Form No. 3329–337 Groundsmaster 228–D 2 & 4 Wheel Drive Traction Units Model No. 30241–230000001 and Up Model No.
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting/Stopping Engine . . . . . . . . . . . . . . . . . . . Bleeding Fuel System . . . . . . . . . . . . . . . . . . . . . . Checking Interlock System . . . . . . . . . . . . . . . . . . Operating Characteristics . . . . . . . . . . . . . . . . . . . Pushing Or Towing Traction Unit . . . . . . . . . . . . Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Greasing Bearings And Bushings . . . . . . . .
This manual uses two other words to highlight information. Important calls attention to special mechanical information and Note: emphasizes general information worthy of special attention. Introduction Read this manual carefully to learn how to operate and maintain your product properly. The information in this manual can help you and others avoid injury and product damage. Although Toro designs and produces safe products, you are responsible for operating the product properly and safely.
• insufficient wheel grip; • Mow only in daylight or in good artificial light. • being driven too fast; • Before attempting to start the engine, disengage all blade attachment clutches, shift into neutral, and engage the parking brake. • inadequate braking; • the type of machine is unsuitable for its task; • Do not put hands or feet near or under rotating parts. Keep clear of the discharge opening at all times.
• Do not change the engine governor settings or overspeed the engine. Operating the engine at excessive speed may increase the hazard of personal injury. • Never store the equipment with fuel in the tank inside a building where fumes may reach an open flame or spark. • Before leaving the operator’s position: • Allow the engine to cool before storing in any enclosure.
• 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 guards can lead to thrown object injuries. Do not resume mowing until the area is cleared. This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death.
Vibration Level Whole Body Hand-Arm This unit does not exceed a vibration level of .5 m/s at the posterior based on measurements of identical machines per ISO 2631 procedures. This unit does not exceed a vibration level of 2.5 m/s at the hands based on measurements of identical machines per ISO 5349 procedures. Safety and Instruction Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost.
93–7822 1. Danger 2. See Operator’s manual 93–6697 3. Fill fuel tank to 1” from bottom of filler neck 1. Read operator’s manual for lubrication intervals 100–6574 92–5774 Cover with 93–7804 for CE 1. Hot surface stay away 93–7804 Apply over 92–5774 for CE 1. 2. 3. 4. 2. Stay away from moving parts 93-7276 1. Danger–Read operator’s manual 2. Tipping hazard–Go slow and avoid sharp turns on slopes to avoid rollover. Deck must be lowered when going down slopes for steering control.
3–6668 1. The battery contains lead. Do not throw it in the garbage. 105–2509 Cover with 105–2511 for CE 105–2511 Use to cover 105–2509 for CE 1. Read operator’s manual for starting instructions 93–7834 1. 2. 3. 4. 93–7840 1. Coolant level 2. Hot surface–keep a safe distance 3. Danger–rear the operator’s manual 4. Explosion hazard–stay away 9 No step Traction pedal Traction–forward Traction–reverse 5. Danger – Shut off PTO prior to raising decks 6.
82-8940 1. Locked 2. Tilt steering 3. Unlocked 93-7833 1. Float the cutting unit(s) over the ground. 2. Lower the cutting unit(s). 3. Raise the cutting unit(s). 4. Fast 5. Engine speed 6. Slow 7. Continuous variable setting 105-7179 1. Read the Operator’s Manual. 93-6686 1. Hydraulic oil 2. Read the Operator’s Manual. 10 2.
106-4389 Part No. 105–0054 1. Headlights–off 2. Headlights–on 3. PTO–off 4. PTO–on 5. Engine coolant temperature 6. Engine–start 11 7.
Specifications Note: Specifications and design subject to change without notice. General Specifications Engine Air Cleaner Fuel Tank Capacity Fuel Pump Cooling System Kubota three cylinder, 4 cycle liquid cooled diesel engine. 26 hp @ 3000. Engine governed to 3200–3250 rpm high idle, no load. Heavy duty remote mounted. 8.5 gal. (32 l) Equipped with a fuel filter/water separator to capture water in the fuel. 12 volt electric (transistor type) w/replaceable fuel filter. 7 qt (6.6 l) capacity.
