Toro 30241, 30242, Groundsmaster 228–D Operator's Manual

Download

Page 1

Groundsmaster 228–D

2 & 4 Wheel Drive Traction Units

Model No. 30241–240000115 and Up Model No. 30242–240000301 and Up

Form No. 3351–531

Operator’s Manual

English (EN, GB)

Page 2

Warning

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

Important The engine in this product is not equipped

with a spark arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate this engine on any forest-covered, brush-covered, or grass-covered land as defined in CPRC 4126. Other states or federal areas may have similar laws.

Contents

Page

Introduction 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safe Operating Practices 3. . . . . . . . . . . . . . . . . . . .

Toro Riding Mower Safety 5. . . . . . . . . . . . . . . . . . .

Safety and Instruction Decals 7. . . . . . . . . . . . . . . . .

Specifications 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Specifications 12. . . . . . . . . . . . . . . . . . . . .

Measurements 13. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional Equipment 13. . . . . . . . . . . . . . . . . . . . . . . .

Setup 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Install Steering Wheel 15. . . . . . . . . . . . . . . . . . . . . .

Install Handle to Hood 15. . . . . . . . . . . . . . . . . . . . . .

Install Seat 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Install Seat Belt

(Model 30242 only) 17. . . . . . . . . . . . . . . . . . . . . . .

Install Manual Tube 17. . . . . . . . . . . . . . . . . . . . . . . .

Install ROPS

(Model 30242 only) 17. . . . . . . . . . . . . . . . . . . . . . .

Activating and Charging the Battery 18. . . . . . . . . . .

Check Tire Pressure 19. . . . . . . . . . . . . . . . . . . . . . . .

Install Rear Weight 20. . . . . . . . . . . . . . . . . . . . . . . . .

Before Operating 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check Engine Oil 21. . . . . . . . . . . . . . . . . . . . . . . . . .

Check Cooling System 21. . . . . . . . . . . . . . . . . . . . . .

Check Hydraulic System Fluid 21. . . . . . . . . . . . . . .

Fill Fuel Tank 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check Rear Axle

(Model 30242 only) 23. . . . . . . . . . . . . . . . . . . . . . .

Check Bidirectional Clutch Lubricant

(Model 30242 only) 23. . . . . . . . . . . . . . . . . . . . . . .

Controls 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting/Stopping Engine 26. . . . . . . . . . . . . . . . . . . .

Bleeding Fuel System 26. . . . . . . . . . . . . . . . . . . . . .

Checking Interlock System 27. . . . . . . . . . . . . . . . . .

Operating Characteristics 27. . . . . . . . . . . . . . . . . . . .

Pushing Or Towing Traction Unit 28. . . . . . . . . . . . .

Lubrication 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Greasing Bearings And Bushings 29. . . . . . . . . . . . .

Service Interval Chart 31. . . . . . . . . . . . . . . . . . . . . .

Maintenance 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Maintenance Schedule 32. . . . . . . . .

Daily Maintenance Checklist 33. . . . . . . . . . . . . . . . .

Maintenance 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Air Cleaner Maintenance 34. . . . . . . . . . . . .

Servicing Air Cleaner 34. . . . . . . . . . . . . . . . . . . . . . .

Cleaning Radiator And Screen 34. . . . . . . . . . . . . . . .

Changing Engine Oil And Filter 35. . . . . . . . . . . . . .

Servicing Fuel System 35. . . . . . . . . . . . . . . . . . . . . .

Bleeding Air From Injectors 36. . . . . . . . . . . . . . . . .

Alternator Belt 37. . . . . . . . . . . . . . . . . . . . . . . . . . . .

PTO Belt 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PTO Clutch Adjustment 37. . . . . . . . . . . . . . . . . . . . .

Adjusting Transmission For Neutral 38. . . . . . . . . . .

Adjusting the Parking Brake Interlock Switch 38. . .

Changing Hydraulic Oil And Filter 39. . . . . . . . . . . .

Adjusting Traction Pedal 40. . . . . . . . . . . . . . . . . . . .

Adjusting Service Brakes 40. . . . . . . . . . . . . . . . . . . .

Adjusting the Tilt Steering Control 41. . . . . . . . . . . .

Changing Rear Axle Lubricant

(Model 30242 only) 42. . . . . . . . . . . . . . . . . . . . . . .

Changing Bidirectional Clutch Lubricant

(Model 30242 only) 42. . . . . . . . . . . . . . . . . . . . . . .

Rear Wheel Toe–in

(Model 30242 only) 42. . . . . . . . . . . . . . . . . . . . . . .

Servicing Battery 43. . . . . . . . . . . . . . . . . . . . . . . . . .

Storing the Battery 43. . . . . . . . . . . . . . . . . . . . . . . . .

Wiring Harness Service 43. . . . . . . . . . . . . . . . . . . . .

Fuses 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Schematic 45. . . . . . . . . . . . . . . . . . . . . . .

Electrical Schematic 46. . . . . . . . . . . . . . . . . . . . . . . .

Storage 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Traction Unit 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The Toro General Commercial Products Warranty 48. . .

 2004 by The Toro Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196

Printed in the USA

Page 3

Introduction

Safety

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.

Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready. Figure 1 illustrates the location of the model and serial numbers on the product.

Figure 1

1. Location of the model and serial numbers

This machine meets or exceeds CEN standard EN 836:1997 , ISO standard 5395:1990 (when appropriate decals applied), and ANSI B71.4-1999 specifications in effect at the time of production when and equipped with rear weight as listed in the weight chart.

Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert CAUTION, WARNING, or DANGER—“personal safety instruction.” Failure to comply with the instruction may result in personal injury or death.

symbol, which means

Safe Operating Practices

The following instructions are from the CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI B71.4-1999.

Training

• Read the operator’s manual and other training material

carefully. Be familiar with the controls, safety signs, and the proper use of the equipment.

• If the operator or mechanic can not read the language of

is the owner’s responsibility to explain this material to them.

Write the product model and serial numbers in the space below:

Model No.

Serial No.

This manual identifies potential hazards and has special safety messages that help you and others avoid personal injury and even death. Danger, Warning, and Caution are signal words used to identify the level of hazard. However, regardless of the hazard, be extremely careful.

Danger signals an extreme hazard that will cause serious injury or death if you do not follow the recommended precautions.

Warning signals a hazard that may cause serious injury or death if you do not follow the recommended precautions.

Caution signals a hazard that may cause minor or moderate injury if you do not follow the recommended precautions.

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.

• Never allow children or people unfamiliar with these

instructions to use or service the mower. Local regulations may restrict the age of the operator.

• Never mow while people, especially children, or pets

are nearby.

• Keep in mind that the operator or user is responsible for

accidents or hazards occurring to other people or their property.

• Do not carry passengers.

• All drivers and mechanics should seek and obtain

professional and practical instruction. The owner is responsible for training the users. Such instruction should emphasize:

– the need for care and concentration when working

with ride-on machines;

– control of a ride-on machine sliding on a slope will

not be regained by the application of the brake. The main reasons for loss of control are:

• insufficient wheel grip;

• being driven too fast;

• inadequate braking;

• the type of machine is unsuitable for its task;

Page 4

• lack of awareness of the effect of ground

conditions, especially slopes;

• incorrect hitching and load distribution.

