Volume Cubic Yards
Cubic Feet
Cubic Inches
Cubic Meters 0.7646
Cubic Meters 0.02832
Cubic Centimeters 16.39
Weight Tons (Short)
Pounds
Ounces (Avdp.)
Metric Tons 0.9078
Kilograms 0.4536
Grams 28.3495
Pressure Pounds/Sq. In. Kilopascal 6.895
Work Foot-pounds
Foot-pounds
Inch-pounds
Newton-Meters 1.356
Kilogram-Meters 0.1383
Kilogram-Centimeters 1.152144
Liquid Volume Quarts Liters 0.9463
Gallons Liters 3.785
Liquid Flow Gallons/Minute Liters/Minute 3.785
Temperature Fahrenheit Celsius 1. Subract 32o
2. Multiply by 5/9
Equivalents and Conversions Page 2 - 2 Groundsmaster® 455-D

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Torque Specifications
Use these torque values when specific torque values The torque values listed below are for lubricated
are not given. DO NOT use these values in place of threads.Platedthreads areconsideredto belubricated.
specified values.
Capscrew Markings and Torque Values - U.S. Customary
5 8
Nm Nm Nm Nm
1/ 7 9 6 8 9
9 7 9 13 18 10 14
5/
3/
7/
1/ 80 90
100 135 80
-18 150 85
135 180
-18 155 210 120
240 325 190
-16 270 365 210
360 490 280
-14 390 530 310
1-8 530 720 420
-14 590 800 480
SAE Grade Number
Capscrew Head Markings
Capscrew Torque - Grade 5 Capscrew Torque - Grade 8
Capscrew Body Size Cast Iron Aluminum Cast Iron Aluminum
ft-lb ft-lb ft-lb ft-lb
4-20 1115 12
-28 12
16-18 1520121622301824
-24 1723141924331925
8-16 3040202540553040
-24 3040253545603545
16-14 4560354565905065
-20 5065405570955575
2-13 709555759513075100
-20 75 100 60 110 150 120
9/16-12 110 140 190 110 150
110 115 155 210 125 170
5/8-11 110 150 190 255 150 205
160 215 290 170 230
3/4-10 255 340 460 270 365
285 380 515 300 410
7/8-9 380 550 745 440 600
420 610 825 490 660
570 820 1100 660 890
650 890 1200 710 960
Capscrew Markings and Torque Values – Metric
mm Nm Nm Nm Nm Nm Nm
6 5 9 4 7 9 7 9 7
7 9 7
8
10 30 40 25 30 45 60
12 55 70 40 55 75 105
14 85 120 160
16 130 180 100 140 175 240
18 170 230 135 180 240 320
Commercial Steel Class 8.8 10.9 12.9
Capscrew Head Markings
Thread Capscrew Torque - Class 8.8 Capscrew Torque - Class 10.9 Capscrew Torque - Class 12.9
Diameter Cast Iron Aluminum Cast Iron Aluminum Cast Iron Aluminum
ft-lb ft-lb ft-lb ft-lb ft-lb ft-lb
14 11 14 11
14 111418111418231418
182514182332182527362128
35 45 50 70 40 55
60 80 95 125 75 100
115 65 90 95 125 145 195 110 150
135 190 210 290 165 220
185 250 290 400 230 310
and Manuals
Product Records
Groundsmaster® 455-D Page 2 - 3 Torque Specifications

Maintenance Schedules
Maintenance Schedules Page 2 - 4 Rev. C Groundsmaster® 455-D

and Manuals
Product Records
Groundsmaster® 455-D Page 2 - 5 Rev. C Maintenance Schedules

Maintenance Charts Page 2 - 6 Groundsmaster® 455-D

____________________
____________________
____________________ __________________
____________________ __________________
____________________ __________________
EQUIPMENT OPERATION AND SERVICE HISTORY REPORT
for
GROUNDSMASTER® 455-D
TORO Model and Serial Number:__________-__________
Engine Numbers: _____________________
Transaxle Numbers: _____________________ _____________________
Rotary Deck Numbers: __________-__________
Date Purchased: ____________________ Warranty Expires__________
Purchased From: ____________________
Contacts: Parts Phone
Service Phone
Sales Phone
See your TORODistributor/Dealer for other Publications, Manuals, and Videos from The TORO Company.

