Part No. 88712SL, Rev. H Service Manual Groundsmaster 224 / 225 / 1000L / 228-D: (See notes in box below) ® Groundsmaster 220-D/223-D 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.
Table Of Contents Chapter 1 - Safety Chapter 6 - Differential Axle Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . 1 - 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 2 - Product Records and Manuals Product Record Form . . . . . . . . . . . . . . . . .
Chapter 12 - Cutting Units Chapter 14 - 4WD Rear Axle Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 7 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 8 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
This page is blank.
Chapter 1 Safety Table of Contents While Performing Maintenance or Service . . . . . 3 Safety and Instruction Decals . . . . . . . . . . . . . . . 3 SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . 1 Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . 1 While Operating. . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety Instructions The Groundsmaster® 220-D has been tested and veri fied for compliance with the B71.
7. Fill the fuel tank with diesel fuel before starting the engine. Avoid spilling any fuel. Fuel is very flammable. Handle fuel carefully. DO NOT SMOKE. C. Do not smoke while handling fuels or lubricants. D. Fill the tank up to approximately one inch (25 mm) from the top of the tank, not the filler neck. Do not overfill. A. Use an approved fuel container. B. Do not fill the fuel tank when the engine is hot or running. E. Wipe up any spilled fuel.
While Doing Maintenance, Troubleshooting, Testing, Adjustments or Repairs 20. Remove the key from the ignition switch and discon nect the negative (–) cable from the battery. Secure the cable off to the side. This will prevent sparks, electrical shocks, or accidental starting of the engine when serv icing, cleaning, adjusting, or storing the machine. 21. Be sure you understand a service procedure before working on the machine.
Safety Instructions Page 1 - 4 Groundsmaster® 220-D (3/88)
Chapter 2 Product Records and Manuals Table of Contents PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . 1 2 2 2 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . Capscrew Markings and Torque Values – U.S. . . Capscrew Markings and Torque Values – Metric .
Equivalents and Conversions Product Records and Manuals Page 2 – 2 Groundsmaster 220–D/223–D
Torque Specifications Groundsmaster 220–D/223–D Page 2 – 3 Product Records and Manuals
Product Records and Manuals Page 2 – 4 Rev.
EQUIPMENT OPERATION AND SERVICE HISTORY REPORT for GROUNDSMASTER® 220-D, 223-D, 224 TORO Model and Serial Number:__________-__________ Deck Model and Serial Number: __________-__________ Engine Numbers: ____________________ Transmission Numbers: ____________________ Drive Axle(s) Numbers: ____________________ Date Purchased: ____________________ Warranty Expires__________ Purchased From: ____________________ ____________________ ____________________ Contacts: Parts ____________________ Phone ___
GROUNDSMASTER® 220-D, 223-D, 224 Maintenance Schedule Minimum Recommended Maintenance Intervals: Maintenance Procedure Check Battery Fluid Level Maintenance Interval & Service 50hrs 100hrs 200hrs 400hrs 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 Change Engine Oil Inspect Air Filter, Dust Cup, and Baffle A Level Service ‡ Replace Engine Oil Filte
GROUNDSMASTER® 220-D, 223-D, 224 Daily Maintenance Check List Unit Designation:__________ TORO ID#:_______-_______ Daily Maintenance:(duplicate this page for routine use) Daily Maintenance Check For Week Of _____________ Maintenance Check Item MON TUES WED THURS FRI SAT SUN _____HRS _____HRS _____HRS _____HRS _____HRS _____HRS _____HRS Safety Interlock Operation Grass Deflector in Down Position Brake Operation Fuel Level Engine Oil Level Cooling System Fluid Level Drain Water/Fuel Separator1 Dust Cup and
A B C D Check PTO Belt Tension Check Fan and Alternator Belt Tension Inspect Cooling System Hoses A-Service required ________________________________ ________________________________ ________________________________ 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 Change Engine Oil Inspect Air Filter, Dust Cup, and Baffle ________________________________ Change Hydraulic Oil ____
(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.
Charge Pressure Test 10.Perform a dynamic charge pressure test to identify possible hydrostat (pump or motor) problems as follows: Using a low pressure gauge, 0 – 1000 psi (0 – 6895 kPa) 1. Engage the parking brake and block the front wheels to prevent movement of the machine. Lower the cutting deck or implement to the floor and turn the engine OFF. A. With pressure gauge still connected, sit in the operator seat, start engine and press the traction pedal to forward. 2. Raise and support the seat. B.