• The owner/user can prevent and is responsible for

accidents or injuries occurring to himself or herself, other people, or property.

• Remember there is no such thing as a safe slope. Travel

on grass slopes requires particular care. To guard against overturning:

– do not stop or start suddenly when going up or

downhill;

– engage clutch slowly, always keep machine in gear,

especially when travelling downhill;

Preparation

• While mowing, always wear substantial footwear, long

trousers, hard hat, safety glasses, and ear protection. Long hair, loose clothing, or jewelry may get tangled in moving parts. Do not operate the equipment when barefoot or wearing open sandals.

• Thoroughly inspect the area where the equipment is to

be used and remove all objects which may be thrown by the machine.

• Warning—Fuel is highly flammable. Take the

following precautions: – Store fuel in containers specifically designed for this

purpose.

– Refuel outdoors only and do not smoke while

refueling.

– Add fuel before starting the engine. Never remove

the cap of the fuel tank or add fuel while the engine is running or when the engine is hot.

– If fuel is spilled, do not attempt to start the engine

but move the machine away from the area of spillage and avoid creating any source of ignition until fuel vapors have dissipated.

– Replace all fuel tanks and container caps securely.

• Replace faulty silencers/mufflers.

• Evaluate the terrain to determine what accessories and

attachments are needed to properly and safely perform the job. Only use accessories and attachments approved by the manufacturer.

• Check that operator’s presence controls, safety switches

and shields are attached and functioning properly. Do not operate unless they are functioning properly.

– machine speeds should be kept low on slopes and

during tight turns;

– stay alert for humps and hollows and other hidden

hazards;

– never mow across the face of the slope, unless the

mower is designed for this purpose.

• Stay alert for holes in the terrain and other hidden

hazards.

• Use care when pulling loads or using heavy equipment.

– Use only approved drawbar hitch points. – Limit loads to those you can safely control. – Do not turn sharply. Use care when reversing. – Use counterweight(s) or wheel weights when

suggested in the operator’s manual.

• Watch out for traffic when crossing or near roadways.

• Stop the blades rotating before crossing surfaces other

than grass.

• When using any attachments, never direct discharge of

material toward bystanders nor allow anyone near the machine while in operation.

• Never operate the machine with damaged guards,

shields, or without safety protective devices in place. Be sure all interlocks are attached, adjusted properly, and functioning properly.

• Do not change the engine governor settings or

overspeed the engine. Operating the engine at excessive speed may increase the hazard of personal injury.

• Before leaving the operator’s position:

– stop on level ground;

Operation

• Do not operate the engine in a confined space where

dangerous carbon monoxide fumes can collect.

• Mow only in daylight or in good artificial light.

• Before attempting to start the engine, disengage all

blade attachment clutches, shift into neutral, and engage the parking brake.

• Do not put hands or feet near or under rotating parts.

Keep clear of the discharge opening at all times.

– disengage the power take-off and lower the

attachments;

Warning

Engine exhaust contains carbon monoxide, which is an odorless, deadly poison that can kill you.

Do not run engine indoors or in an enclosed area.

– change into neutral and set the parking brake;

Page 5

– stop the engine and remove the key.

• Disengage drive to attachments when transporting or

not in use.

• Stop the engine and disengage drive to attachment

– before refuelling; – before removing the grass catcher/catchers; – before making height adjustment unless adjustment

can be made from the operator’s position. – before clearing blockages; – before checking, cleaning or working on the mower; – after striking a foreign object or if an abnormal

vibration occurs. Inspect the mower for damage and

make repairs before restarting and operating the

equipment.

• Keep all parts in good working condition and all

hardware and hydraulic fittings tightened. Replace all worn or damaged parts and decals.

• If the fuel tank has to be drained, do this outdoors.

• Be careful during adjustment of the machine to prevent

entrapment of the fingers between moving blades and fixed parts of the machine.

• On multi-spindle mowers, take care as rotating one

blade can cause other blades to rotate.

• Disengage drives, lower the cutting units, set parking

brake, stop engine and remove key and disconnect spark plug wire. Wait for all movement to stop before adjusting, cleaning or repairing.

• Clean grass and debris from cutting units, drives,

silencers/mufflers, and engine to help prevent fires. Clean up oil or fuel spillage.

• Reduce the throttle setting during engine run-out and, if

the engine is provided with a shut-off valve, turn the fuel off at the conclusion of mowing.

• Keep hands and feet away from the cutting units.

• Look behind and down before backing up to be sure of

a clear path.

• Slow down and use caution when making turns and

crossing roads and sidewalks. Stop cylinders/reels if not mowing.

• Be aware of the mower discharge direction and do not

point it at anyone.

• Do not operate the mower under the influence of

alcohol or drugs

• 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.

Maintenance and Storage

• Keep all nuts, bolts and screws tight to be sure the

equipment is in safe working condition.

• Never store the equipment with fuel in the tank inside a

building where fumes may reach an open flame or spark.

• Allow the engine to cool before storing in any

enclosure.

• To reduce the fire hazard, keep the engine,

silencer/muffler, battery compartment and fuel storage area free of grass, leaves, or excessive grease.

• Check the grass catcher frequently for wear or

deterioration.

• Use jack stands to support components when required.

• Carefully release pressure from components with stored

energy.

• Disconnect battery and remove spark plug wire before

making any repairs. Disconnect the negative terminal first and the positive last. Reconnect positive first and negative last.

• Use care when checking the cylinders/reels. Wear

gloves and use caution when servicing them.

• Keep hands and feet away from moving parts. If

possible, do not make adjustments with the engine running.

• Charge batteries in an open well ventilated area, away

from spark and flames. Unplug charger before connecting or disconnecting from battery. Wear protective clothing and use insulated tools.

Toro Riding Mower Safety

The following list contains safety information specific to Toro products or other safety information that you must know that is not included in the CEN, ISO, or ANSI standard.

This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death.

Use of this product for purposes other than its intended use could prove dangerous to user and bystanders.

• Know how to stop the engine quickly.

• Do not operate the machine while wearing tennis shoes

or sneakers.

Page 6

• Wearing safety shoes and long pants is advisable and

required by some local ordinances and insurance regulations.

sufficient force to penetrate the skin and cause serious injury. Seek immediate medical attention if fluid is injected into skin.

• Handle fuel carefully. Wipe up any spills.

• Check the safety interlock switches daily for proper

operation. If a switch should fail, replace the switch before operating the machine. After every two years, replace all interlock switches in the safety system, whether they are working properly or not.

• Before starting the engine, sit on the seat.

• Using the machine demands attention. To prevent loss

of control: – Do not drive close to sand traps, ditches, creeks, or

other hazards.

– Reduce speed when making sharp turns. Avoid

sudden stops and starts.

– When near or crossing roads, always yield the

right-of-way.

– Apply the service brakes when going downhill to

keep forward speed slow and to maintain control of the machine.

• Raise the cutting units when driving from one work

area to another.

• Do not touch the engine, silencer/muffler, or exhaust

pipe while the engine is running or soon after it has stopped because these areas could be hot enough to cause burns.

• If the engine stalls or loses headway and cannot make it

to the top of a slope, do not turn the machine around. Always back slowly, straight down the slope.

• Before disconnecting or performing any work on the

hydraulic system, all pressure in the system must be relieved by stopping the engine and lowering the cutting units and attachments to the ground.

