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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. F

Wiring Schematics

Summary of Contents for Groundsmaster 1000L

Page 1: ...change product specifications or this manual without notice This safety symbol means DANGER WARN ING or CAUTION PERSONAL SAFETY IN STRUCTION When you see this symbol carefully read the instructions th...

Page 2: ...pair 3 38 Troubleshooting 8 5 Governor System Repairs 3 45 Testing 8 7 Fuel System Repairs 3 50 Repairs 8 11 Removing and Installing the Engine 3 58 Cylinder Head Overhaul 3 60 Chapter 9 Brake System...

Page 3: ...1 Seasonal Storage 13 1 Chapter 14 4WD Rear Axle Specifications 14 2 General Information 14 3 Adjustments 14 4 Repairs 14 5 Chapter 14 1 4WD Axle Groundsmaster 228 D with Dae Dong Axle Specifications...

Page 4: ...This page is blank...

Page 5: ...ervice and Repair Manual please contact The Toro Company Commercial Service Department 8111 Lyndale Avenue South Minneapolis MN 55420 2 Never allow children or adults unfamiliar with opera tion of thi...

Page 6: ...up look to the rear to make sure no people or obstacles are behind the machine G Watch out for traffic when near or going across roads Always yield the right of way 13 The grass deflector must always...

Page 7: ...hi Diesel Engine Safety and Instruction Decals If a decal becomes damaged or illegible replace it The decals are shown and part numbers listed in the Opera tor s Manual and Parts Catalog for your mach...

Page 8: ...Safety Instructions Page 1 4 Groundsmaster 220 D 3 88...

Page 9: ...223 D on the OPERATION AND SERVICE HISTO RY REPORT form Use this information when referring to your machine TORQUE SPECIFICATIONS 3 Capscrew Markings and Torque Values U S 3 Capscrew Markings and Torq...

Page 10: ...Equivalents and Conversions Product Records and Manuals Page 2 2 Groundsmaster 220 D 223 D...

Page 11: ...Torque Specifications Page 2 3 Groundsmaster 220 D 223 D Product Records and Manuals...

Page 12: ...Product Records and Manuals Page 2 4 Rev B Groundsmaster 220 D 223 D...

Page 13: ...and Serial Number __________ __________ Deck Model and Serial Number __________ __________ Engine Numbers ____________________ Transmission Numbers ____________________ Drive Axle s Numbers __________...

Page 14: ...Air Filter Replace Gasoline Fuel Filter gas unit Check Rear Wheel Toe In and Steering Linkage Replace Transmission Filter C Level Torque Wheel Lug Nuts Service Drain and Clean Fuel Tank diesel unit C...

Page 15: ...ater Fuel Separator 1 Dust Cup and Baffle Air Filter Radiator Screen for Debris Unusual Engine Noises 2 Unusual Operating Noises Transmission Oil Level Hydraulic Hoses for Damage Fluid Leaks Tire Pres...

Page 16: ...Check Electric Clutch Gap Adjustment Replace Gasoline Fuel Filter gas unit Lubricate All Grease Fittings Check PTO Belt Tension Check Rear Wheel Toe In Lubricate Brake Cables Check Fan and Alternator...

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...

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Page 114: ...uired amount of shims from the shim pack see Charge Relief Valve Service in the Repairs section of this chap ter NOTE For every 0 010 in 0 254 mm of shim thick ness there is an approximate 2 PSI 50 kP...

Page 115: ...ng shims to the relief valve does not increase pressure inspect the condition of the charge pump ger otor and internal housing see Charge Pump Service in the Repairs section of this chapter If the cha...

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Page 147: ...Wiring Schematics Groundmaster 224 Figure 1 Groundsmaster 220 D 223 D Page 5 3 Rev F Wiring Schematics...

Page 148: ...Groundmaster 225 Serial Numbers 60001 to 200999999 Figure 2a Wiring Schematics Page 5 4 Rev F Groundsmaster 220 D 223 D...

Page 149: ...Rev F Groundsmaster 220 D 223 D Wiring Schematics Page 5 5 Groundmaster 225 Serial Numbers higher than 21000000 Figure 2b...

Page 150: ...Groundmaster 1000L Figure 2c Wiring Schematics Page 5 5 1 Rev F Groundsmaster 220 D 223 D...

Page 151: ...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 F...

Page 152: ...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 F Groundsmaster 220 D 223 D...

Page 153: ...Rev F Groundsmaster 220 D 223 D Wiring Schematics Page 5 5 4 Groundmaster 228 D Figure 2f...

