Form No. 3325-400 Rev A ® Groundsmaster® 228-D 4-Wheel Drive Traction Unit Model No.
Contents Contents 2 Introduction 3 Safety Safe Operating Practices Toro Mower Safety Safety and Instruction Decals 3 3 5 8 Specifications 12 Installing Rear Weights 14 Before Operating Check the Engine Oil Check the Cooling System Check Hydraulic System Fluid Fill the Fuel Tank Check the Rear Axle Lubricant Check the Bi-Directional Clutch’s Lubricant 15 15 15 15 16 17 17 Controls 18 Operation Starting/Stopping the Engine Bleeding the Fuel System Checking the Interlock System Operating Characte
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. injury or death if you do not follow the recommended precautions.
• Never let children or untrained people operate or service the equipment. Local regulations may restrict the age of the operator. • The owner/user can prevent and is responsible for accidents or injuries occurring to himself or herself, other people or property. brake is engaged before starting the engine. Only start the engine from the operator’s position. Use seat belts, if provided. • Slow down and use extra care on hillsides. Be sure to travel in the recommended direction on hillsides.
• Use care when loading or unloading the machine into a trailer or truck • Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision. battery. Wear protective clothing and use insulated tools. • Maintenance and storage • Disengage the drives, lower the implement, set the parking brake, stop the engine and remove the key. Wait for all movement to stop before adjusting, cleaning or repairing.
• • installed. Before operating a machine with roll over protection be certain the seat belts are attached and seat is latched to prevent the seat from pivoting forward. Use only Toro-approved attachments. Warranty may be voided if used with unapproved attachments. Slope Operation Slopes and ramps are a major factor related to loss-ofcontrol and tip-over accidents, which can result in severe injury or death. All slopes and ramps require extra caution.
• • • service as required. Sound Pressure Level Battery acid is poisonous and can cause burns. Avoid contact with skin, eyes and clothing. Protect your face, eyes and clothing when working with a battery. This unit has an equivalent continuous A-weighted sound pressure at the operator ear of: 90 dB(A), based on measurements of identical machines per Directive Battery gases can explode. Keep cigarettes, sparks and flames away from the battery. Sound Power Level 84/538/EEC and amendments.
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. 2 1 1 2 93-7830 1. Danger—See operator’s manual 2. Wheel torque specifications 93-7822 1. Danger 2. See Operator’s manual 3. Fill the fuel tank to 1” from bottom of the filler neck 3 5 4 1 1 4 2 93-7841 1. Danger—See operator’s manual 1 2 4 3 5 105-2512 1. Danger—Read operator’s manual 2.
1 1 2 1 2 3 3 4 105-2511 4 1. Read operator’s manual for starting instructions 93-7276 1. 2. 3. 4. Explosion hazard—wear eye protection. Caustic liquid hazard—flush with water and seek first aid. Fire hazard — no sparks, flame, or smoking Poison—keep children a safe distance from the battery. 1 1 2 100-6581 1. To lock parking brake—Latch pedals together, apply brake pedals and pull up on knob 2. To unlock parking brake—step on brake pedals 2 4 3 93-7840 1. 2. 3. 4.
2 9 8 3 4 7 3 1 6 4 5 1 3 5 6 1 2 93-7834 1. 2. 3. 4. 5. 6. No step Traction pedal Traction—forward Traction—reverse Danger—Shut off power take-off prior to raising decks Danger—Do not operate decks when they are in raised position 93-7833 1. 2. 3. 4. 5. 6. 7. 8. 9.
1 Part No. 104-3484 1. See the operator’s manual 7 1 2 6 3 4 5 Part No. 105-0054 1. 2. 3. 4. 5. 6. 7.
Specifications Note: Specifications and design subject to change without notice.General Specifications Engine Kubota three-cylinder, 4-cycle, liquid-cooled diesel engine. 26 hp @ 3000. Engine governed to 3200–3250 rpm high idle, no load. Air Cleaner Heavy-duty remote mounted. Fuel Tank Capacity 8.5 gal. (32 l) Equipped with a fuel filter/water separator to capture water in the fuel. Fuel Pump 12-volt electric (transistor type) w/replaceable fuel filter. Cooling System 7 qt (6.6 l) capacity.
Power take-off drive The power take-off shaft is clutched by a belt directly from the engine output shaft. The power take-off shaft engaged by an electric clutch/brake assembly. Power takeoff speed—2200 RPM@3250 RPM engine speed. Implement Connection Universal joint and telescoping shaft assembly. Lift Cylinders Two with 2 in. (51 mm) bore, 3.5 in. (89 mm) stroke. Interlock Switches Prevent engine starting if the traction pedal or power take-off switch are engaged.
