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Toro Groundsmaster 220-D Service Manual

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Preface
This Service and Overhaul Manual was written to give
the service technician information about the TORO
®
Groundsmaster
220-D/223-D mowers.
This manual is not designed to teach component theory.
The purpose of this manual is to provide the service
technician with a working guide for safe maintenance,
troubleshooting, test, repair, and overhaul procedures.
The Toro Company has made every effort to make this
service manual a useful and lasting addition to every
service facility. To assure proper and effective service,
and to provide the best performance for the life of the
machine, you should read this manual carefully.
Read the complete sequence of instructions (example:
steps 1 - 6) before performing a procedure.
The Toro Company reserves the right to change product
specifications or this manual without notice.
Groundsmaster 224 / 225 / 1000L / 228-D: (See notes in box below)
Groundsmaster
© The Toro Company – 1988, 1992, 1996, 2000, 2001, 2002, 2003, 2004, 2005
®
220-D/223-D
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.
Use this book along with the Toro
Operator's Manual and Parts Catalog for
the specific model and serial number of the
machine, and the engine manual listed
below:
Groundsmaster 224:
Mitsubishi GL3 Engine Service Guide
(Toro Part No. 91773SL).
Groundsmaster 1000L:
Kawasaki FD620 Engine Service Manual
(Toro Part No. 492-4713).
Groundsmaster 225:
Briggs-Daihatsu 3LC Engine Repair
Manual (Toro Part No. 99048SL).
Groundsmaster 228-D:
Kubota 05 Series Shop Manual
(Toro Part No. 01090SL).
Part No. 88712SL, Rev. H
Service Manual

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Summary of Contents for Toro Groundsmaster 220-D

  • Page 1 (Toro Part No. 492-4713). Groundsmaster 225: Briggs-Daihatsu 3LC Engine Repair Manual (Toro Part No. 99048SL). Groundsmaster 228-D: Kubota 05 Series Shop Manual (Toro Part No. 01090SL). © The Toro Company – 1988, 1992, 1996, 2000, 2001, 2002, 2003, 2004, 2005...
  • Page 2 Table Of Contents Chapter 1 - Safety Chapter 6 - Differential Axle Safety Instructions......1 - 1 Introduction .
  • Page 3 Chapter 12 - Cutting Units Chapter 14 - 4WD Rear Axle Introduction......12 - 1 Specifications .
  • Page 4 This page is blank.
  • Page 5 Obey the following safety instructions. Read and understand these instructions before op ­ ® erating the Groundsmaster 220-D or doing maintenance, troubleshooting, testing, ad ­ justments or repairs. Failure to comply with the safety instructions may result in personal injury.
  • Page 6 7. Fill the fuel tank with diesel fuel before starting the C. Do not smoke while handling fuels or lubricants. engine. Avoid spilling any fuel. Fuel is very flammable. Handle fuel carefully. DO NOT SMOKE. D. Fill the tank up to approximately one inch (25 mm) from the top of the tank, not the filler neck.
  • Page 7 If major repairs are ever needed, or assis ­ Use paper or cardboard, not hands, to search for leaks. tance is desired, contact an Authorized TORO Distribu­ Hydraulic fluid escaping under pressre can have suffi­ tor or Dealer.
  • Page 8 ® Safety Instructions Page 1 - 4 Groundsmaster 220-D (3/88)

  • Page 9: Table Of Contents

    Chapter 2 Product Records and Manuals Table of Contents PRODUCT RECORDS ......1 TORQUE SPECIFICATIONS ....3 EQUIVALENTS AND CONVERSIONS .

  • Page 10: Equivalents And Conversions

    Equivalents and Conversions Product Records and Manuals Groundsmaster 220–D/223–D Page 2 – 2...

  • Page 11: Torque Specifications

    Torque Specifications Groundsmaster 220–D/223–D Product Records and Manuals Page 2 – 3...
  • Page 12 Product Records and Manuals Groundsmaster 220–D/223–D Page 2 – 4 Rev. B...