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Page 183: ...tside ends of the axle shafts The entire drive line of the axle assembly is made of alloy steel The axle has a die cast aluminum housing that also serves as the hydraulic oil reservoir Power is transm...

Page 184: ..._____________________________________________________________________________________________________________________________________________________ __________________________________________________...

Page 185: ...alling 8 Remove both of the front wheels 9 If unit is equipped with 4WD remove nut Fig 3B Item 47 washer Item 27 and flange Item 26 from differential axle pinion Item 12 Use Differential Gear 26 27 47...

Page 186: ...n the brake shoes by turning the star wheel inside the brake drum assemb ly See Chapter 7 Steering and Brakes Figure 5 2 Line up the hole in the axle shaft flange and remove the backing plate nuts whi...

Page 187: ...ter 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...

Page 188: ...onnel away during this procedure WARNING Figure 11 8 Inspect the shaft for possible damage Fig 12 Inspect the sealing surface of the hub and shaft Re place it if the seal has grooved the surface more...

Page 189: ...re 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...

Page 190: ...ts Fig 18 If installing socket head screws tighten the nuts to a torque of 16 20 ft lb 2 3 Kgm If reinstalling hex head screws tighten the nuts to a torque of 37 45 ft lb 5 6 Kgm IMPORTANT Hold the so...

Page 191: ...devices i e hammer handles under the differ ential case and pry firmly upward The bearing cups must be kept with their mating cones Fig 21 4 Remove the ring gear cap screws Using a hard wooden block...

Page 192: ...shown Fig 23 Figure 23 l 6 Put the case in a vise Drive the lock pin out of the pinion shaft Fig 24 Use a sma l drift punch as shown To prevent personal injury always wear a face shield or safety gogg...

Page 193: ...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 If unit has an expansion plug re...

Page 194: ...mm piece of steel or a screwdriver blade under the edge of the spur gear This will prevent the spur gear from cocking and possibly cracking the housing Fig 30 When the pinion is close to being presse...

Page 195: ...the proper size against the cup Press the cup out of the housing Fig 33 Figure 33 15 Position the front housing on a press bed with the bearing saddles resting on the press bed Protect the bearing sad...

Page 196: ...e axle assembly D Inspect the differential case for wear in the side gear and pinion mate area Replace the case if its machined areas are scored or if the pinion mate shaft fits loosely in the bore 2...

Page 197: ...n is etched 3 this pinion would require 0 003 in less than a pinion etched 0 This means that by removing shims the mounting distance of the pinion is increased to 1 213 in which is just what 3 indicat...

Page 198: ...pinion set is used to establish the proper amount of shims required prior to installing the pinion gear see page 15 The final pinion position will be verified by using the gear contact pattern method...

Page 199: ...Fig 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...

Page 200: ...ead 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 carrie...

Page 201: ...pinion gears line up with the holes of the case If the gears cannot be rotated by hand install one of the axle shafts into the side gear spline and use a pipe wrench to turn the shafts Figure 47 14 I...

Page 202: ...010 and 030 inch sizes Fig 51 18 Assemble new differential bearing cups to differen tial bearing cones Seat differential assembly with drive gear on proper side of carrier into carrier bearing cra dle...

Page 203: ...ring the gears into specification For example if the backlash needed to be changed by 004 inch the shim pack should be changed by 006 inch as a starting point High backlash is corrected by moving the...

Page 204: ...igure 55 Backlash correct Thinner pinion position shims required Drive Side Side Heel Toe Coast Heel Toe Figure 56 Backlash incorrect Thinner pinion position shim re quired Adjust backlash to match Si...

Page 205: ...pinion closer to the ring gear Drive pattern moves deeper on the tooth flank contact and slightly toward the toe Coast pattern moves deeper on the tooth and to ward the heel 4 Thinner pinion position...

Page 206: ...Repairs Page 6 24 Groundsmaster 220 D 223 D...

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Page 301: ...f Contents SPECIFICATIONS 2 GENERAL INFORMATION 3 TM Four Matic 4WD Over Running Clutch Operation 3 ADJUSTMENTS 4 Rear Wheel Toe in 4 REPAIRS 5 Drive Shaft Service 5 Rear Axle Removal and Installation...

Page 302: ..._______________________________________________________________________________________________________________________________________________ Specifications Item Specification Lubricant Fig 1 2 3 SA...

Page 303: ...hill the forward movement of the traction unit slows This causes the rear axle pinion speed to slow down As soon as the rear axle pinion is Figure 4a turning the same speed as the drive shaft the roll...

Page 304: ...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 Th...

Page 305: ...aft yoke flange to flange on front axle differential not shown Clutch Service 1 To disassemble clutch remove six 6 capscrews Item 34 and lockwashers Item 33 Remove axle coupling Item 32 from clutch ho...