• Check all fuel lines for tightness and wear on a regular

basis. Tighten or repair them as needed.

• If the engine must be running to perform a maintenance

adjustment, keep hands, feet, clothing, and any parts of the body away from the cutting units, attachments, and any moving parts, especially the screen at the side of the engine. Keep everyone away.

• To ensure safety and accuracy, have an Authorized Toro

Distributor check the maximum engine speed with a tachometer. Maximum governed engine speed should be 3200 RPM.

• If major repairs are ever needed or if assistance is

desired, contact an Authorized Toro Distributor.

• Use only Toro-approved attachments and replacement

parts. The warranty may be voided if used with unapproved attachments.

Sound Pressure Level

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 98/37/EC and amendments.

Sound Power Level

• 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.

Maintenance and Storage

• Make sure all hydraulic line connectors are tight and all

hydraulic hoses and lines are in good condition before applying pressure to the system.

• Keep your body and hands away from pin hole leaks or

nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not your hands, to search for leaks. Hydraulic fluid escaping under pressure can have

This unit has a sound power level of: 105 dB(A) 1 pW, based on measurements of identical machines per Directive 2000/14/EC and amendments.

Vibration Level

Hand-Arm

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.

Whole Body

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.

Page 7

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.

93–7830

1. Danger–See operator’s manual

2. Wheel torque specifications

67–1710

Cover with

93–7841 for CE

93–7841

Use to cover 67–1710 for CE

1. Danger–See operator’s manual

1. Fan blades can cause injury

1. Danger

2. See Operator’s manual

93-6680

93–7272

2. Stay away from moving parts

93–7822

3. Fill fuel tank to 1” from bottom of filler neck

1. Lock – Unlock deck service lock

100–6577

Page 8

1. Warning—read the

Operator’s Manual.

2. Thrown object hazard—keep bystanders a safe distance from the machine.

Cover with 107–2925 for CE

Apply over 92–5774 for CE

3. Cutting hazard of hand or foot—stay away from moving parts.

92-5774

107-2925

4. Warning—engage the parking brake, stop the engine, and remove the ignition key before leaving the machine.

5. Tipping hazard—do not drive the machine on a slope greater than 10 degrees; when driving down slopes, lower the cutting unit, and if the roll bar is installed, wear the seat belt.

Page 9

93–6697

1. Read operator’s manual for lubrication intervals

106-6754

1. Warning—do not touch the hot surface.

2. Cutting/dismemberment hazard, fan and entanglement hazard, belt—stay away from moving parts

105–2509

Cover with

105–2511 for CE

1. Engine coolant under pressure

2. Explosion hazard—read the

Operator’s Manual.

1. Locked

2. Tilt steering

106-5976

3. Warning—do not touch the hot surface.

4. Warning—read the

Operator’s Manual.

82-8940

3. Unlocked

105–2511

Use to cover 105–2509 for CE

1. Read operator’s manual for starting instructions

93-6686

1. Hydraulic oil 2. Read the

Manual.

Operator’s

1. Read the

Manual.

Operator’s

105-7179

2. Parking brake

Page 10

Battery Symbols

Some or all of these symbols are on your battery.

1. Explosion hazard

2. No fire, open flames, or smoking.

3. Caustic liquid/chemical burn hazard

4. Wear eye protection

5. Read the

Manual.

6. Keep bystanders a safe distance from the battery.

Operator’s

7. Wear eye protection; explosive gases can cause blindness and other injuries

8. Battery acid can cause blindness or severe burns.

9. Flush eyes immediately with water and get medical help fast.

10. Contains lead; do not discard.

1. Float the cutting unit(s) over the ground.

2. Lower the cutting unit(s).

3. Raise the cutting unit(s).

4. Fast

93-7833

5. Engine speed

6. Slow

7. Continuous variable setting

1. No step

2. Traction pedal

3. Traction–forward

4. Traction–reverse

93–7834

5. Danger – Shut off PTO prior to raising decks

6. Danger – Do not operate decks when they are in raised position

Page 11

107-2920

1. Headlights–off

2. Headlights–on

3. PTO–off

4. PTO–on

Part No. 105–0054

5. Engine coolant temperature

6. Engine–start

7. Engine–stop

Page 12

Specifications

Note: Specifications and design subject to change without notice.

General Specifications

Engine

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

Electrical

Drive Coupling Transmission driven by steel shaft with flexible rubber couplings at each end.

Transmission Hydrostatic, U–type. Implement Relief Setting — 700-800 psi (4 826 - 5 516 kPa).

Hydraulic Filter Replaceable 25 micron filter mounted directly to transmission.

Front Axle

Rear Axle

Brakes

Kubota three cylinder, 4 cycle liquid cooled diesel engine. 26 hp @ 3000. Engine governed to 3200–3250 rpm high idle, no load.

7 qt (6.6 l) capacity. Remote mounted expansion tank 1 qt (0.946 l) capacity. System contains a 50/50 mix of ethylene glycol anti-freeze and water. Front mounted air/oil cooler used to cool hydraulic oil for the hydrostatic transmission.

12 volt with 530 cold cranking amps at 0 F and 75 minute reserve capacity at 80 F.

The front axle serves as a hydraulic fluid reservoir and mates directly with the transmission. Approximately 6 qt (5.7 l) capacity.

Model 30242 only–The rear axle is mechanically driven from the front axle by a universal shaft. Axle has a bidirectional – overrunning clutch in rear driveshaft. When lubricating rear axle, use SAE 80W-90 gear lube, API GL-5. Lubricant capacity is approximately 3.1 qt. (2.9 L).

Mechanical drum type. Individually controlled by two pedals connected by cable and conduit for steering assist. Pedals may be latched together for two wheel braking. Lever provided for parking brake.

Tires

Ground Speed 0–10 MPH forward and reverse.

Power Steering Tilt steering wheel, released and locked by single lever control.

Main Frame Frame is welded, formed steel.

Instrumentation

Controls

PTO Drive

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

Front Tires — 23 x 8.50 – 12, Rear Tires — 16 x 6.50 – 8. All tires 4 ply rating, tubeless type. Pressure — 20 psi (138 kPa).

Fuel gauge, water temperature gauge, hour meter and warning lights for high temperature shutdown, oil pressure, amperage and glow plug are mounted on the console.

Throttle, PTO switch, parking brake, implement lift, implement lift lock, ignition switch and high temperature override switch are all hand-operated. Forward/reverse traction pedal and turning brakes are foot operated.

Splined PTO shaft is clutched by a torque-teamed HA Section, spring tensioned V-belt directly from engine output shaft. PTO shaft engaged by electric clutch/brake assembly. PTO speed — 2200 RPM @ 3250 RPM engine speed.

Prevents engine starting if traction pedal or PTO switch are engaged. Stops engine if operator leaves seat with either traction pedal or PTO switch engaged. Stops engine if traction pedal is engaged with parking brake engaged.