Implement Relief Pressure Test Using a low pressure gauge, 0 – 1000 psi (0 – 6895 kPa) 1. Perform steps 1 through 7 of the Charge Pressure Test. 2. With the engine running at 3200 RPM, move the lift control lever to the RAISE position and allow the cutting unit or implement to fully raise. Continue to hold the lever in the RAISE position and observe the pressure gauge. The pressure reading should be from 700 to 800 PSI (4826 to 5516 kPa) as the implement relief valve lifts. 3.
Wiring Schematics Groundmaster 224 Figure 1 Groundsmaster 220–D/223–D Page 5 – 3 Rev.
Groundmaster 225 (Serial Numbers 60001 to 200999999) Figure 2a Wiring Schematics Page 5 – 4 Rev.
Groundmaster 225 (Serial Numbers higher than 21000000) Figure 2b Groundsmaster 220–D/223–D Page 5 – 5 Rev.
Groundmaster 1000L Figure 2c Wiring Schematics Page 5 – 5.1 Rev.
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 Groundsmaster 220–D/223–D Page 5 – 5.2 Rev.
Groundmaster 220–D (Serial Numbers 80000001 to 90000349) Groundsmaster 223–D 4WD (Serial Numbers 90500 and higher) Figure 2e Wiring Schematics Page 5 – 5.3 Rev.
Groundmaster 228–D Figure 2f Groundsmaster 220–D/223–D Page 5 – 5.4 Rev.
Chapter 6 Differential Axle Table of Contents INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Removal and Installation . . . . . . . . . . . . . . . 1 2 3 3 Axle Shaft Disassembly and Wheel Bearing Service . . . . . . . . . . . . . . . . . 4 Differential and Housing Disassembly. . . . . . . . . 8 Differential and Housing Reassembly . . . . . . . .
Specifications Item Specification __________________________________________________________________________________________ Front wheel lug nut torque 45 to 55 ft-lb ________________________________________________________________________________________________________________________________________________________ Front to rear housing torque 18 to 28 ft-lb _______________________________________________________________________________________________________________________________________________
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. Remove the fuel tank. (See Removing and Installing the Fuel Tank in the Fuel System Repairs section of Chapter 3 - Mitsubishi Diesel Engine.) 4. Remove the hydrostatic transmission.
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. 1. After the wheel has been removed, slide the brake drum off of the axle flange (Fig. 5). NOTE: It may be necessary to loosen the brake shoes by turning the star wheel inside the brake drum assemb ly.
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. 10). IMPORTANT: Drilling completely through the re tainer ring could damage the shaft.
7. After drilling, put a chisel in position across the hole and strike sharply 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. Keep all personnel away during this procedure. Figure 11 8. Inspect the shaft for possible damage (Fig. 12). Inspect the sealing surface of the hub and shaft.
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). Install the new seal to a depth of 1.218 in. into the housing (Fig. 15, 16). After the seal has been assembled, put grease on the lip of the seal. Figure 15 1.
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. Push the axle shaft as far as possible into the axle housing (Fig. 17). Wheel end gasket material: P/N 92-8775 Liquid Gasket Kit (Kit contains Loctite Ultra-Gray gasket eliminator and instructions.
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. When reassembling, place them back in the same position. Figure 20 3. To remove the differential assembly, place two wooden devices (i.e. hammer handles) under the differ ential case and pry firmly upward.
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. Put the case in a vise. Drive the lock pin out of the pinion shaft (Fig. 24). Use a small drift punch as shown.
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. Figure 26 9. Remove the eight side cover capscrews. Remove the the side cover from the carrier assembly (Fig. 27). Clean the gasket material from the mating surfaces before reassembly. Figure 27 10.
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. 3C) must be removed before pressing pinion out of housing. Figure 29 12. Position the housing assembly on a suitable press. Place a 1/8 inch (3 mm) piece of steel or a screwdriver blade under the edge of the spur gear.
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. Figure 32 14. To remove the outer pinion bearing cup, position the housing in a press. Place a press plate of the proper size against the cup. Press the cup out of the housing (Fig. 33). Figure 33 15.
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. Inspect the housings for cracks and external damage that could affect the operation of the axle assembly. D. Inspect the differential case for wear in the side gear and pinion mate area.
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. On the button end of each pinion there is a plus (+) or minus (–) number, or a (0) number. This number indi cates the best running position for each particular gear set.