Installing Rear Weights 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 Rear Weight Required Left Side Weight Required Weight Part Number Weight Description Quantity 52” Rear Discharge Deck (Model 30568) or 52” Side Discharge Deck 20 lbs. 0 lbs. 92-8763 Weight Kit – 20 lb. 1 52” Side Discharge Deck with 9 cu. ft. Hopper 0 lbs. 0 lbs.
Before Operating Check the Engine Oil CAUTION The engine is shipped with 4 qt (3.8 l) of oil in the crankcase; however, check the oil level before and after you first start the engine. 1. Park the machine on a level surface, stop the engine and remove the key from the ignition switch. Open the hood. 2. Remove the dipstick (Fig. 2), wipe it clean and reinstall it. Remove it again and check the oil level.
Expected Ambient Temperature with a wrench. Recommended Viscosity and Type (Extreme) over 32° C SAE 30, Type SF, CC or CD engine oil (Normal) 4–37° C SAE 10W-30 or 10W-40, Type SF,CC or CD engine oil (Cool) –1 to 10° C SAE 5W-30, Type SF, CC or CD engine oil (Winter) Below –1° C Type “F” or “FA” ATF Automatic Transmission Fluid 4. Check all hoses and fittings for leaks. 1 Note: Do not mix engine oil and automatic transmission fluid or hydraulic component damage may result.
mm) from the bottom of the filler neck with diesel fuel. 4. Install the fuel tank cap tightly after filling tank. 1 1 Figure 7 1. Fill/check plug (one on each end of the axle) Check the Bi-Directional Clutch’s Lubricant Figure 5 1. Fuel tank cap Check the Rear Axle Lubricant 1. Position the machine on a level surface. 2. Rotate the clutch (Fig 8) so the check plug (shown in the 12:00 o’clock position) is positioned at 4:00 o’clock.
Controls must be engaged to prevent accidental movement of the machine. To engage the parking brake, push the lock arm (Fig. 10) on so that it locks together with the right pedal. Next, push down fully on both pedals and pull parking brake knob out (Fig. 9) then release the pedals. To release the parking brake, depress both pedals until the parking brake knob retracts.
The hydraulic lift lever (Fig. 12) has three positions: FLOAT, TRANSPORT and RAISE. To lower the cutting unit to the ground, move the lift lever forward into the notch in the seat platform—FLOAT. Use the FLOAT position for mowing and when the machine is not in operation. To raise the cutting unit, pull the lift lever rearward to the RAISE position. Fuel Gauge The fuel gauge (Fig. 12) indicates the quantity of fuel remaining in the fuel tank.
Oil Pressure Warning Light The oil pressure warning light (Fig. 12) glows when engine oil pressure drops below a safe level. If low oil pressure occurs, stop the engine and determine the cause. Repair the damage before starting the engine again. Lift Lever Lock Lock the lift lever (Fig. 12) in the raised position when performing maintenance on the cutting unit. Seat Adjusting Handle To adjust the seat, loosen the adjusting knobs and slide the seat to the desired position.
Operation Note: Determine the left and right sides of the machine from the normal operating position. in forward and reverse for one to two minutes. Also operate the lift lever and power take-off lever to assure proper operation of all parts. Turn the steering wheel to the left and right to check steering response. Then shut the engine off and check fluid levels. Also check for oil leaks, loose parts and any other noticeable malfunctions.
2. Unlatch and raise the hood. 3. Open the air bleed screw on the fuel injection pump (Fig. 13). CAUTION If the safety interlock switches are disconnected or damaged, the machine could operate unexpectedly and cause personal injury. 1 Figure 13 • Do not tamper with the interlock switches. • Check the operation of the interlock switches daily and replace any damaged switches before operating the machine. • Replace switches every two years, regardless of whether they are operating properly. 1.
Turn the ignition key to OFF to stop the engine. before initial operation because it has a hydrostatic transmission and its characteristics are different than some turf maintenance machines with which you may be familiar. Pay attention to the transmission, engine speed, load on the cutting blades, and the importance of the brakes. Pushing or Towing the Traction Unit In an emergency, the you can push or tow the traction unit for a very short distance.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule Maintenance Service Interval After the first 10 hours Maintenance Procedure • Check the power take-off belt tension. • Check the fan and alternator belt tension. • Change the transmission filter. • Torque the wheel lug nuts. After first 50 hours • Change the engine oil filter. • Torque the engine head and check engine RPM.
Service Interval Charts CHECK/SERVICE (DAILY) Filters A. Air B. Fuel C. Fuel D. Transmission oil E. Engine oil Part No. 98-9763 98-7612 98-9764 23-2300 99-8384 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Oil levels (Engine/Trans) Coolant level Tire pressure Belts (Fan and power take off) Fuel—Diesel only Battery Grease, lube points Radiator screen Air filter Electrical clutch gap .017-.