Page 13

Measurements

Length 82 in. Width (Rear Wheels) 47 in. Height w/o ROPS 50 in. Weight

Model 30241 Model 30242

1220 lb. 1480 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

Debris Blower 48” V–Plow Kit Model No. 30750 V–Plow Mounting Kit Arm Rest Kit Model No. 30707 Rear Discharge Shield Kit Model No. 30578 Rear Weight Box Kit Part No. 24–5780 Grass Collection System Wide Tires w/rim

23 x 10.5 –12, 4 ply

23 x 10.5 –12, 6 ply Wheel Weights–50 lbs. (23kg.) Part No. 11–0440 Rear Weight Kit–70 lbs. (32 kg.) Part No. 24–5780 Weight Kit–20 lbs. Part No. 92–8763 Tire Chains (Front) Part No. 11–0390 Tire Chains (Rear–4 Wheel Drive)) Part No. 76–1840 Standard Seat Kit Model No. 30624 Deluxe Seat Kit Model No. 30625

Model No. 30569

Model No. 30553 Model No. 30823

Model No. 30749

Model No. 30502

Part No. 62–7020 Part No. 69–9870

Required with 30750 V–plow. Tire chains, part no. 11–0390



recommended.

 52” Blower Kit (for Model 30555 deck) or Model 30506 62” Blower

Kit (for Model 30551 deck) can be used with either Model No. 30504, 9 cu. ft. Hopper Kit or Model No. 30505, 15 cu. ft. Hopper Kit. Model 30504 used on 2 wheel drive traction unit only.

Page 14

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

Steering wheel Cover

Handle Screws

Seat belt Screw Lockwasher Flatwasher

Manual tube & cap R–clamp Capscrew Washer

ROPS Bolt Washer Nut

Roll pin Capscrew 5/16–18 x 1–3/4” lg. Locknut 5/16–18

Qty. Use

1 1

1 2

2 2 2 2

1 2 2 2

1 4 8 4

1 2 2

Install steering wheel

Install handle to hood

Mount seat belt on Model 30242

Install on right underside of seat

Mount ROPS on Model 30242

Secure universal shaft to implement

Cylinder pin Cotter pin 3/16 x 1–1/2”

Brake return springs 2 Mount to deck lift arms Ignition & hood latch key 1 Decals–CE 3 Apply to machine for CE Operator’s Manual (Traction Unit) 2 Read before operating machine Engine Operator’s Manual 1 Engine Warranty 1 Predelivery Inspection Form 1 Parts Catalog 1 CE Certificate 1 Operator Video 1 View before operating machine

Secure deck lift arms to lift cylinders

Page 15

Warning

• 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.

Install Steering Wheel

1. Remove steering wheel from seat plate. Remove cap

from steering wheel (Fig. 2).

2. Remove jam nut from steering shaft. Make sure foam

collar and dust cover are on steering shaft (Fig. 2). Slide steering wheel onto steering shaft.

3. Secure steering wheel to shaft with jam nut and tighten

it to 10–15 ft–lb.

Install Handle to Hood

1. Mount handle to top of hood with (2) screws (Fig. 3).

Figure 3

1. Handle

Install Seat

4. Mount cover to steering wheel.

Figure 2

1. Steering wheel

2. Jam nut

3. Dust cover

4. Foam collar

5. Cover

The Groundsmaster 228–D is shipped without the seat assembly. Either optional Seat Kit, Model No. 30624 or

30625 must be installed.

Seat Kit, Model No. 30624, Standard Seat

1. Attach “U” springs to seat mounting brackets with (4)

capscrews and flange nuts as shown in figure 4.

Figure 4

1. U–spring

2. Seat mounting bracket

2. Secure seat mount assemblies to bottom of seat with (4)

flange head capscrews and (4) spacers (Fig. 4). Spacers to be positioned between seat and seat mount.

Note: Mount the bracket in the forward set of tapped mounting holes in seat.

3. Spacer

Page 16

3. Remove hair pin cotter and pull back on locking spring

flap to pivot mounting plate forward (Fig. 5).

Figure 5

1. Hair pin

2. Lock spring flap

3. Seat mounting plate

4. Hold mounting plate in upright position with support

rod (Fig. 6).

Figure 7

1. Mounting plate

2. Seat spring

3. Shoulder bolt with washer and locknut (2)

4. Adjustment handle (2)

Seat Kit, Model No. 30625, Deluxe Seat:

1. Position threaded mounting studs of seat suspension

into holes in seat mounting plate.

2. Remove hair pin cotter and pull back on locking spring

flap to pivot mounting plate forward (Fig. 5).

3. Hold mounting plate in upright position with support

rod (Fig. 6).

4. Secure seat suspension to seat mounting plate with (4)

flange locknuts (Fig. 8).

Figure 6

1. Mounting plate

2. Support rod

3. Indent

5. Mount seat and spring assembly to rear holes in seat

mounting plate with two shoulder bolts, small I.D. flat washers and locknuts (Fig. 4 & 7).

6. Secure front slot of seat springs to traction unit front

mounting holes with adjustment handles and flatwashers (Fig. 4 & 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.

Figure 8

1. Seat suspension

5. Mount seat to seat suspension with (4) capscrews,

lockwashers and flatwashers (Fig. 8).

6. Connect seat switch connector to traction unit wire

harness connector.

7. Adjust seat for operator’s comfort and weight. To adjust

seat fore and aft, pull handle on left side of seat assembly outward (Fig. 9). Release handle to lock seat

Page 17

position. To adjust for operator’s weight, turn spring tension knob; clockwise to increase tension, counterclockwise to decrease spring tension (Fig. 9).

Install Manual Tube

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. 11).

1. Seat

2. Suspension assembly

3. Mounting plate

Figure 9

4. Forward/backward handle

5. Spring tension knob

Install Seat Belt

(Model 30242 only)

1. Install tether straps and each end of seat belt to holes in

back of seat with (2) 7/16 x 20 – 1” lg. capscrews, 7/16 flatwashers and 7/16 lockwashers. Tighten securely. Latch side of belt to be mounted to left side of seat.

Figure 11

1. Manual tube 2. R–clamps

3. Install manual tube into R–clamps, insert manual into

tube and thread cap into tube (Fig. 11). Tighten capscrews.

Install ROPS

(Model 30242 only)

1. Remove capscrews, flatwashers, and flange lock nuts

secured to legs of ROPS frame.

2. Lower ROPS frame over machine while aligning

mounting holes with frame mounting holes located behind fenders. ROPS leg with bracket to be positioned on right side of machine.

Figure 10

1. Seat belts 2. Tether strap

3. Secure each leg of ROPS to machine frame with a

capscrew, (2) flatwashers and a flange lock nut previously removed (Fig. 12). Shorter capscrew used to secure right leg of ROPS frame. Capscrew heads to be positioned outward. Torque fasteners to 50-60 ft–lbs.

Page 18

1. ROPS

Figure 12

Figure 14

1. Electrolyte

4. Allow approximately 20 to 30 minutes for the

electrolyte to soak into the plates. Refill as necessary to bring the electrolyte to within about 1/4 inch (6 mm) of the bottom of the fill well (Fig. 14).

Note: When operating machine, always use the seat belt and ROPS together.

Activating and Charging the Battery

Use only electrolyte (1.265 Specific Gravity) to fill battery initially.

1. Remove the battery from the machine.

Important Do not add electrolyte while the battery is in

the machine. You could spill it, causing corrosion.

2. Clean the top of the battery and remove the vent caps

(Fig. 13).

Figure 13

1. Vent caps

3. Carefully fill each cell with electrolyte until the plates

are covered with about 1/4 inch (6 mm) of fluid.