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. Insert the pinion into the housing. NOTE: A number marked on the new ring and pinion set is used to establish the proper amount of shims required prior to installing the pinion gear (see page 15).
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. torque to rotate) (Fig. 43).
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. Apply a small bead of Permatex No. 2 or silicone sealant to the outer edge of the carrier bore. Install the expansion plug (or seal if equipped with flange for 4WD) into carrier until plug or seal seats firmly in carrier bore (Fig. 45). Figure 45 12.
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. Rotate the side gears until the holes of the washers and pinion gears line up with the holes of the case.
16. Put the ring gear onto the differential case and start the new capscrews into the gear with your fingers. Tighten the screws, alternating back and forth across the gear to allow the gear to be pulled evenly into place. Tighten the cap screws to a torque of 45 - 65 ft-lb (6.2 9.0 KgM) (Fig. 50). Figure 50 17. When installing new differential bearings, reuse the original shims or use new shims of the same thickness. Press the bearing onto the differential case.
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.
Drive Side Heel Toe Coast Side Heel Toe Backlash correct. Thicker pinion position shims required. Figure 55 Drive Side Heel Toe Coast Side Heel Toe Backlash correct. Thinner pinion position shims required. Figure 56 Drive Side Heel Toe Coast Side Heel Toe Backlash incorrect. Thinner pinion position shim re quired. Adjust backlash to match. Figure 57 Repairs Page 6 - 22 Rev.
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. Increasing backlash moves the ring gear away from the pinion. Drive pattern moves higher and toward the heel. Coast pattern moves slightely lower and toward the toe. 3.
Repairs Page 6 - 24 Groundsmaster® 220-D/223-D
Chapter 14 Groundsmaster 223-D with Inasaka axle 4WD Rear Axle Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION ................... TM Four-Matic 4WD Over-Running Clutch Operation . . . . . . . . . . . . ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Wheel Toe-in. . . . . . . . . . . . . . . . . . . . . . . . Groundsmaster® 223-D 2 3 3 4 4 REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications Item Specification __________________________________________________________________________________________ Lubricant (Fig.
General Information TM 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 ax l e incorporates an OVER-RUNNING (ROLLER) 49 RPM Locked Unlocked CLUTCH THAT TRANSMITS POWER ONLY IN THE FORWARD DIRECTION.
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. Tighten tie rod clamps when adjustment is correct. 1 Figure 6 1. Tie rod Steering Stop The rear axle steering stops help prevent over travel of the steering cylinder in case of impact on rear wheels.
Repairs Drive Shaft Service 0.34 ± 0.03″ Arrow end of roller clutches must face 6-bolt flange end of clutch housing toward rear axle) 25 0.040″ MAX 24 24 A 23 32 B 30 Apply Never-seeze 28 Detail A Detail B B 27 25 26 34 29 Figure 8 Removing Drive Shaft Clutch Service 1. Put machine on a level surface, lower cutting unit, stop the engine and remove the key from the ignition switch. Block the rear wheels to prevent the machine from moving. 1.
0.34 ± 0.03″ Arrow end of roller clutches must face 6-bolt flange end of clutch housing toward rear axle) 25 0.040″ MAX 24 24 A 23 32 B 30 Apply Never-seeze 28 Detail A Detail B B 27 25 26 34 29 Figure 9 6. Install clutch assembly onto yoke shaft, then install other thrust washer. Install retaining ring (Item 23) to secure clutch assembly to shaft. Install axle coupling (Item 32) to clutch housing with six (6) capscrews and lockwashers, then tighten capscrews evenly. 7.
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 tions to steering cylinder. Mark hoses so they will be installed correctly during reassembly. Disconnect hoses from fittings on steering cylinder. Put plugs or caps on open hoses and fittings to prevent contamination of hydraulic system. 6. Remove capscrew (Item 10) from pin (Item 8).
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. 1 Figure 11 1. Drain plugs Repairs Page 14 - 8 Rev.
Apply Loctite 20 - 24 ft-lb 16 - 20 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. Remove bolts (Fig. 12, Item 43) securing axle tubes (Item 16, 44) to differential case (Item 24). Separate axle tubes and axles from differental case. 3. Remove bolts (Fig.