  • Page 13: Operation And Service History Reports

    Drive Axle(s) Numbers: ____________________ Date Purchased: ____________________ Warranty Expires__________ Purchased From: ____________________ ____________________ ____________________ Contacts: Parts ____________________ Phone __________________ Service ____________________ Phone __________________ Sales ____________________ Phone __________________ See your TORO Distributor/Dealer for other Publications, Manuals, and Videos from The TORO Company.
  • Page 14 GROUNDSMASTER® 220-D, 223-D, 224 Maintenance Schedule Minimum Recommended Maintenance Intervals: Maintenance Procedure Maintenance Interval & Service 400hrs 200hrs 100hrs Check Battery Fluid Level 50hrs Check Battery Cable Connections Lubricate All Grease Fittings Lubricate Brake Cables Check Cutting Unit Gear Box Oil Level Clean Under Cutting Unit Belt Covers Check Cutting Unit Drive Belt Adjustment A Level...
  • Page 15 GROUNDSMASTER® 220-D, 223-D, 224 Daily Maintenance Check List Unit Designation:__________ Daily Maintenance: TORO ID#:_______-_______ (duplicate this page for routine use) Daily Maintenance Check For Week Of _____________ TUES THURS _____ _____ _____ _____ _____ _____ _____ Maintenance Check Item Safety Interlock Operation...
  • Page 17 (For Groundsmaster 220-D/223-D only) For Groundsmaster 228-D, use the Toro Operator's Manual and Parts Catalog along with the Kubota 05 Series Workshop Manual (Toro Part No. 01090SL). Rev. D...
  • Page 114 Charge Pressure Test 10.Perform a dynamic charge pressure test to identify Using a low pressure gauge, 0 – 1000 psi (0 – 6895 kPa) possible hydrostat (pump or motor) problems as follows: 1. Engage the parking brake and block the front wheels A.
  • Page 115 Implement Relief Pressure Test NOTE: If the implement relief pressure is 700 to 800 Using a low pressure gauge, 0 – 1000 psi (0 – 6895 kPa) PSI (4826 to 5516 kPa) and a steering or lift problem oc- curs, inspect for a problem unrelated to the hydraulic cir- 1.
  • Page 147 Wiring Schematics Groundmaster 224 Figure 1 Page 5 – 3 Rev. F Groundsmaster 220–D/223–D Wiring Schematics...
  • Page 148 Groundmaster 225 (Serial Numbers 60001 to 200999999) Figure 2a Page 5 – 4 Wiring Schematics Rev. F Groundsmaster 220–D/223–D...
  • Page 149 Groundmaster 225 (Serial Numbers higher than 21000000) Figure 2b Page 5 – 5 Rev. F Groundsmaster 220–D/223–D Wiring Schematics...
  • Page 150 Groundmaster 1000L Figure 2c Page 5 – 5.1 Rev. F Groundsmaster 220–D/223–D Wiring Schematics...
  • Page 151 Groundmaster 220–D (All Serial Numbers except 80000001 to 90000349) Groundsmaster 223–D 2WD (All Serial Numbers) Groundsmaster 223–D 4WD (Serial Numbers 300001 to 90499) Figure 2d Page 5 – 5.2 Rev. F Wiring Schematics Groundsmaster 220–D/223–D...
  • Page 152 Groundmaster 220–D (Serial Numbers 80000001 to 90000349) Groundsmaster 223–D 4WD (Serial Numbers 90500 and higher) Figure 2e Page 5 – 5.3 Rev. F Groundsmaster 220–D/223–D Wiring Schematics...
  • Page 153 Groundmaster 228–D Figure 2f Page 5 – 5.4 Rev. F Wiring Schematics Groundsmaster 220–D/223–D...
  • Page 183 Chapter 6 Differential Axle Table of Contents INTRODUCTION ......1 Axle Shaft Disassembly TORQUE SPECIFICATIONS ....2 and Wheel Bearing Service .
  • Page 184 0.00 to 0.005 in. Special Tools NOTE: Order special tools from the TORO SPECIAL Catalog for your Toro equipment. Some tools may also TOOLS AND APPLICATIONS GUIDE (COMMERCIAL be available from a local supplier. PRODUCTS) . Some tools may be listed in the Parts...

  • Page 185: Repairs

    Repairs Axle Removal and Installation 1. Disconnect the battery cable from the negative (–) battery post. 2. Remove the cutting unit from the suspension frame. Remove the cutting unit suspension frame from the traction unit. (See the Repairs section of Chapter 12 - Cutting Units.) 3.