Warning

Charging the battery produces gasses that can explode.

Never smoke near the battery and keep sparks and flames away from battery.

5. Connect a 3 to 4 amp battery charger to the battery

posts. Charge the battery at a rate of 3 to 4 amps until the specific gravity is 1.250 or higher and the temperature is at least 60F (16C) with all sells gasing freely.

6. When the battery is charged, disconnect the charger

from the electrical outlet and battery posts.

Note: After the battery has been activated, add only distilled water to replace normal loss, although maintenance–free batteries should not require water under normal operating conditions.

Warning

CALIFORNIA

Proposition 65 Warning

Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after

handling.

Page 19

Warning

Battery terminals or metal tools could short against metal tractor components causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury.

• When removing or installing the battery, do not

allow the battery terminals to touch any metal parts of the tractor.

• Do not allow metal tools to short between the

battery terminals and metal parts of the tractor.

7. Reinstall the battery to the machine.

Figure 15

1. Negative (–) 2. Positive (+)

8. First, install the positive cable (red) to the positive (+)

terminal and then the negative cable (black) to the negative (–) terminal of the battery (Fig. 15). Slide the rubber boot over the positive terminal to prevent a possible short from occurring.

Warning

Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury.

• Always disconnect the negative (black) battery

cable before disconnecting the positive (red) cable.

• Always connect the positive (red) battery cable

before connecting the negative (black) cable.

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.

Check Tire Pressure

The tires are over–inflated for shipping. Therefore, release some of the air to reduce the pressure. Correct air pressure in front and rear tires is 20 psi.

Page 20

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.

52” Rear Discharge Deck

(Model 30568)

52” Side Discharge Deck

(Model 30555)

52” Side Discharge Deck

with 9 cu. ft. Hopper

52” Side Discharge Deck

with 15 cu. ft. Hopper

62” Side Discharge Deck

(Model 30551)

62” Side Discharge Deck

with 9 cu. ft. Hopper

62” Side Discharge Deck

with 15 cu. ft. Hopper

62” Guardian Recycler Deck

(Model 30569)

72” Side Discharge Deck

(Model 30553)

Rear

Weight

Required

0 lb. 0 lb. – – –

0 lb. 215 lb. *77–6700

55 lb. 0 lb. 24–5790

0 lb. 180 lb.* *77–6700

70 lb. 0 lb. 24–5780 Rear Weight Kit 1

90 lb. 0 lb. 24–5780

Left Side Weight

Required

Weight

Part

Number

92–9670

24–5780

325–8 3253–7 3–8847 3217–9

92–8763

92–9670

& 24–5780 24–5790

325–8 3253–7 3–8847 3217–9

92–8763

Weight Description Qty.

75 lb. Wheel Weight

Bracket Kit

Rear Weight Kit

Rear Weight–35 lb.

Capscrew–1/2–13 x 2”

Lockwasher–1/2

Spacer

Nut–1/2

Weight Kit–20 lb.

75 lb. Wheel Weight

Bracket Kit

& Rear Weight Kit Rear Weight Kit

Capscrew–1/2–13 x 2”

Lockwasher–1/2

Spacer

Nut–1/2

Rear Weight Kit

Weight Kit–20 lb.

1 2

1 2 2 2 2

1 1

1 2 2 2 2

* 75 lb. wheel weight (included with 15 cu. ft. hopper) required on left wheel

Page 21

Before Operating

Check Engine Oil

Check Cooling System

Clean debris off screen and radiator/oil cooler daily, more often if conditions are extremely dusty and dirty; refer to section on Engine Cooling System.

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. Park machine on a level surface, stop engine and

remove key from ignition switch. Open hood.

2. Remove dipstick (Fig. 16), wipe clean and reinstall

dipstick. Remove dipstick and check oil level. Oil level should be up to FULL mark on dipstick

The cooling system is filled with a 50 / 50 solution of water and permanent ethylene glycol anti–freeze. Check level of coolant in expansion tank at beginning of each day before starting the engine. Capacity of cooling system is 7 quarts (6.6 l).

Caution

• If engine has been running, pressurized hot

coolant can escape when radiator cap is removed and cause burns.

1. Check level of coolant in expansion tank (Fig. 18).

Coolant level should be between the marks on side of tank.

Figure 16

1. Dipstick

3. If oil is below FULL mark, remove fill cap (Fig. 17)

and add SAE 10W–30 CD, CE, CF, CF–4 or CG–4 classification oil until level reaches FULL mark on dipstick. DO NOT OVERFILL.

Figure 17

1. Oil fill

4. Install oil fill cap and close hood.

Figure 18

1. Expansion tank

2. If coolant level is low, remove expansion tank cap and

replenish the system. DO NOT OVERFILL.

3. Install expansion tank cap.

Check Hydraulic System Fluid

The axle housing acts as the reservoir for the system. The transmission and axle housing are shipped from the factory with approximately 5 quarts (4.7 l) of high quality hydraulic fluid. Check the level of hydraulic fluid before

the engine is first started and daily thereafter.

Appropriate hydraulic fluids are listed below.

Page 22

The following list is not assumed to be all–inclusive. Hydraulic fluids produced by other manufacturers may be used if they can cross reference to find an equivalent to the products listed. Toro will not assume responsibility for damage caused by improper substitutions, so use only products from reputable manufacturers who will stand behind their recommendation.

4. Check all hoses and fittings for leaks.

Fill Fuel Tank

Danger

Universal Tractor Hydraulic Fluid

Mobil Mobil Fluid 424 Amoco 1000 Fluid Chevron Tractor Hydraulic Fluid Conoco Power-Tran 3 Exxon Torque Fluid Pennzoil Hydra–Tranz Shell Donax TD Texaco TDH

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.

1. Position machine on a level surface. Place all control in

neutral position and start the engine. Run engine at lowest possible RPM to purge the system of air. DO NOT ENGAGE PTO. Cycle steering wheel several times fully to the left and right. Raise the cutting unit to extend lift cylinders, aiming steering wheels straight forward and stop the engine.

2. Remove dipstick cap (Fig. 19) from filler neck and wipe

it with a clean rag. Screw dipstick cap finger-tight onto filler neck; then remove it and check level of fluid. If level is not within 1/2 inch (13 mm) from the groove in the dipstick (Fig. 19), add enough high quality hydraulic fluid to raise level to groove mark. Do not overfill.

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.

• Use a funnel and fill the fuel tank outdoors, in

an open area, when the engine is off and is cold. Wipe up any fuel that spills.

• Do not fill the fuel tank completely full. Add fuel

to the fuel tank until the level is 1 in. (25 mm) below the bottom of the filler neck. This empty space in the tank allows the fuel to expand.

• Never smoke when handling fuel, and stay away

from an open flame or where fuel fumes may be ignited by a spark.

• Store fuel in a clean, safety-approved container

and keep the cap in place.

1. Using a clean rag, clean area around fuel tank cap.

2. Remove cap from the fuel tank (Fig. 20).

3. Fill the 8.5 gallon (32 l) tank to within 1 inch (25 mm)

from the bottom of the filler neck with diesel fuel.

4. Install fuel tank cap tightly after filling tank.

Figure 19

1. Hydraulic system reservoir fluid/add dipstick cap

3. Thread dipstick fill cap finger-tight onto filler neck. It is

not recommended to tighten cap with a wrench.