6 - 8 ft-lb 12 - 20 ft-lb Apply Loctite 12 - 20 ft-lb Figure 13 E. Tighten bolts (Item 1, 35) to a torque of 16 - 20 ft-lb (220-280 Kg-Cm). Assembly 1. Use new gaskets and seals when reassembling axle. 3. Assemble knuckle assembly (Fig. 13): 2. Assemble differential case (Fig. 12): A. Assemble differential. Use medium strength Loc tite on bolts (Item 7) and tighten evenly to a torque of 20 - 24 ft-lb (270-330 Kg-Cm). B. Assemble pinion gear (Item 30) and bearing case (Item 33).
B. Assemble knuckle pin (Item 20) and knuckle case (Item 38) to match knuckle arm (Item 8) with knuckle pin. Fasten capscrew (Item 10) temporarily (will be removed to fill with lubricant). C. Assemble wheel shaft (Item 35) to cover (Item 30). D. Assemble gear (Item 5) to wheel shaft and install cover and wheel shaft assembly to knuckle case (Item 38). Note that top two (2) capscrews (Item 39), securing cover (Item 30) are a shorter length.
Repairs Page 14 - 12 Rev.
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Stop Bolt Adjustment . . . . . . . . . . . . . . . . . SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . Bevel Gear Case and Axle Case . . . . . . . . . . . . . . .
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 Steering Stop Bolt Adjustment The rear axle steering stop bolts help prevent over–travel of the steering cylinder in case of impacts on rear wheels.
Bevel Gear Case and Axle Case The following procedures assume the rear axle assembly has been removed from the machine. 1 Removal 6 1. Remove the mounting screws, nuts, and lock washers. Remove the bevel gear case/axle case assembly and O-ring from the axle support (Fig. 1). 5 4 2. Mark both right and left bevel gear case/axle case assemblies. 2 3 IMPORTANT: Do not interchange right and left bevel gear case/axle case assemblies. 1. 2. 3. 4. Figure 1 Cap screw Lock nut Lock washer Axle support 5.
5. Remove the knuckle pin mounting screws and the knuckle pin. Remove the gasket and any remaining gasket material from either mating surface (Fig. 4). 6. While holding the bevel gear case, lightly tap the upper end of the bevel gear shaft out of the upper bearing and upper bevel gear. 7. Pull the bevel gear case from the axle case and remove the upper bevel gear, collar, spacer, and thrust washer from the gear case. 8. Remove the axle case cover screws, cover, and the O-ring from the axle case.
Installation 1. Coat new shaft seals with grease and install in axle case and bevel gear case as shown (Fig. 6). 3 2 1 1. Axle case 2. Bevel gear case 2. Install the lower bevel gear, and bevel gear shaft in the axle case cover. Coat a new O-ring with grease and install the axle case cover (Fig. 7). Tighten cover screws to 17 to 20 ft-lbs. (23 to 27 Nm). 3. Slide the bevel gear case over the bevel gear shaft and install the thrust washer, spacer, bevel gear, and collar.
5. Determine necessary quantity of support shims. 4 A. Lubricate the axle case support bushing with a thin coat of grease and slide axle case support onto knuckle pin. B. Position support shims that were removed during disassembly between axle case support and axle case. Install mounting screws into axle case. Slowly tighten screws while frequently checking for clearance (vertical endplay) between axle case support and knuckle pin.
9. Remove the bevel gear case/axle case assembly from the axle support. Coat a new O-ring with grease and temporarily install the axle cover assembly. Position a dial indicator at the tooths center. Prevent the axle from turning and measure the lower bevel gear to axle gear backlash (Fig. 10). LOWER BEVEL GEAR BACKLASH: 0.004 to 0.016 in. (0.10 to 0.40 mm) 10.Adjust backlash by increasing or reducing axle bearing shim thickness (see Axle Shafts in this section of this manual).
Axle Shafts The following procedures assume the rear axle assembly has been removed from the machine. 1 Removal 4 3 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. 14). 3. Remove the shims, spacer, and retaining ring. Drive the axle out of the bearing and cover. Remove and discard the axle shaft seal. 4.
Input Shaft/Pinion Gear The following procedures assume the rear axle assembly has been removed from the machine. Removal 7 1. Remove input shaft/pinion gear assembly from the axle support. Remove the shims and bearing case Oring. 5 2. Release the stake washer and remove the locknut. Remove and discard the stake washer (Fig. 16). 4 3. Drive the input shaft/pinion gear out from the outer bearing cone and bearing case. Remove and discard the oil seal and O-ring. 8 4.