  • Page 186: Axle Shaft Disassembly And Wheel Bearing Service

    Axle Shaft Disassembly and Wheel Bearing Service NOTE: When servicing the bearing and seal area of the axle shaft, it is recommended that you replace hex head screws and flange nuts with socket head screws (94­ 6934), washers (94-6936) and nuts (94-6935). See Figure 18.
  • Page 187 4. Remove the inner axle shaft seal (Fig. 8). Discard the seal and replace with a new one at the time of assembly. Figure 8 5. Center punch the outside of the retaining ring (Fig. 9). Figure 9 6. Drill a 1/4 inch hole (approximate) into the outside of the retainer ring to a depth of about 3/4 the thickness of the ring (Fig.
  • Page 188 7. After drilling, put a chisel in position across the hole and strike sharp y to break the ring. Replace with a new ring at time of reassembly (Fig. 11). WARNING Wear protective safety goggles when break ­ ing the retaining ring. Personal injury could result from flying metal particles.
  • Page 189 11. Slide a new retaining ring on the axle shaft and support the shaft and ring in a suitable press (Fig. 14). Press the retaining ring firmly against the bearing. Figure 14 12. Put a light coating of No. 1 Permatex on the outside diameter of a new grease seal (surface that contacts the axle housing).

  • Page 190: Differential And Housing Disassembly

    13. Assemble the bearing retainer bolts to the axle housing. Apply a 0.625 in. (16 mm) bead of gasket material to flange on end of axle housing, then install the axle shaft assembly into the axle housing. Be careful not to damage the oil seal and bearing. Line up the holes of the brake assembly and oil seal.
  • Page 191 2. Remove the four bearing cap screws and remove the caps. Place the caps in a safe place to avoid damaging their machined surfaces (Fig. 20). The bearing caps are marked for identification. The letters or numbers are in horizontal and vertical posi­ tions.
  • Page 192 5. Do not remove the bearings from the differential case unless bearing failure is evident. It is recommended that whenever bearings are removed (regardless of usage) they must be replaced with new ones. Remove the case side bearing with a puller as shown (Fig. 23). Figure 23 6.
  • Page 193 8. To remove the side gears and pinion mate gears, rotate the side gears. This will allow the pinion mate gears to turn to the opening of the case (Fig. 26). Remove the pinion mate gears and the spherical wash ­ ers behind the gears.
  • Page 194 11. Before pressing pinion out of housing: If unit was equipped with an expansion plug (re ­ moved in step 10), remove the snap ring and shim from the end of the pinion (Fig. 29). If unit is equipped with a flange for 4WD (no expan ­ sion plug), nut, washer and flange (Fig.
  • Page 195 13. Clamp the inner pinion bearing with a universal bearing remover (Fig. 32). Position the unit in a press and carefully push the drive pinion out of the bearing. DO NOT allow the pinion to drop on the floor - damage will result.