Figure 20

1. Fuel tank cap

Page 23

Check Rear Axle

Check Bidirectional Clutch

(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. Remove check plugs from axle and make sure lubricant

is up to bottom of each hole. If level is low, remove fill plugs and add enough lubricant to bring the level up to the bottom of the check plug holes (Fig. 21 & 22).

Figure 21

1. Check plug 2. Fill plug

Lubricant

(Model 30242 only)

1. Position the machine on a level surface.

2. Rotate clutch (Fig. 23) so check plug (shown in 12

O’clock position) is positioned at 4 O’clock.

Figure 23

1. Bidirectional clutch 2. Check plug

3. Remove check plug. Fluid level should be up to hole in

clutch. If fluid level is low, add Mobil Fluid 424. Clutch should be approximately 1/3 full.

4. Install check plug.

1. Fill/check plug (one on each end of axle)

Note: Do not use engine oil (i.e. 10W30) in bidirectional clutch. Anti–wear and extreme pressure additives will cause undesirable clutch performance.

Figure 22

Page 24

Controls

Service Brakes

The left and right brake pedals (Fig. 24) are connected to the left and right front wheels. Since both brakes work independently of each other, the brakes can be used to turn sharply or to increase traction if one wheel tends to slip while operating on certain slope conditions. However, wet grass or soft turf could be damaged when brakes are used to turn sharply. To make a “quick-stop”, depress both brake pedals together. Always lock brakes together when transporting the traction unit.

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. 24) then release the pedals. To release parking brake, depress both pedals until parking brake knob retracts. Before starting the engine, however, lock arm may be disengaged from left brake pedal so both pedals work independently with each front wheel.

Traction Pedal

Traction pedal (Fig. 26) has two functions: one is to make the machine move forward, the other is to make it move rearward. Using the heel and toe of the right foot, depress top of pedal to move forward and bottom of pedal to move rearward. Ground speed is proportionate to how far pedal is depressed. For maximum ground speed, traction pedal must be fully depressed while throttle is in FAST position. Maximum speed forward is 10 mph (16 Km/hr) (approx.). To get maximum power under heavy load or when ascending a hill, have throttle in FAST position while depressing traction pedal slightly to keep engine rpm high. When engine rpm begins to decrease, release traction pedal slightly to allow rpm to increase.

1. Parking brake knob

2. Right brake pedal

1. Left brake pedal

2. Right brake pedal

Figure 24

3. Left brake pedal

Figure 26

1. Traction pedal

Figure 25

3. Lock arm

Parking Brake

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. 25) on

Page 25

Tilt Steering Control

The tilt steering control is a lever on right side of steering column (Fig. 27). Pull lever rearward to adjust steering wheel to desired fore or aft operating position and push lever forward to lock adjustment.

Figure 27

1. Tilt steering control

Caution

• Never raise cutting unit while blades are

rotating because it is hazardous.

Figure 28

1. Hydraulic Lift lever

2. PTO Switch

3. Temperature gauge

4. Fuel gauge

5. Ignition switch

6. Temperature override switch

7. Throttle

8. Hour meter

9. Engine coolant temperature

10. Glow plug indicator

11. Charge indicator

12. Oil pressure indicator

13. Lift lever lock

Temperature Gauge

The temperature gauge (Fig. 28) registers the temperature of the coolant in the cooling system. If temperature of coolant gets too high the engine will shut off automatically.

Fuel Gauge

Hydraulic LIft Lever

The hydraulic lift lever (Fig. 28) has three positions: FLOAT, TRANSPORT and RAISE. To lower cutting unit to the ground, move lift lever forward into notch in seat platform — FLOAT. The FLOAT position is used for mowing and when machine is not in operation. To raise cutting unit, pull lift lever rearward to the RAISE position. After cutting unit is raised, allow lift lever to move to the TRANSPORT position. Cutting unit must be raised when driving from one work area to another.

PTO Switch

Pull up on sleeve on toggle switch handle and move handle to ON to ENGAGE electric PTO clutch (Fig. 28). Pull up on sleeve and move handle to OFF to DISENGAGE electric PTO clutch. The only time the PTO switch should be in the ENGAGE position is when the implement is down in operating position and ready to begin operation.

The fuel gauge (Fig. 28) indicates quantity of fuel remaining in fuel tank.

Ignition Switch

Three positions: OFF, ON / Preheat and START. (Fig. 28).

Temperature Override Switch

Press and hold override switch (Fig. 28) to start engine after high temperature shut down. Use only for emergency operation.

Throttle

Throttle (Fig. 28) is used to operate engine at various speeds. Moving throttle forward increases engine speed — FAST; rearward decreases engine speed — SLOW. The throttle controls the speed of the cutter blades and, in conjunction with traction pedal, controls ground speed of the traction unit.

Page 26

–Hour Meter

The hour meter (Fig. 28) registers accumulated hours of engine operation.

Engine Coolant Temperature Warning Light

The light illuminates and engine shuts down when coolant reaches a excessively high temperature (Fig. 28).

A. Initial start up of a new machine. B. Engine has ceased running due to lack of fuel. C. Maintenance has been performed upon fuel system

components; i.e., filter replaced, separator serviced, etc. Refer to Bleeding The Fuel System.

1. Ensure parking brake is set, PTO switch is in OFF

position and lift lever is in TRANSPORT or FLOAT position. Remove foot from traction pedal and insure it is in neutral.

Glow Plug Indicator

When lit, indicates glow plugs are on (Fig. 28).

Charge Indicator

Illuminates when system charging circuit malfunctions (Fig. 28).

Oil Pressure Warning Light

The oil pressure warning light (Fig. 28) 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.

LIft Lever Lock

Lock lift lever (Fig. 28), in raised position, when performing maintenance on cutting unit.

Seat Adjusting Handle – Standard Seat

To adjust seat, loosen adjusting knobs and slide seat to desired position. Tighten knobs to lock seat in place.

2. Move throttle control to full FAST position.

3. Turn ignition switch to ON / Preheat position. An

automatic timer will control preheat for 6 seconds. After preheat, turn key to START position. CRANK ENGINE FOR NO LONGER THAN 15 SECONDS. Release key when engine starts. If additional preheat is required, turn key to OFF position then to ON / preheat position. Repeat process as required.

4. Run engine at idle speed or partial throttle until engine

warms up.

Note: Move throttle to FAST position when restarting a warm engine.

5. When engine is started for the first time, or after engine

oil change, or overhaul of engine, transmission or axle, operate the machine in forward and reverse for one to two minutes. Also operate the lift lever and PTO lever to assure proper operation of all parts. Turn power steering wheel to the left and right to check steering response. Then shut engine off and check fluid levels, check for oil leaks, loose parts and any other noticeable malfunctions.

Caution

Seat Adjusting Handle — Deluxe Seat

To adjust seat, move lever on left side outward, slide seat to desired position and release lever so it will lock in track.

Operation

Note: Determine the left and right sides of the machine from the normal operating position.

Starting/Stopping Engine

Important The fuel system must be bled if any of the

following situation have occurred.

• Shut engine off and wait for all moving parts to

stop before checking for oil leaks, loose parts or other malfunctions.

6. To stop engine, move throttle control backward to

SLOW position, move PTO switch to OFF position and rotate ignition key to OFF. Remove key from switch to prevent accidental starting.