GROUNDSMASTER® 455-D Maintenance Schedule
Minimum Recommended Maintenance Intervals:
Maintenance Procedure Maintenance Interval & Service Type:
Every
Every
Every
Every 800hrs
Inspect Air Filter, Dust Cup, and Baffle Every 400hrs
200hrs
100hrs
Lubricate All Grease Fittings 50hrs
A Level
Check Cutting Unit Gear Box Oil Level Service
‡ Change Engine Oil and Filter
Check Battery Level and Connections B Level
Inspect Cooling System Hoses Service
Service Air Cleaner Filter Element
† Inspect PTO and Cutting Unit Belts
‡ Check Electric Deck Clutches Adjustment
‡ Check Electric PTO Clutch Adjustment C Level
† Torque Wheel Lug Nuts Service
Replace Fuel Filter
Check Front Transaxle Oil level
Check Rear Axle Oil level (4wd)
Inspect Fuel Lines and Connections D Level
‡ Check Engine RPM (idle and full throttle) Service
† Inspect Engine Fan Belt
Inspect Engine Timing Belt (see note below)
Drain and Clean Fuel Tank
Change Hydraulic Oil
‡ Replace Hydraulic Oil Filter
Change Front Transaxle Oil
Pack Rear Axle Bearings (2wd)
Change Rear Axle Oil (4wd) E Level
Check Rear Wheel Toe-in Service
† Initial break in at 10 hours
‡ Initial break in at 50 hours
Replace Moving Hydraulic Hoses
Replace Safety Switches Annual Recommendations:
Items listed are recommended every 1500 hours or
Cooling System - Flush/Replace Fluid 2 years whichever occurs first.
Replace PTO Belts/Cutter Deck Belts
See Operator's and Service Manual for specifications and procedures)
NOTE: Replace Timing Belt if worn, cracked or oil soaked.Anew Timing Belt should be installed
any time the Belt is removed or loosened.

_____________
_____ _____ _____ _____ _____ _____ _____
GROUNDSMASTER® 455-D Daily Maintenance Check List
Unit Designation:__________
Daily Maintenance:(duplicate this page for routine use) TORO ID#:_______-_______
Maintenance Check Item
Daily Maintenance Check For Week Of
MON
HRS TUES HRS WED HRS THURS HRS FRI HRS SAT HRS SUN HRS
Safety Interlock Operation
Brake Operation
Engine Oil Level
Fuel Level
Cooling System Fluid Level
Drain Water/Fuel Separator
Optional Air Filter Precleaner
Radiator & Screen for Debris
1
Unusual Engine Noises2
Unusual Operating Noises
Hydraulic System Oil Level
Hydraulic Hoses for Damage
Fluid Leaks
Tire Pressure
Instrument Operation
Cutting Unit SafetyDoors
Height-of-Cut Adjustment
Clean Deck Belt area1
Condition of Blades
Lubricate All Grease Fittings
3
Touch-up damaged paint
1 = Use only low pressure compressed air for debris removal.Do not use water.
2 = Check Glow Plugs and Injector Nozzles, if hard starting, excess smoke, or rough running is noted.
3 = Immediatelyafter every washing, regardless of the interval listed.
Notation for areas of concern: Inspection performed by:________________
Item Date Information
1
2
3
4
5
6
7 (See Operator's and Service Manual for specifications and procedures)

_______________________________
______________________________ ______________________________ ______________________________ ______________________________ ______________________________ ______________________________ _________________________________ ______________________________ ______________________________ _________________________________ ______________________________ ______________________________ _________________________________
_________________________________ _________________________________
______________________________ _________________________________ ______________________________ _________________________________ ______________________________ _________________________________
GROUNDSMASTER® 455-D Supervisor Maintenance Work Order Date:______________ (duplicate this page for routine use)
Unit Designation: TORO I.D. #: Remarks:
____________-____________
Service to perform (circle): A B C D E Other
Technician:
A -Service (every 50 hours) B -Service (every 100 hours) C -Service (every 200 hours)
Inspect Air Filter, Dust Cup, & Baffle Lubricate All Grease Fittings Check Battery Level and Connections Inspect PTO and Cutting Unit Belts
Check Cutting Unit Gear Box Oil Inspect Cooling System Hoses
A-Service required
Torque Wheel Lug Nuts A and B Service required
D -Service (every 400 hours) E -Service (every 800 hours) Other
Inspect Engine Fan Belt Replace Moving Hoses Inspect Engine Timing Belt Replace Safety Switches
Check Rear Axle Oil level (4wd) Drain and Clean Fuel Tank Coolant System - Flush/Replace Fluid
Inspect Fuel Lines and Connections Replace PTO/ Cutter Deck Belts
Change Front Transaxle Oil
A, B, and C Service required
Check Rear Wheel Toe-in A, B, C, and D Service required
Hours:
Change Engine Oiland Filter Service Air Cleaner Filter Element
Check ElectricDeck Clutches Adjustment Check ElectricPTO Clutch Adjustment
- Annual Service and Specials
Replace FuelFilter
Check Front Transaxle Oillevel
Change Hydraulic Oil & Filter
Check Engine RPM (Idle/Full Throttle)
Pack RearAxle Bearings (2WD) Change RearAxle Oil (4WD)
(See Operator's and Service Manual for specifications and procedures) Form No. 95-851-SL