  • Page 196: Differential And Housing Reassembly

    Differential and Housing Reassembly 1. Inspect the differential parts for damage before assembling. A. If any bearings are damaged they must be re ­ placed with new ones. B. Check the ring, pinion, and spur gear for abnormal wear and damage; replace worn components. C.
  • Page 197 Ring and Pinion Set Rings gears and pinions are supplied in matched sets only. Matching numbers are etched on both the pinion and ring gear (Fig. 37). The mounting distance from the bottom of the differen­ tial bearing bores to the button end of the pinion is 1.210 in.
  • Page 198 4. Install a new inner bearing cup using a press plate of proper diameter. Reuse the original shims or use new shims of the same thickness. Push the bearing cup into the housing until it bottoms against the housing (Fig. 38). Figure 38 5.
  • Page 199 7. Support the drive pinion in a suitable press (Fig. 41). Figure 41 8. Install the outer pinion spacer with the chamfer to­ wards the pinion splines and install the new outer pinion bearing cone (Fig. 42). Figure 42 9. With a hollow press sleeve of proper diameter, press on the outer bearing cone race until the drive pinion seats in the carrier and a slight drag is noticed when the gear is rotated by hand (2-13 in.-lb.
  • Page 200 10. Install the shim and snap ring onto the end of the pinion shaft. Use the thickest shim possible which will permit installation of the snap ring (Fig. 44). Limit the end play to 0.000 - 0.005 inch (0.000 - 0.127 mm). Figure 44 11.
  • Page 201 13. Place the differential case in a vise as shown (Fig. 47). Apply grease to new side gear thrust washers and hubs of the side gears. Apply grease to new pinion mate spherical washers and pinion mate gears. Place the side gears and thrust washers in the case. Install the pinion gears while holding the side gears in place.
  • Page 202 Seat differential assembly with drive gear on proper side of carrier into carrier bearing cra ­ dles. NOTE: Groundsmaster 220-D/223-D application re­ quires that the ring gear teeth face away from the spur Figure 51 gear cover.
  • Page 203 19. Using a dial indicator, check the ring gear backlash in three equally spaced points. Ring gear backlash should be .003 - .007 inch (.076 - .178 mm) and must not vary more than .002 in. between points checked (Fig. 53). If the backlash is not in this range, move the shims which are located beneath the differential bearings, from one side to the other until the correct backlash is attained.
  • Page 204 Drive Side Coast Side Heel Heel Backlash correct. Thicker pinion position shims required. Figure 55 Drive Side Coast Side Heel Heel Backlash correct. Thinner pinion position shims required. Figure 56 Drive Side Coast Side Heel Heel Backlash incorrect. Thinner pinion position shim re­ quired.
  • Page 205 Gear Pattern Movements Summary 1. Decreasing backlash moves the ring gear closer to the pinion. Drive pattern (convex side of gear) moves lower and toward the toe. Coast pattern (concave side of gear) moves slightly higher and toward the heel. 2.
  • Page 206 ® Repairs Page 6 - 24 Groundsmaster 220-D/223-D...
  • Page 301 Chapter 14 Groundsmaster 223-D with Inasaka axle 4WD Rear Axle Table of Contents SPECIFICATIONS ......2 REPAIRS .

  • Page 302: Specifications

    Specifications Item Specification __________________________________________________________________________________________ Lubricant (Fig. 1, 2, 3) SAE 80W90 gear lube ________________________________________________________________________________________________________________________________________________________ Rear wheel toe-in 1/8 inch ________________________________________________________________________________________________________________________________________________________ Wheel nut torque 45 - 55 ft-lb Figure 1 Figure 3 (Right-hand end of axle shown) 1. Drain plugs 1. Check plugs (2) 2.

  • Page 303: General Information

    General Information Four-Matic 4WD Over-Running Clutch Operation A drive shaft connected to the front axle provides power for the rear 4WD drive axle. The drive shaft tor the rear Locked 49 RPM ax l e incorporates an OVER-RUNNING (ROLLER) Unlocked CLUTCH THAT TRANSMITS POWER ONLY IN THE FOR- 50 RPM WARD DIRECTION...

  • Page 304: Adjustments

    Adjustments Rear Wheel Toe-in 1. Measure center–to–center distance (at axle height) at front and rear of steering tires. Front measurement must be 1/8 in. less than rear measurement. 2. To adjust, loosen clamps at both ends of tie rod. 3. Rotate tie rod to move front of tire inward or outward. 4.

  • Page 305: Repairs

    Repairs Drive Shaft Service 0.34 ± ″ Arrow end of roller 0.03 utches must face 6-bolt f ange end of ″ 0.040 MAX utch housing toward rear axle) Apply Never-seeze Detail A Detail B Figure 8 Removing Drive Shaft Clutch Service 1.
  • Page 306 0.34 ± ″ Arrow end of roller 0.03 clutches must face 6-bolt f ange end of ″ 0.040 MAX clutch housing toward rear axle) Apply Never-seeze Detail A Detail B Figure 9 6. Install clutch assembly onto yoke shaft, then install 2.

  • Page 307: Rear Axle Removal And Installation

    Rear Axle Removal and Installation 45 - 55 ft-lb Figure 10 1. Remove drive shaft (see Drive Shaft Service). 5. Remove rear wheels. 2. Thoroughly clean around hydraulic hoses connec ­ 6. Remove capscrew (Item 10) from pin (Item 8). Re­ tions to steering cylinder.