9. Use a depth gauge to measure the distance from the end face of the input shaft/pinion gear to the mating surface of the bearing case. Subtract the “Design Cone Center Distance” from this distance to determine initial shim thickness (Fig. 18). Design Cone Center Distance 1 DESIGN CONE CENTER DISTANCE (distance from mating surface of axle support to end face of pinion gear): 1.870 + 0.002 in. (47.5 + 0.05 mm) 2 NOTE: Bearing case shims are available in 0.004 in. (0.1 mm) and 0.008 in. (0.
Differential Gear The following procedures assume the rear axle assembly has been removed from the machine. 5 7 6 Removal 2 1 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 differential shafts assemblies. 4 2. Mark and pull the differential shaft assemblies from the axle support. 3. Remove input shaft/pinion gear assembly, shims, and O-ring from the axle support (Fig. 20). 4.
Inspection 1. Measure the differential side gear O.D. and the differential 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) 1 SIDE GEAR O.D. (Factory Spec.): 1.335 to 1.337 in. (33.91 to 33.95 mm) DIFFERENTIAL CASE I.D. (Factory Spec.): 1.339 to 1.341 in. (34.00 to 34.06 mm) 2. Measure the differential pinion shaft O.D. and the pinion gear I.D.
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). 3 2 1 2. Apply molybdenum disulfide to the splines and bearing surfaces of the differential pinion gears, pinion washers, and side gears. 3. Install the side gear shims and side gears in their original location in the differential case. 4. Place the differential pinion gears and pinion washers in their original location in the differential case.
Pinion Gear to Ring Gear Engagement The final position of the pinion gear is verified by using the gear contact pattern method as described in the following procedure. PROFILE TOP LAND GEAR TOOTH DEFINITIONS (Fig. 27): Toe – the portion of the tooth surface at the end towards the center. TOE HEEL Heel – the portion of the gear tooth at the outer end. LENGTHWISE BEARING ARC Top Land – top surface of tooth. 1.
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. Install thicker or additional bearing case shim(s) to move pinion shaft toward ring gear. Figure 30 B. Install thinner or remove differential bearing shim(s) to move ring gear backward. C.
4WD Rear Axle (Groundsmaster 228–D with Dae Dong axle) Page 10.1 – 16 Rev.
Chapter 15 GuardianR 62I RecyclerR Cutting Unit Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Height of Cut Adjustment . . . . . . . . . . . . . . . . . . . . . Roller Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . Skid Adjustment . . .
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. Cutter Housing: 4” deep housing is made of 12 gauge steel and reinforced with 10 gauge channel and plates. Cutting Unit Drive: Isolation mounted gear box on cutting unit is driven by PTO shaft. Power is transmitted to the blades by one hex ”AA” section belt.
Groundsmaster 223–D 4 GAL/MIN Page 15 – 3 Rev. B 70–150 PSI STEERING CYLINDER STEERING VALVE .
Troubleshooting Guardian 62 Recycler Cutting Unit 85 To 110 Page 15 – 4 Rev.
Adjustments Height of Cut Adjustment The height–of–cut is adjustable from 1–1/2 to 4–1/2 inches in 1/2 inch increments, by adding or removing an equal number of spacers from the front and rear castor forks. The height–of–cut chart below gives the combinations of spacers to use for all height–of–cut settings. 2. Remove or add ”C” shaped spacers at the narrow portion of the spindle shaft, below castor arm, to get desired height–of–cut.
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 repositioned in the top bracket holes. To adjust front and rear rollers: 1. Remove cotter pins securing roller shafts to underside of deck. 2. Slide shafts out of lower bracket holes, align rollers with top holes and install shafts. 3. Install cotter pins to secure assemblies.
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 lithium base grease or molybdenum base grease, after every 8 hours of operation or daily, whichever comes first NOTE: Lubricate immediately after washing, regardless of the service interval listed.
Checking and Correcting Blade Mismatch If there is mismatch between the blades, the grass will appear streaked when it is cut. This problem can be corrected by making sure the blades are straight and all blades are cutting on the same plane. 1. Using a 3 foot long carpenters level, find a level surface on the shop floor. 2. Raise height–of–cut to the highest position: refer to Adjusting Height–Of–Cut. 3. Lower cutting unit onto flat surface. Remove covers from top of cutting unit. 4.
Checking Gearbox Lubricant The gear box in designed to operate on SAE 80–90 wt. gear lube. Although the gear box is shipped with lubricant from the factory, check the level before operating the cutting unit. 1 1. Position the machine and cutting unit on a level surface. 2. Remove check plug from side of gear box and make sure lubricant is up to bottom of hole. If level of lubricant is low, remove fill plug on top of gear case and add enough lubricant to bring it up to bottom of hole in side.