Page 306: ...tighten capscrews evenly 7 Lubricate clutch through grease fitting with No 2 General Purpose Lithium Grease Installing Drive Shaft 1 Apply never seize to splines of traction shaft and axle input shaf...

Page 307: ...system 3 Loosen rear wheel capscrews Item 18 4 Block front tires and jack up rear of machine until there is approximately one inch clearance between rear tires and the ground SECURELY BLOCK FRAME 5 Re...

Page 308: ...inder 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 Figur...

Page 309: ...e shaft Item 35 and bevel gear Item 5 C Remove capscrews Item 10 securing knuckle arm Item 8 to knuckle case Item 28 Pull off knuckle arm toward upper side and pull off case toward bottom D Remove cap...

Page 310: ...tooth contact of bevel gear Item 6 to pinion Item 30 Use shims Item 29 to make good contact with light load between bevel gear and pinion Fig 13 D After adjusting tooth contact use shims Item 5 to ma...

Page 311: ...280 Kg Cm C Assemble wheel shaft Item 35 to cover Item 30 4 Install axle on machine see Rear Axle Removal and Installation D Assemble gear Item 5 to wheel shaft and install cover and wheel shaft assem...

Page 312: ...Repairs Page 14 12 Rev B Groundsmaster 223 D...

Page 313: ...Stop Bolt Adjustment 2 Installation 9 SERVICE AND REPAIRS 2 Differential Gear 11 Bevel Gear Case and Axle Case 3 Removal 11 Removal 3 Inspection 12 Inspection 4 Installation 13 Installation 5 Pinion...

Page 314: ...r trav el of the steering cylinder in case of impacts on rear wheels When the steering cylinder is fully extended a gap of 1 16 1 6 mm should exist between left side bev el gear case casting and stop...

Page 315: ...el gear case axle case assemblies Figure 1 1 Cap screw 5 Bevel gear case axle 2 Lock nut case assembly 3 Lock washer 6 O ring 4 Axle support 3 Remove the axle cover mounting screws Remove the axle cov...

Page 316: ...from bevel gear case and axle case Fig 4 Inspection 1 Measure the knuckle pin O D and the axle case sup port bushing I D to determine the bushing to pin clear ance Fig 5 Replace components as necessar...

Page 317: ...r bevel gear and collar Make sure the bevel gear shaft is completely seated in the upper and lower bearings Fig 7 4 Install the knuckle pin Use medium strength Loctite thread locker and tighten the kn...

Page 318: ...ompound to screw threads reinstall screws and torque from 57 to 67 ft lb 77 to 91 N m IMPORTANT Correct engagement between bevel gears is critical to axle performance and durability 7 Temporarily inst...

Page 319: ...emove the bevel gear case axle case assembly and O ring from the axle support Fig 11 2 Mark and pull the differential shaft assembly from the axle support 3 Remove the retaining ring and bevel gear Fi...

Page 320: ...new axle shaft seal with grease and install in axle cover as shown Fig 15 2 Press the axle cover and bearing assembly onto the axle shaft Press only on the inner race of the cover bearing Fig 15 3 In...

Page 321: ...ring assembly in the bearing case and install the outer bearing cone NOTE The bearings must be completely seated There should be no input shaft pinion gear end play 3 Coat a new oil seal with grease a...

Page 322: ...ng screws Figure 18 to 35 to 41 ft lbs 47 to 56 Nm 1 Input shaft pinion gear 2 Bearing case 11 Insert a screwdriver through the drain plug hole to hold ring gear and measure the pinion gear to ring ge...

Page 323: ...ring pin from the differential case with a punch and hammer Discard the spring pin Fig 21 NOTE Mark and arrange all components so they can be reassembled in their original position 7 Remove the differ...

Page 324: ...nd the pinion gear I D to determine the pinion shaft to pinion gear clearance Fig 24 Replace components as nec essary PINION SHAFT TO PINION GEAR CLEARANCE 0 001 to 0 010 in 0 03 to 0 25 mm PINION SHA...

Page 325: ...tion 9 Ideal tooth contact should cover more than 35 of each tooth surface The contact area should be in the center of each tooth and extend 1 3 to 1 2 way across each tooth from the toe small end Fig...

Page 326: ...e input shaft pinion gear bearing case shims or by moving the differential gear case differential bear ing shims Fig 29 NOTE Bearing case shims are available in 0 004 in 0 10 mm and 0 008 in 0 20 mm t...