Chapter 3
Engine
Table of Contents
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
IDENTIFICATION AND SPECIFICATIONS . . . . . . . 3
General Specifications . . . . . . . . . . . . . . . . . . . . 3
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cylinder Head Gasket . . . . . . . . . . . . . . . . . . . . . 4
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Valve Recess . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Valve Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Swirl Chambers . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cylinder / Piston Matching . . . . . . . . . . . . . . . . . 8
Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . 10
SPECIALTOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . .11
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Valve Clearance Adjustment . . . . . . . . . . . . . . . 17
Engine Speed Adjustments . . . . . . . . . . . . . . . . 17
Throttle Cable Adjustments . . . . . . . . . . . . . . . . 17
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . 18
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . 20
Low Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Noisy Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Pre-heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Smoke During Operation . . . . . . . . . . . . . . . . . . 25
Starting Problems . . . . . . . . . . . . . . . . . . . . . . . 26
TESTINGAND INSPECTION . . . . . . . . . . . . . . . . 27
Injection Pump Timing . . . . . . . . . . . . . . . . . . . . 27
Glow Plug Test . . . . . . . . . . . . . . . . . . . . . . . . . 27
Compression Test . . . . . . . . . . . . . . . . . . . . . . . 28
Injector Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Injection Pump Fuel Delivery Test . . . . . . . . . . . 31
Thermostat Test . . . . . . . . . . . . . . . . . . . . . . . . . 32
FUEL SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . 33
Priming the Fuel System . . . . . . . . . . . . . . . . . . 33
Injection Pump Removal . . . . . . . . . . . . . . . . . . 33
Injection Pump Repair . . . . . . . . . . . . . . . . . . . . 33
Injector Service . . . . . . . . . . . . . . . . . . . . . . . . . 34
TIMING BELT REPLACEMENT . . . . . . . . . . . . . . . 36
Timing Belt Removal . . . . . . . . . . . . . . . . . . . . . 36
Timing Belt Installation . . . . . . . . . . . . . . . . . . . 38
INJECTION PUMP TIMING . . . . . . . . . . . . . . . . . . 40
Timing of Injection Pump . . . . . . . . . . . . . . . . . . 40
PREPARATION FOR ENGINE REPAIR . . . . . . . . . 42
Cylinder and Cylinder Block . . . . . . . . . . . . . . . 42
ENGINE REMOVAL AND INSTALLATION . . . . . . . 43
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . 45
Disassembly of External Components . . . . . . . . 45
Injection Pump Removal . . . . . . . . . . . . . . . . . . 46
Cylinder Head Removal . . . . . . . . . . . . . . . . . . . 47
Oil Pump Removal . . . . . . . . . . . . . . . . . . . . . . . 47
Crankshaft and Piston Removal . . . . . . . . . . . . 48
Cylinder Head Overhaul . . . . . . . . . . . . . . . . . . 49
Crankshaft Installation . . . . . . . . . . . . . . . . . . . . 51
Pistons and Connecting Rod Assembly . . . . . . . 53
Oil Seal Installation . . . . . . . . . . . . . . . . . . . . . . 54
Oil Pump Installation . . . . . . . . . . . . . . . . . . . . . 54
Flywheel Installation . . . . . . . . . . . . . . . . . . . . . 55
Cylinder Head Gasket Selection . . . . . . . . . . . . 56
Cylinder Head Installation . . . . . . . . . . . . . . . . . 56
Cylinder Head Tightening . . . . . . . . . . . . . . . . . 57
Valve Clearance Adjustment . . . . . . . . . . . . . . . 57
Assembly of External Components . . . . . . . . . . 60
Engine
Groundsmaster 455-D Page 3 - 1 Rev. B Engine

Introduction
The following pages give information about specifica-
tions, maintenance, troubleshooting, testing and repair
of the diesel engine used in the Groundsmaster®455-D
mowers.
Most repairs and adjustments require tools which are
commonly available in many service shops. Special
toolsaredescribedintheSpecialToolssection.Theuse
of some specialized test equipment is explained, how-
ever, the cost of the test equipment and the specialized
nature of some repairs may dictate that the work be
done at a qualified diesel engine repair facility.
Service and repair parts for the Peugeot engine used in
the Groundsmaster 455-D are supplied through TORO
Distributors.RepairpartsmaybeorderedbyTOROPart
Number. If no parts list is available be sure to provide
your dealer or distributor with the TORO Model Number
and Serial Number.
Aplate, riveted to the left-hand side of the engine block
carries the Engine Serial Number. Always include the
engine serial number with parts orders and warranty
claims.
Engine Page 3 - 2 Rev. B Groundsmaster 455-D