Measurements Length 82 in. Width (Rear Wheels) 47 in. Height 50 in. Weight 1150 lb. Optional Equipment 52” Side Discharge Cutting Unit Model No. 30555 52” Rear Discharge Cutting Unit Model No. 30568 62” Side Discharge Cutting Unit Model No. 30551 62” Guardian Recycler Cutting Unit 72” Side Discharge Cutting Unit Model No. 30569 Debris Blower Model No. 30823 48” V–Plow Kit V–Plow Mounting Kit Model No. 30553 Model No. 30750 Model No. 30749 Arm Rest Kit Model No.
Setup Note: Determine the left and right sides of the machine from the normal operating position. Note: Use this chart as a checklist to ensure that all parts necessary for assembly have been received. Without these parts, total set-up cannot be completed. Some parts may have already been assembled at the factory. Description Qty. Steering wheel 1 Cover 1 Manual tube 1 R–clamp 2 Capscrew 2 Washer 2 Roll pin 1 Capscrew 5/16–18 x 1–3/4” lg.
Seat Kit, Model No. 30624, Standard Seat Warning 1. Attach “U” springs to seat mounting brackets with (4) capscrews and flange nuts as shown in figure 3. • PTO universal shaft is attached to traction unit frame. DO NOT ENGAGE PTO without first removing universal shaft or coupling it to a suitable implement. 2 3 Install Rear Wheels 1. Remove nuts from wheel hubs. Mount wheels and torque nuts to 45–55 ft–lbs. Install Steering Wheel 2. Remove steering wheel from seat plate.
4. Hold mounting plate in upright position with support rod (Fig. 5). 6. Secure front slot of seat springs to traction unit front mounting holes with adjustment handles and flatwashers (Fig. 3 & 5). 7. Connect seat switch connector to traction unit wire harness connector. 8. Adjust seat to desired operating position. Loosen adjustment handles, slide seat fore or aft in slotted holes and tighten adjustment handles to secure in place. 1 3 2 Seat Kit, Model No. 30625, Deluxe Seat: 1.
Install Manual Tube position. To adjust for operator’s weight, turn spring tension knob; clockwise to increase tension, counterclockwise to decrease spring tension (Fig. 8). 1. Remove manual tube and R–clamps secured to seat plate. Retain (2) mounting capscrews and flatwashers. 2. Loosely mount R–clamps to outer holes in right side of seat with (2) capscrews and flatwashers previously removed. (Fig. 10). 1 3. Install manual tube into R–clamps, insert manual into tube and thread cap into tube (Fig. 10).
3. Secure the cables to the proper battery post. The positive (+) red cable goes to the positive post and the negative (–) black cable goes to the negative post on the battery. 1 Warning • Connecting cables to the wrong post could damage the electrical system and result in personal injury. Note: Make sure battery cables are routed away from any sharp edges or moving parts. 4. Coat the terminal with sealant such as Grafo 112X, Toro Part No. 505-47 and install the rubber boot onto positive terminal.
Install Rear Weight Two Wheel Drive Groundsmaster 228–D Series Traction Units comply with ANSI B71.4–1999 Standard when equipped with rear weight. Use chart below to determine combinations of weight required. Order parts from your local Authorized Toro Distributor. Four Wheel Drive Groundsmaster 228–D Series Traction Units do not need additional rear weight to comply with ANSI B71.4–1999 Standard. Rear Weight Required Left Side Weight Required Weight Part Number Weight Description Qty.
1. Check level of coolant in expansion tank (Fig. 14). Coolant level should be between the marks on side of tank. Before Operating Check Engine Oil The engine is shipped with 4 qt (3.8 l) of oil in the crankcase; however, level of oil must be checked before and after the engine is first started. 1 1. Park machine on a level surface, stop engine and remove key from ignition switch. Open hood. 2. Remove dipstick (Fig. 13), wipe clean and reinstall dipstick. Remove dipstick and check oil level.
Fill Fuel Tank Note: Many hydraulic fluids are almost colorless, making it difficult to spot leaks. A red dye additive for the hydraulic system oil is available in 2/3 oz. (20 ml) bottles. One bottle is sufficient for 4–6 gal (15–22 1) of hydraulic oil. Order part no.44–2500 from your authorized Toro distributor. Danger Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive. A fire or explosion from fuel can burn you and others and can cause property damage. 1.
Check Rear Axle Check Bidirectional Clutch Lubricant (Model 30242 only) (Model 30242 only) The rear axle has three separate reservoirs which use SAE 80W-90 wt. gear lube. Although the axle is shipped with lubricant from the factory, check the level before operating the machine. 1. Position the machine on a level surface. 2. Rotate clutch (Fig. 19) so check plug (shown in 12 O’clock position) is positioned at 4 O’clock. 1. Position the machine on a level surface. 2.