Bleeding Fuel System

1. Park the machine on a level surface. Make sure fuel

tank is at least half full.

2. Unlatch and raise hood.

Page 27

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.

• Use a funnel and fill the fuel tank outdoors, in

an open area, when the engine is off and is cold. Wipe up any fuel that spills.

• Do not fill the fuel tank completely full. Add fuel

to the fuel tank until the level is 1 in. (25 mm) below the bottom of the filler neck. This empty space in the tank allows the fuel to expand.

• Never smoke when handling fuel, and stay away

from an open flame or where fuel fumes may be ignited by a spark.

• Store fuel in a clean, safety-approved container

and keep the cap in place.

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.

Caution

If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury.

• 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 or not.

1. Move PTO switch to OFF position and remove foot

from traction pedal so it is fully released.

3. Open the air bleed screw on the fuel injection pump

(Fig. 29).

Figure 29

1. Fuel injection pump bleed screw

4. Turn key in ignition switch to the ON position. Electric fuel pump will begin operation, thereby forcing air out around air bleed screw. Leave key in ON position until solid stream of fuel flows out around screw. Tighten screw and turn key to OFF.

2. Rotate the ignition key to START. Engine should crank.

If engine cranks, proceed to step 3. If engine does not crank, there may be a malfunction in the interlock system.

3. Raise off the seat and engage the PTO switch while the

engine is running. The engine should stop within 2 seconds. If engine stops, the switch is operating correctly; thus, proceed to step 4. If engine does not stop, there is a malfunction in the interlock system.

4. Raise off the seat and depress the traction pedal while

engine is running the PTO lever is disengaged. The engine should stop within 2 seconds. If engine stops, the switch is operating correctly; thus, proceed to step 5 If engine does not stop, there is a malfunction in the interlock system.

5. Engage the parking brake. Depress the traction pedal

while engine is running and the PTO lever is disengaged. The engine should stop within 2 seconds. If engine stops, the switch is operating correctly; thus, continue operation. If engine does not stop, there is a malfunction in the interlock system.

Operating Characteristics

Note: Normally, engine should start after above bleeding procedures are followed. However, if engine does not start, air may be trapped between injection pump and injectors; refer to Bleeding Air From Injectors.

Checking Interlock System

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

Practice driving the GROUNDSMASTER 228–D before initial operation because it has a hydrostatic transmission and its characteristics are different than some turf maintenance machines. Some points to consider when operating the traction unit and cutting unit are the transmission, engine speed, load on the cutting blades, and the importance of the brakes.

To maintain enough power for the traction unit and cutting unit while mowing, regulate traction pedal to keep engine rpm high and somewhat constant. A good rule to follow is: decrease ground speed as the load on the cutting blades increases; and increase ground speed as load on the blades decreases. This allows the engine, working with the

Page 28

transmission, to sense the proper ground speed while maintaining high blade tip speed necessary for good quality-of-cut. Therefore, allow traction pedal to move upward as engine speed decreases, and depress pedal slowly as speed increases. By comparison, when driving from one work area to another—with no load and cutting unit raised—have throttle in FAST position and depress traction pedal slowly but fully to attain maximum ground speed.

Caution

This machine produces sound levels in excess of 85dBA at the operators ear and can cause hearing loss through extended periods of exposure.

Pushing Or Towing Traction Unit

In an emergency, the traction unit can be pushed or towed for a very short distance. However, Toro does not recommend this as standard procedure.

Important Do not push or tow the traction unit faster

than 2 to 3 mph (3.2 to 4.8 Km/hr) because transmission may be damaged. IF traction unit must be moved a considerable distance, transport it on a truck or trailer. Whenever traction unit is pushed or towed, by-pass valve must be open.

1. Remove hair pin, pivot seat platform forward and locate

seat support rod in detent notch.

Wear hearing protection when operating this machine.

Caution

Adequate rear weight is necessary to prevent the rear wheels from leaving the ground. Do not stop suddenly while cutting unit or implement is raised. Do not travel down hill with the cutting unit or implement raised. If the rear wheel leaves the ground, steering is lost.

Another characteristic to consider is the operation of the brakes. The brakes can be used to assist in turning the machine; however, use them carefully, especially on soft or wet grass because the turf may be torn accidentally. The brakes can be used to great advantage to control the direction of the cutting unit when trimming along fences or similar objects. The other benefit of the brakes is to maintain traction. For example; in some slope conditions, the uphill wheel slips and loses traction. If this situation occurs, depress uphill brake pedal gradually and intermittently until the uphill wheel stops slipping; thus, increasing traction on the downhill wheel. If independent braking is not desired, engage the lever on left brake pedal with right pedal. This provides simultaneous braking at both wheels.

2. Depress and hold the pins located in the center of the

two (2) check valve assemblies in the top of the transmission (Fig. 30) while pushing or towing the machine.

Figure 30

1. Transmission check valve by–pass pins (2)

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.

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.

Page 29

Lubrication

1. Wipe grease fitting clean so foreign matter cannot be

forced into the bearing or bushing.

2. Pump grease into the bearing or bushing.

Greasing Bearings And Bushings

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. Bearings and bushings must be lubricated daily when operating conditions are extremely dusty and dirty. Dusty and dirty operating conditions could cause dirt to get into the bearings and bushings, resulting in accelerated wear. Lubricate grease fitting immediately after every washing, regardless of interval specified.

Apply a liberal coating of grease to the check valve pins once each year (Fig. 30). Also grease the bearings in the rear axle every 500 hours, or yearly, whichever comes first (not shown). The bearing and bushing lubrication points are:

• PTO universal shaft (Fig. 31)

• Lift arm pivot bushings (Fig. 32)

• Brake pivot bushings (Fig. 33)

• Brake cables (drive wheel and brake pedal ends)

(Fig. 33).

3. Wipe up excess grease.

Figure 31

• PTO tension pivot (Fig. 34)

• Rear PTO bearing (Fig. 34).

2 Wheel Drive Only

• Rear wheel spindle bushings (Fig. 35)

• Steering plate bushings (Fig. 36)

• Axle pin bushing (Fig. 36);

• Drive shaft (3) (Fig. 37)

4 Wheel Drive Only

• Tie rod ends (2) (Fig. 38)

• Cylinder rod ends (2) (Fig. 38)

• Steering pivots (2) (Fig. 38)

• Axle pivot pin (Fig. 38)

Figure 32

Page 30

Figure 33

Figure 36

Figure 34

Figure 35

Figure 37

Figure 38

Page 31

Service Interval Chart

Page 32

Maintenance

Note: Determine the left and right sides of the machine from the normal operating position.