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. 3. Roll cutting unit away from the traction unit separating male and female sections of PTO shaft. 1 Figure 9 1.
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. Hook brake return springs to holes in traction unit lift arms. 3 2 1 Figure 11 1. Pivot pin 2. Lift arm 3. Lift arm pivot bracket 1 Figure 12 1. Brake return spring Groundsmaster 223–D Page 15 – 11 Rev.
Connecting Lift Arms to Cutting Unit 1. Move cutting unit into position in front of traction unit. 1 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 attained. Do not tighten jam nuts at this time. 3 2.25” 3. Move lift lever to FLOAT position.
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. Replace the belt if any of these conditions are evident. 1. Lower cutting unit to the shop floor. Remove belt covers from top of cutting unit and set covers aside. 2 2.
Servicing Front Castor Arm Bushings The castor arms have bushings pressed into the top and bottom of the tube and after many hours of operation, the bushings will wear. To check the bushings, move castor fork back and forth and from side to side. If castor spindle is loose inside the bushings, bushings are worn and must be replaced. 6. Inspect castor spindle for wear and replace it if damaged. 7. Push castor spindle through bushings and mounting tube. Slide thrust washer and spacer(s) onto spindle.
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–lubricated, bearing wear will be minimal. However, failure to keep bearing lubricated will cause rapid wear. A wobbly castor wheel usually indicates a worn bearing. 1. Remove locknut from capscrew holding castor wheel assembly between castor fork. Grasp castor wheel and slide capscrew out of fork. 2 1 2.
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 replacement blades made by other manufacturers because they could be dangerous. 3 1. Raise cutting unit to highest position, shut the engine off and engage the parking brake. Block cutting unit to prevent it from falling accidentally. 2 2.
Inspecting and Sharpening Blades 1. Raise cutting unit to highest position, shut the engine off and engage the parking brake. Block cutting unit to prevent it from falling accidentally. 2. Examine cutting ends of the blade carefully, especially where the flat and curved parts of the blade meet (Fig. 22–A). Since sand and abrasive material can wear away the metal that connects the flat and curved parts of the blade, check the blade before using the machine. If wear is noticed (Fig.
Gearbox Repair 1 2 3 4 5 6 7 8 9 11 10 12 14 13 15 16 17 2 2 18 19 Figure 24 Gear Box Disassembly removed from the shaft. 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 then tapping against the back of the bearing cup until driven out of the cap. 2. Remove capscrews and lift out shaft and cap assemblies. 3. Remove cap assemblies and bearing cones (Item 12) from shafts (Item 17, 19).
17 12 14 4, 5, 6 16 1 9 3 10 11 19 2 13 8 7 2 18 Figure 25 Gear Box Pre–Assembly 1. Start with one of the shafts (Item 17) and put one of the gears (Item 10) over the shaft so the tooth side is towards the turned end of the shaft. Align the keyway in the gear with the keyway in the shaft and install one of the keys (Item 8) in the keyway. 2. Install one set of shims (Item 11) onto the turned end of the shaft. Press one of the bearing cones (Item 9) over the turned end of the shaft.
Gear Box Final Assembly 1. Bearing drag is adjusted by the amount of gaskets (Item 4, 5, 6) used between the cap and housing machined surfaces. 2. Put two 0.015 in. gaskets on the machined surface of the housing, then install the shaft and cap assembly in the housing so the bearing cone (Item 9) on the shaft assembly and bearing cup (Item 3) in the housing are mating. Align the holes in the cap with the holes in the gaskets and housing. 3. Install capscrews and tighten.
Blade Spindle Service Removing Spindle Housing Assembly 1 2 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. Start the engine and raise the cutting unit. Turn the engine OFF and remove the key from the key switch. Block up the cutting unit so it cannot fall accidentally. 4. Using a rag or thickly padded glove, grasp end of blade.
Installing Spindle, Bearings and Seals Into Spindle Housing IMPORTANT: If a new spindle housing is being used, new bearings and matched snap ring set must be installed; see step 1 below. Never use old bearings, spacer, and snap ring with a new spindle housing. If installing bearings into a used spindle housing that still has a snap ring installed, use only new bearings with cups and spacer – not the large snap ring because it is not required; see step 2 below. installed. 8.
This page is blank.
Commercial Products © The Toro Company