Parking Brake Controls Whenever the engine is shut off, the parking brake must be engaged to prevent accidental movement of the machine. To engage the parking brake, push lock arm (Fig. 21) on left brake pedal so that it locks together with the right pedal. Next, push down fully on both pedals and pull parking brake knob out (Fig. 20) then release the pedals. To release parking brake, depress both pedals until parking brake knob retracts.
Tilt Steering Control 1 4 3 2 5 The tilt steering control is a lever on right side of steering column (Fig. 23). Pull lever rearward to adjust steering wheel to desired fore or aft operating position and push lever forward to lock adjustment. 6 7 1 13 12 11 10 9 8 Figure 24 1. 2. 3. 4. 5. 6. Hydraulic Lift lever PTO Switch Temperature gauge Fuel gauge Ignition key switch Temperature override switch 7. Throttle 8. Hour meter 9. Engine coolant temperature 10. Glow plug indicator 11.
–Hour Meter Oil Pressure Warning Light The hour meter (Fig. 24) registers accumulated hours of engine operation. The oil pressure warning light (Fig. 24) glows when oil pressure in engine drops below a safe level. If low oil pressure ever occurs, stop engine and determine the cause. Repair the damage before starting the engine again. Engine Coolant Temperature Warning Light LIft Lever Lock The light illuminates and engine shuts down when coolant reaches a excessively high temperature (Fig. 24).
Bleeding Fuel System Operation 1. Park the machine on a level surface. Make sure fuel tank is at least half full. Note: Determine the left and right sides of the machine from the normal operating position. 2. Unlatch and raise hood. Starting/Stopping Engine Danger Important The fuel system must be bled if any of the following situation have occurred. Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive.
Checking Interlock System operating the traction unit and cutting unit are the transmission, engine speed, load on the cutting blades, and the importance of the brakes. The purpose of the safety interlock system is to prevent the engine from cranking or starting unless the traction pedal is in neutral and the PTO switch is in the OFF position. In addition, the engine will stop when the PTO control is engaged or traction pedal is depressed with operator off the seat or when parking brake is engaged.
Before stopping the engine, disengage all control and move throttle to SLOW. Moving throttle to SLOW reduces high engine speed, noise and vibration. Turn ignition key to OFF to stop the engine. 3. Start engine momentarily after repairs are completed and make sure the pins are in the full disengaged (fully up) position. Important Running the machine with by-pass valve open will cause the transmission to overheat.
1. Wipe grease fitting clean so foreign matter cannot be forced into the bearing or bushing. Lubrication 2. Pump grease into the bearing or bushing. Greasing Bearings And Bushings 3. Wipe up excess grease. The traction unit has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. If machine is operated under normal conditions, lubricate all bearings and bushings after every 50 hours of operation.
Figure 29 Figure 32 Figure 30 1 Figure 33 Figure 31 Figure 34 30
Service Interval Chart 31
Maintenance Note: Determine the left and right sides of the machine from the normal operating position.
Caution If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition and disconnect the wire from the spark plug before you do any maintenance. Set the wire aside so that it does not accidentally contact the spark plug. Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Maintenance Check Item Mon. Tues. Wed. Thurs. Fri.
2. Gently slide filter (Fig. 37) out of air cleaner body to reduce the amount of dust dislodged. Avoid knocking filter against air cleaner body. Maintenance General Air Cleaner Maintenance 1. Check air cleaner body for damage which could possibly cause an air leak. Replace a damaged air cleaner body. 2. Service the air cleaner filter when air cleaner indicator (Fig. 35) shows red or every 400 hours (more frequently in extreme dusty or dirty conditions). Do not over service air filter. 1 1 Figure 37 1.
To thoroughly clean the radiator: 1. Remove the screen. 2. Working from the fan side of the radiator, either spray the radiator with a water hose or blow with compressed air. 3. After the radiator is thoroughly cleaned, clean out debris that may have collected in the channel at the radiator base. 4. Clean and install the screen. Figure 39 1. Oil filter Changing Engine Oil And Filter 6. After oil is drained, reinstall drain plug and wipe up any oil that is spilled.
1 1 2 Figure 40 1. Water separator 2. Drain plug Figure 41 1. Fuel pre filter Replace filter canister after every 400 hours of operation. 1. Clean area where filter canister mounts. 3. Lubricate gasket on filter canister with clean oil. 3. Slide hose clamps onto ends of fuel lines. Push fuel lines onto fuel filter and secure them with hose clamps. Be sure arrow on side of filter points toward the injection pump. 4.