  • Page 308: Axle Repair

    Rear Axle Repair Before disassembling axle, remove hydraulic cylinder (Fig. 9, Item 28), cylinder support (Item 17), tie rod tube and clamp assembly (Item 12) and steering arms (Items 46, 31). Disassembly 1. Remove drain plugs (Fig. 11) and let oil drain out into containers.
  • Page 309 Apply Loctite 16 - 20 ft-lb 20 - 24 ft-lb Shim for backlash adjustment Measure backlash here: 0.003 - 0.01″ Shim for bevel gear to pin ­ ion contact adjustment Tighten to pre-load bearings. Pinion shaft should rotate with 2.0 - 5.5 in-lb torque 16 - 20 ft-lb Figure 12 2.
  • Page 310 6 - 8 ft-lb 12 - 20 ft-lb Apply Loctite 12 - 20 ft-lb Figure 13 Assembly E. Tighten bolts (Item 1, 35) to a torque of 16 - 20 ft-lb (220-280 Kg-Cm). 1. Use new gaskets and seals when reassembling axle. 3.
  • Page 311 B. Assemble knuckle pin (Item 20) and knuckle case medium strenght Loctite on capscrews (Item 28) (Item 38) to match knuckle arm (Item 8) with knuckle securing cover (Item 26). pin. Fasten capscrew (Item 10) temporarily (will be removed to fill with lubricant). F.
  • Page 312 ® Repairs Page 14 - 12 Rev. B Groundsmaster 223-D...
  • Page 313 Chapter 14.1 Groundsmaster 228–D with Dae Dong Axle 4WD Rear Axle Table of Contents NOTE: For machines with Mitsubishi axle, see Chapter 14 “4WD Rear Axle” in this manual. SPECIFICATIONS ......2 Input Shaft/Pinion Gear .

  • Page 314: Specifications

    Specifications Item Specification Wheel lug nut torque (font and rear) 45–55 ft-lbs. (61 to 75 Nm) Rear wheel toe-in 0.000 to 0.125 in. (0.0 to 3.0 mm) Tire pressure (front and rear) 20 psi (138 kPa) Axle lubricant SAE GL-5 80W90 gear lube Bi–directional clutch lubricant Mobil 424 hydraulic fluid Adjustments...

  • Page 315: Bevel Gear Case And Axle Case

    Bevel Gear Case and Axle Case The following procedures assume the rear axle assem- bly has been removed from the machine. Removal 1. Remove the mounting screws, nuts, and lock wash- ers. Remove the bevel gear case/axle case assembly and O-ring from the axle support (Fig. 1). 2.

  • Page 316: Inspection

    5. Remove the knuckle pin mounting screws and the knuckle pin. Remove the gasket and any remaining gas- ket material from either mating surface (Fig. 4). 6. While holding the bevel gear case, lightly tap the up- per end of the bevel gear shaft out of the upper bearing and upper bevel gear.

  • Page 317: Installation

    Installation 1. Coat new shaft seals with grease and install in axle case and bevel gear case as shown (Fig. 6). Figure 6 1. Axle case 3. Shaft seal 2. Bevel gear case 2. Install the lower bevel gear, and bevel gear shaft in the axle case cover.
  • Page 318 5. Determine necessary quantity of support shims. 57 to 67 ft–lb A. Lubricate the axle case support bushing with a (77 to 91 N–m) thin coat of grease and slide axle case support onto knuckle pin. B. Position support shims that were removed during VERTICAL disassembly between axle case support and axle ENDPLAY...

  • Page 319: Differential Shafts

    9. Remove the bevel gear case/axle case assembly NOTE: Axle bearing shims are available in 0.008 in. from the axle support. Coat a new O-ring with grease (0.2 mm), 0.012 in. (0.3 mm), and 0.020 in. (0.5 mm) and temporarily install the axle cover assembly. Position thickness.

  • Page 320: Axle Shafts

    Axle Shafts The following procedures assume the rear axle assem- bly has been removed from the machine. Removal 1. Remove the axle cover mounting screws. Remove the axle cover from the axle case as an assembly (Fig. 13). 2. Use a bearing puller to remove the bearing and bevel gear as shown (Fig.

  • Page 321: Input Shaft/Pinion Gear

    Input Shaft/Pinion Gear The following procedures assume the rear axle assem- bly has been removed from the machine. Removal 1. Remove input shaft/pinion gear assembly from the axle support. Remove the shims and bearing case O- ring. 2. Release the stake washer and remove the locknut. Remove and discard the stake washer (Fig.
  • Page 322 9. Use a depth gauge to measure the distance from the end face of the input shaft/pinion gear to the mating sur- face of the bearing case. Subtract the “Design Cone Center Distance” from this distance to determine initial shim thickness (Fig. 18). Design Cone Center Distance...