Lubrication CAUTION Greasing Bearings And Bushings If you leave the key in the ignition switch, someone could accidentally 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. The traction unit has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease.
Figure 16 Figure 19 Figure 17 Figure 20 Figure 18 27
cleaner body to reduce the amount of dust dislodged. Avoid knocking the filter against the air cleaner body. General Air Cleaner Maintenance 1. Check air cleaner body for damage that could possibly cause an air leak. Replace a damaged air cleaner body. 2. Service the air cleaner filter when the air cleaner indicator (Fig. 21) shows red or every 400 hours (more often in extreme dusty or dirty conditions). Do not over-service the air filter. 1 1 Figure 23 1. Filter 3.
Cleaning the Radiator and Screen To prevent the engine from overheating, the screen and radiator must be kept clean. Normally, check the screen and radiator daily and clean any debris off these parts. However, it will be necessary to check and clean the screen and radiator more often in extremely dusty and dirty conditions. 1 Figure 24 1. Drain plug Note: If the engine shuts off due to overheating, first check the radiator and screen for excessive build-up of debris. 4.
Fuel Lines and Connections operating hours or yearly, whichever occurs first. Check the lines and connections every 400 hours or yearly, whichever comes first. Inspect for deterioration, damage or loose connections. 1. Clamp both fuel lines that connect to the fuel filter so fuel cannot drain when you remove the lines (Fig. 27). Water Separator DANGER Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive.
assure tension is correct. injection pump. Bleeding Air from Injectors 2 Note: This procedure should be used only if the fuel system has been purged of air through normal priming procedures and the engine will not start; refer to Bleeding the Fuel System, page .21 1 1. Loosen the pipe connection to the No. 1 injector nozzle and holder assembly at injection pump. Figure 29 1. Alternator 2. Mounting bolt 1 Adjusting the Throttle 1. Adjust the throttle cable (Fig.
2. 38 mm 2 Remove the left-hand bracket nut and bolt so that you can remove the retainer bracket’s rubber bumper (Fig. 32). 4 5 1 3 Figure 31 2 1. Tensioning spring 2. Tensioning rod jam nut 3. Tension adjusting bolt 3. 4. 3 Use a 1⁄2” wrench to tighten or loosen the belttensioning spring (Fig. 31). Adjust the spring to a length of 1-1⁄2” (38 mm). 6 Tighten the jam nut. 1 Figure 32 To Replace the Belt: 1. 2. 3. 4. 5. 6. Clutch .
Do not engage the parking brake. engine off. Depress only the right brake pedal and engage the parking brake. 2. 2. Jack up the left front side of the machine until the tire is off the shop floor. Support the machine with jack stands to prevent it from falling accidentally. 3. Lift the seat. Visually inspect the traction linkage for a possible binding condition. Correct it, if necessary, and check machine operation. If the condition still exists, repeat steps 1 and 2 and go to step 4. 4.
8. screw. by the hydraulic system transmission charge pump. Check adjustment as follows: 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 the system will minimize this condition. Engage the parking brake. Depress the traction pedal while the engine is running and the power take-off lever is disengaged. The engine should stop within 2 seconds.
7. off. axle must be changed. After two minutes, check the transmission fluid level; refer to Check Hydraulic System Fluid, page 15. 1. Position the machine on a level surface. 2. Clean the area around the three drain plugs, (1) on each end and (1) in the center (Fig. 38). 3. Remove the plugs, allowing the oil to drain into drain pans. 4. After oil is drained, apply thread-locking compound on the drain plug threads and install it in the axle. 5.
check wheel toe-in. 5. 2 After attaining your desired adjustment, tighten the screw on the rod clamp and secure the ball joint to the mounting bracket. Servicing the Battery 1 Important Before welding on the machine, Figure 39 1. Clutch 2. Check plug disconnect the ground cable from the battery to prevent damage to the electrical system. 4. Remove the check plug allowing all lubricant to flow into the drain pan. 5. Rotate the clutch so the check plug is positioned at 4:00 o’clock. 6.
necessary. Fuses Fuses are accessible under the seat plate (Fig. 40). 5. Grease or oil all grease fittings, pivot points, and transmission by-pass valve pins. Wipe off any excess lubricant. 6. Lightly sand and use touch up the paint on where paint is scratched, chipped or rusted. Repair any dents in the metal body. 7. Service the battery and cables as follows: 1 A. Remove the battery terminals from the battery posts. B. Figure 40 C.
8. Check the oil filler cap and fuel tank cap to ensure they are securely in place.