Alternator Belt PTO Belt 1. Condition and Tension – Check condition and tension of belts (Fig. 43) after every 100 operating hours. To Check Tension: 1. Turn engine off and remove the ignition key. Set the parking brake. Raise the engine hood and allow the engine to cool. A. Proper tension will allow 3/8 in. (10 mm) deflection when a force of 10 lbs. is applied on the belt midway between the pulleys. 2. Loosen the tensioning rod jam nut (Fig. 45). B. If deflection is not 3/8 in.
PTO Clutch Adjustment 1. Park machine on a level surface and shut engine off. Depress only the right brake pedal and engage the parking brake. The power take off electric clutch can be adjusted by following the following procedure: 2. Jack up left side of machine until front and rear tires are off shop floor. Support machine with jack stands to prevent it from falling accidentally. 1. Turn engine off and remove the ignition key. Set the parking brake. Raise the engine hood and allow the engine to cool.
Adjusting the Parking Brake Interlock Switch 6. Press down on parking brake rod and push up on switch until compressed length of switch plunger is .030” (Fig. 49, inset) . This the distance between the brake rod paddle and switch plunger housing. 1. Turn engine off and remove the ignition key. Do not engage the parking brake. 7. Tighten switch mounting screws and nuts. 8. With parking brake disengaged, the switch circuit should have continuity.
6. Start engine, cycle steering and lift cylinders, and check for oil leaks. allow engine to run for about five minute. Then shut engine off. Cold weather start–up may result in “stiff” operation of the steering until the hydraulic system has warmed up. Using proper weight hydraulic oil in system will minimize this condition. 7. After two minutes, check level of transmission fluid; refer to Check Hydraulic System Fluid. Note: Many hydraulic fluids are almost colorless, making it difficult to spot leaks.
1 1 1 3 2 Figure 53 Figure 52 1. Rod end 2. Jam nut 1. Brake cable jam nuts 3. Traction rod Adjusting the Tilt Steering Control 4. To reduce rear speed, Adjusting Service Brakes If steering wheel tilt control lever must be adjusted, proceed as follows: Adjust the service brakes when there is more than one inch (25 mm) of “free travel” of the brake pedals, or when the brakes do not work effectively. Free travel is the distance the brake pedal moves before braking resistance is felt. 1.
2. Slide cover up steering shaft to expose pivot bracket (Fig. 55). 5. Fill axle with lubricant; refer to Check Rear Axle Lubricant. 2 Changing Bidirectional Clutch Lubricant 1 (Model 30242 only) After every 400 hours of operation, the oil in the bidirectional clutch must be changed. 1. Position the machine on a level surface. 2. Clean area around check plug on bidirectional clutch. 3 3. Rotate clutch so check plug is positioned downward (Fig. 57). Figure 55 1. Pivot plate 2. Small nut 2 3.
Fuses 2. Remove nuts securing one tie rod ball joint to mounting bracket on axle and disconnect ball joint from axle (Fig. 56). Fuses are accessible under seat plate (Fig. 58). 3. Loosen screw on tie rod clamp. Rotate ball joint in or out to adjust length of tie rod. 4. Reinstall ball joint to mounting bracket and check wheel toe-in. 5. After attaining desired adjustment, tighten screw on tie rod clamp and re–secure ball joint to mounting bracket.
Hydraulic Schematic HYDROSTATIC TRANSMISSION & CHARGE PUMP 800 PSI 70-150 PSI LIFT CYLINDERS 4 GAL/MIN .
15 A GY 45 OPTIONAL LIGHT / FUSE BLOCK PK VIO Y Y S F 4 7.
Engine Storage 1. Drain the engine oil from the oil pan and replace the drain plug. Traction Unit 2. Remove and discard the oil filter. Install a new filter. 1. Thoroughly clean the traction unit, cutting unit and the engine, paying special attention to these areas: 3. Refill the engine with 4 quarts (3.8 l) of recommended motor oil. Refer to Changing Crankcase Oil. • radiator and radiator screen 4. Start the engine and run at idle speed for two minutes. • underneath the cutting unit 5.
The Toro General Commercial Products Warranty A Two-Year Limited Warranty Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your 1996 or newer Toro Commercial Product (“Product”) purchased after January 1, 1997, to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first.