  • Page 323: Differential Gear

    Differential Gear The following procedures assume the rear axle assem- bly has been removed from the machine. Removal 1. Remove bevel gear case/axle case assemblies (see Bevel Gear Case/Axle Case Assembly in this section of this manual). IMPORTANT: Do not interchange right and left dif- ferential shafts assemblies.

  • Page 324: Inspection

    Inspection 1. Measure the differential side gear O.D. and the dif- ferential case I.D. to determine the side gear to case clearance (Fig. 23). Replace components as necessary. SIDE GEAR TO CASE CLEARANCE: 0.002 to 0.012 in. (0.05 to 0.30 mm) SIDE GEAR O.D.

  • Page 325: Installation

    Installation 1. If the ring gear was removed, use medium strength Loctite thread locker and tighten the mounting screws to 22 to 25 ft-lbs. (30 to 34 Nm). 2. Apply molybdenum disulfide to the splines and bear- ing surfaces of the differential pinion gears, pinion wash- ers, and side gears.

  • Page 326: Pinion Gear To Ring Gear Engagement

    Pinion Gear to Ring Gear Engagement The final position of the pinion gear is verified by using PROFILE the gear contact pattern method as described in the fol- TOP LAND lowing procedure. GEAR TOOTH DEFINITIONS (Fig. 27): Toe – the portion of the tooth surface at the end to- LENGTHWISE wards the center.

  • Page 327: Gear Pattern Movement Summary

    Gear Pattern Movement Summary Heel Contact Base Contact Every gear has a characteristic pattern. The illustrations show typical patterns only and explain how patterns shift as gear location is changed. 1. If contact is toward the heel or base of the gear (Fig. 30): A.
  • Page 328 4WD Rear Axle Page 10.1 – 16 Groundsmaster 228–D (Groundsmaster 228–D with Dae Dong axle) Rev. D...
  • Page 329 Chapter 15 Guardian 62 Recycler Cutting Unit Table of Contents SPECIFICATIONS ......2 Separating Cutting Unit from Traction Unit .

  • Page 330: Specifications

    Specifications Width of Cut: 62 in. Cutting Unit Blades: Three 21–3/4” long and 1/4” thick heat treated steel, Recycler blades . Height–of–Cut: Adjustable from 1–1/2” to 4–1/2” in 1/2” increments. Castor Wheels: Front and rear castor wheels have 8 in. x 3.50 in.

  • Page 331: Schematic

    Schematic Groundsmaster 223–D Guardian 62 Recycler Cutting Unit Page 15 – 3 Rev. B...
  • Page 332 85 To 110...

  • Page 333: Adjustments

    Adjustments Height of Cut Adjustment The height–of–cut is adjustable from 1–1/2 to 4–1/2 in- 2. Remove or add ”C” shaped spacers at the narrow ches in 1/2 inch increments, by adding or removing an portion of the spindle shaft, below castor arm, to get de- equal number of spacers from the front and rear castor sired height–of–cut.

  • Page 334: Roller Adjustment

    Roller Adjustment Note: If cutting unit is to be used in the 1” or 1–1/2” height–of–cut setting, cutting unit rollers must be reposi- tioned in the top bracket holes. To adjust front and rear rollers: 1. Remove cotter pins securing roller shafts to under- side of deck.
  • Page 335 Service and Repairs Lubrication The cutting unit must be lubricated regularly. If machine is operated under normal conditions, lubricate castor bearings and bushings with No. 2 general purpose lithi- um base grease or molybdenum base grease, after ev- ery 8 hours of operation or daily, whichever comes first NOTE: Lubricate immediately after washing, regardless of the service interval listed.

  • Page 336: Checking And Correcting Blade Mismatch

    Checking and Correcting Blade Mismatch If there is mismatch between the blades, the grass will 6. Compare measurements of outer blades with the appear streaked when it is cut. This problem can be cor- center blade. Center blade must not be more than 3/8 of rected by making sure the blades are straight and all an inch lower than the outer blades.

  • Page 337: Checking Gearbox Lubricant

    Checking Gearbox Lubricant The gear box in designed to operate on SAE 80–90 wt. gear lube. Although the gear box is shipped with lubri- cant from the factory, check the level before operating the cutting unit. 1. Position the machine and cutting unit on a level sur- face.