Page 327: ...ring gear backward C Repeat until proper tooth contact and pinion gear to ring gear backlash are correct 2 If contact is toward the toe or tip of the gear Fig 31 A Install thinner or remove bearing c...

Page 328: ...4WD Rear Axle Page 10 1 16 Groundsmaster 228 D Groundsmaster 228 D with Dae Dong axle Rev D...

Page 329: ...ing Lift Arms to Traction Unit 11 Connecting Lift Arms to Cutting Unit 12 Connecting PTO Shaft to Cutting Unit Gearbox 12 Replacing Drive Belt 13 Servicing Front Castor Arm Bushings 14 Servicing Casto...

Page 330: ...AA section belt Spindle shafts are 1 inch diameter and supported by two greaseable tapered roller bearings Cutting Unit Blades Three 21 3 4 long and 1 4 thick heat treated steel Recycler blades Casto...

Page 331: ...ecycler Cutting Unit Schematic STEERING CYLINDER COUNTERBALANCE MANIFOLD 4 GAL MIN 3 CID 800 PSI 70 150 PSI G1 P1 P2 S BYP OUT CI 75 PSI LC1 100 PSI Rev B HYDROSTATIC TRANSMISSION CHARGE PUMP STEERING...

Page 332: ...Troubleshooting 85 To 110 Guardian 62 Recycler Cutting Unit Page 15 4 Rev B Groundsmaster 223 D...

Page 333: ...hole 3 Spacers 1 Start the engine and raise the cutting unit so height of cut can be changed Stop engine after cutting unit is raised Note 1 height of cut can be attained by modifying the castor fork...

Page 334: ...ve cotter pins securing roller shafts to under side 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 Skid Ad...

Page 335: ...diately after washing regardless of the service interval listed The cutting unit has bearings and bushings that must be lubricated and these lubrication points are front castor spindle bushings Fig 5...

Page 336: ...an 3 8 of an inch lower than the outer blades proceed to step 7 and add shims between spindle hous ing and bottom of cutting unit 7 Remove capscrews flatwashers lockwashers and nuts from outer spindle...

Page 337: ...Position the machine and cutting unit on a level sur face 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 to...

Page 338: ...is not connected to cut personal injury Do not start engine and engage PTO le ver when PTO shaft is not connected to Mounting Cutting Unit to Traction Unit 1 Position machine on a level surface and sh...

Page 339: ...er 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 1 2 3 Figure 11 1 Pivot pin 2 Lift a...

Page 340: ...o outside of castor arm FIg 14 1 3 2 2 25 Figure 13 Note Ball joint mount to be above castor arm when as 1 Lift Arm 2 Ball Joint 3 Jam Nut sembled 5 Tighten large jam nut securing ball joint to lift a...

Page 341: ...on 3 Remove carriage bolts and flange nuts securing gear box plate to deck Lift gear box plate and gear box off deck and lay it on top of deck 4 Remove old belt from around spindle pulleys and idler p...

Page 342: ...e out of mounting tube Allow thrust washer and spacer s to remain on bottom of spindle 4 Insert pin punch into top or bottom of mounting tube and drive bushing out of tube Also drive other bushing out...

Page 343: ...to fall out Remove bushing from opposite side of wheel hub 4 Check the bearing spanner and inside of wheel hub for wear Replace defective parts 5 To assemble the castor wheel push bushing into wheel h...

Page 344: ...ing a rag or thickly padded glove Remove blade bolt lockwasher anti scalp cup and blade from spindle shaft 3 Install blade sail facing toward cutting unit with anti scalp cup lockwasher and blade bolt...

Page 345: ...nder s area 3 Inspect cutting edges of all blades Sharpen the cut ting edges if they are dull or nicked Sharpen only the top of the cutting edge and maintain the original cutting angle to make sure of...

Page 346: ...be removed from the shaft 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 o...

Page 347: ...as shown in the illustration 4 Repeat steps 1 3 with the other set of parts to complete the assembly 5 Put one of the caps Item 16 down with the machined surface facing up Install a new seal Item 13...

Page 348: ...ws and tighten 4 The shaft should have a very slight amount of bearing drag If the shaft turns hard the cap must be removed and gasket s need to be added If the shaft has no bearing drag or has end pl...

Page 349: ...m spindle housing 4 Allow the bearings and small thick spacer to fall out of the spindle housing 5 Using a punch and hammer drive both of the bearing cups out of the spindle housing Also drive the lar...

Page 350: ...sembly is correct by support ing the first cup and pressing the second against it 4 Apply a film of grease on lips of both seals then install bearing and seal into bottom of spindle housing Re member...

Page 351: ...This page is blank...

Page 352: ...Commercial Products The Toro Company...

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