  • Page 338: Separating Cutting Unit From Traction Unit

    Separating Cutting Unit From Traction Unit 1. Position machine on level surface, lower cutting unit to floor, move lift lever to float position, shut engine off and engage parking brake. 2. Remove the capscrews, flatwashers and locknuts securing the ball joint mounts to castor arms on cutting unit.

  • Page 339: Installing Lift Arms To Traction Unit

    Installing Lift Arms to Traction Unit 1. Mount lift arms to pivot brackets and lift cylinders with pivot pins and 3/32” x 1–1/4” lg. cotter pins, supplied with traction unit. Lift arms to be mounted with ball joint ends positioned outward. 2.

  • Page 340: Connecting Lift Arms To Cutting Unit

    Connecting Lift Arms to Cutting Unit 1. Move cutting unit into position in front of traction unit. 2. Measure distance from end of each lift arm to center of ball joint (grease fitting). Distance should be 2.25”. If distance is not 2.25”, loosen jam nut securing ball joint to lift arm and rotate ball joint in or out until distance is at- tained.

  • Page 341: Replacing Drive Belt

    Replacing Drive Belt The blade drive belt, tensioned by the stationary idler pulley, is very durable. However, after many hours of use, the belt will show signs of wear. Signs of a worn belt are: squealing when belt is rotating, blades slipping when cutting grass, frayed edges, burn marks and cracks.

  • Page 342: Servicing Front Castor Arm Bushings

    Servicing Front Castor Arm Bushings The castor arms have bushings pressed into the top and 6. Inspect castor spindle for wear and replace it if dam- bottom of the tube and after many hours of operation, aged. the bushings will wear. To check the bushings, move 7.

  • Page 343: Servicing Castor Wheels And Bearings

    Servicing Castor Wheels and Bearings The castor wheel rotates on a high–quality roller bearing and is supported by a spanner bushing. Even after many hours of use, provided that the bearing was kept well–lu- bricated, bearing wear will be minimal. However, failure to keep bearing lubricated will cause rapid wear.

  • Page 344: Removing Blade

    The blade must be replaced if a solid object is hit, the blade is out–of–balance or if the blade is bent. Always use genuine TORO replacement blades to be sure of safety and optimum performance. Never use replace- ment blades made by other manufacturers because they could be dangerous.

  • Page 345: Inspecting And Sharpening Blades

    Inspecting and Sharpening Blades 1. Raise cutting unit to highest position, shut the en- gine off and engage the parking brake. Block cutting unit to prevent it from falling accidentally. 2. Examine cutting ends of the blade carefully, espe- cially where the flat and curved parts of the blade meet (Fig.

  • Page 346: Gearbox Repair

    Gearbox Repair 10 12 Figure 24 removed from the shaft. Gear Box Disassembly 1. Drain lubricant from gear box. 6. Remove bearing cups (Item 14) from cap by putting a punch through the shaft bore and through the seal and 2.
  • Page 347 4, 5, 6 Figure 25 Gear Box Pre–Assembly surface facing up. Install a new seal (Item 13) into the cap with the open side toward the machined side of the 1. Start with one of the shafts (Item 17) and put one of cap.
  • Page 348 Gear Box Final Assembly 4. The shaft should have a very slight amount of bearing drag. If the shaft turns hard, the cap must be removed 1. Bearing drag is adjusted by the amount of gaskets and gasket(s) need to be added. If the shaft has no (Item 4, 5, 6) used between the cap and housing ma- bearing drag, or has end play, the cap must be removed chined surfaces.

  • Page 349: Blade Spindle Service

    Blade Spindle Service Removing Spindle Housing Assembly 1. Lower the cutting unit, shut the engine off and engage the parking brake. 2. Remove deck covers from top of cutting unit. Release belt tension. Remove belt from spindle to be serviced. 3.
  • Page 350 Installing Spindle, Bearings and Seals Into Spindle installed. Housing 8. Push pulley onto splines of spindle shaft and retain the parts together with the large flat washer and nut. IMPORTANT: If a new spindle housing is being used, new bearings and matched snap ring set must be Tighten the nut to 100 –...
  • Page 351 This page is blank.
  • Page 352 Commercial Products © The Toro Company...

This manual is also suitable for:

Groundsmaster 223-dGroundsmaster 224Groundsmaster 1000lGroundsmaster 225Groundsmaster 228-d

Table of Contents