Recommended Maintenance Schedule

Maintenance Service

Interval

After first 10 hours

After first 50 hours • Change Engine Oil and Filter

Every 50 hours

Every 100 hours

Every 200 hours

Maintenance Procedure

• Check PTO Belt Tension

• Check Fan and Alternator Belt Tension

• Change Transmission Filter

• Torque Wheel Lug Nuts

• Check Battery Fluid Level

• Check Battery Cable Connections

• Lubricate All Grease Fittings

• Lubricate Brake Cables

• Inspect Air Filter, Dust Cup, and Baffle

• Change Engine Oil and Filter

• Check Electric Clutch Gap Adjustment

• Check PTO Belt Tension

• Check Fan and Alternator Belt Tension

• Inspect Cooling System Hoses

• Check Rear Wheel Toe–In and Steering Linkage

• Change Transmission Filter

• Torque Wheel Lug Nuts

• Service Air Filter

• Drain and Clean Fuel Tank

Every 400 hours

Every 1000 hours

• Change Fuel/Water Separator Filter

• Change Rear Axle Lubricant (4 wheel drive only)

• Coat Transmission Bypass Pins with Grease

• Torque Head, Adjust Valves and Check Engine RPM

• Replace Moving Hoses

• Replace Safety Switches

• Coolant System – Flush/Replace Fluid

• Replace Hydraulic Oil

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.

Page 33

Daily Maintenance Checklist

Duplicate this page for routine use.

For the week of:

Maintenance Check Item

Check Safety Interlock Operation Check Grass Deflector in Down Position Check Brake Operation Check Fuel Level Check Engine Oil Level Check Cooling System Fluid Level Check Drain Water/Fuel Separator Check Air Filter Restriction Indicator

Check Radiator & Screen for Debris Check Unusual Engine Noises

Check Unusual Operating Noises Check Transmission Oil Level Check Hydraulic Hoses for Damage Check Fluid Leaks Check Tire Pressure Check Instrument Operation

Mon. Tues. Wed. Thurs. Fri. Sat. Sun.

Check Condition of Blades Lubricate All Grease Fittings

Touch–up Damaged Paint

= Check glow plug and injector nozzles, if hard starting, excess smoke or rough running is noted.

= Immediately after every washing, regardless of the interval listed.

= If indicator shows red

Important Refer to your engine operator’s manual for additional maintenance procedures.

Page 34

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. 39) shows red or every 400 hours (more frequently in extreme dusty or dirty conditions). Do not over service air filter.

2. Gently slide filter (Fig. 41) out of air cleaner body to reduce the amount of dust dislodged. Avoid knocking filter against air cleaner body.

Figure 39

1. Air cleaner indicator

3. Be sure cover is sealing around air cleaner body.

Servicing Air Cleaner

1. Pull latch outward and rotate air cleaner cover

counter–clockwise. Remove cover from body (Fig. 40). Clean inside of air cleaner cover.

Figure 41

1. Filter

3. Inspect filter and discard if damaged. Do not wash or reuse a damaged filter.

Cleaning Air Filter

A. Blow compressed air from inside to the outside of

dry filter element. Do not exceed 100 psi to prevent damage to the element.

B. Keep air hose nozzle at least 2” from filter and

move nozzle up and down while rotating the filter element. Inspect for holes and tears by looking through the filter toward a bright light.

4. Inspect new filter for shipping damage. Check sealing end of filter. Do not install a damaged filter.

5. Insert new filter properly into air cleaner body. Make sure filter is sealed properly by applying pressure to outer rim of filter when installing. Do not press on flexible center of filter.

6. Reinstall cover and secure latch. Make sure cover is positioned with TOP side up.

Figure 40

1. Air cleaner latch 2. Air cleaner cover

7. Reset indicator (Fig. 39) if showing red.

Cleaning 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, if necessary, clean any debris off these parts. However, it will be necessary to check and clean the screen and radiator frequently in extremely dusty and dirty conditions.

Note: If engine shuts off due to overheating, first check the radiator and screen for excessive buildup of debris.

Page 35

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.

Changing Engine Oil And Filter

Check oil level after each day’s operation or each time machine is used. Change oil and filter initially after first 50 hours of operation; change oil and filter after every 100 hours of operation thereafter. If possible, run engine just before changing oil because warm oil flows better and carries more contaminants than cold oil.

1. Position machine on a level surface.

2. Open the hood. Set drain pan under the oil pan and in

line with drain plug (Fig. 42).

3. Clean area around drain plug.

Figure 42

1. Drain plug

Figure 43

1. Oil filter

6. After oil is drained, reinstall drain plug and wipe up any

oil that is spilled.

7. Fill crankcase with oil; refer to Check Crankcase Oil.

Servicing Fuel System

Note: Refer to Fill Fuel Tank With Diesel Fuel for proper fuel recommendations.

Fuel Tank

Drain and clean fuel tank every 800 hours operation or yearly, whichever comes first. Also, drain and clean tank if fuel system becomes contaminated or if machine is to be stored for an extended period. Use clean diesel fuel to flush out the tank.

Fuel Lines and Connections

Check lines and connections every 400 hours or yearly, whichever comes first. Inspect for deterioration, damage or loose connections.

4. Remove oil drain plug and allow oil to flow into drain

pan.

5. Remove and replace oil filter (Fig. 43).

Water Separator

Drain water or other contaminants from water separator (Fig. 44) daily.

1. Place a clean container under fuel filter.

2. Loosen drain plug on bottom of filter canister. Tighten

plug after draining.

Page 36

Figure 44

1. Water separator 2. Drain plug

Replace filter canister after every 400 hours of operation.

1. Clean area where filter canister mounts.

2. Remove filter canister and clean mounting surface.

3. Lubricate gasket on filter canister with clean oil.

4. Install filter canister by hand until gasket contacts

mounting surface, then rotate an additional 1/2 turn.

Replacing Fuel Pre Filter

Replace the fuel pre filter (Fig. 45), located between fuel tank and fuel pump after every 400 operating hours or yearly, whichever occurs first.

1. Clamp both fuel lines that connect to the fuel filter so

fuel cannot drain when lines are removed (Fig. 45).

2. Loosen the hose clamps at both ends of the filter and

pull fuel lines off filter.

Figure 45

1. Fuel pre filter

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.

Bleeding Air From Injectors

Note: This procedure should be used only if fuel system has been purged of air through normal priming procedures and engine will not start; refer to Bleeding Fuel System.

1. Loosen the pipe connection to the No. 1 injector nozzle and holder assembly at injection pump.

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.

• Use a funnel and fill the fuel tank outdoors, in

an open area, when the engine is off and is cold. Wipe up any fuel that spills.

• Do not fill the fuel tank completely full. Add fuel

to the fuel tank until the level is 1 in. (25 mm) below the bottom of the filler neck. This empty space in the tank allows the fuel to expand.

• Never smoke when handling fuel, and stay away

from an open flame or where fuel fumes may be ignited by a spark.

• Store fuel in a clean, safety-approved container

and keep the cap in place.

Figure 46

1. No. 1 injector nozzle

2. Move throttle to FAST position.

3. Turn key in key switch to START position and watch

fuel flow around connector. Turn key to OFF position when solid flow is observed.

4. Tighten pipe connector securely.

5. Repeat steps on remaining nozzles.

Page 37

Alternator Belt

1. Condition and Tension – Check condition and tension

of belts (Fig. 47) after every 100 operating hours.

5. Install the new PTO belt and re–tension the pulley

spring to 2–7/8” (73 mm) (Fig. 48).

6. Tighten the jam nut (Fig. 48) and close the hood.

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.

B. If deflection is not 3/8 in. (10 mm), loosen alternator

mounting bolts. Increase or decrease alternator belt tension and tighten bolts. Check deflection of belt again to assure tension is correct.

Figure 47

1. Alternator 2. Mounting bolt

2–7/8” (73 mm)

Figure 48

1. Tensioning spring

2. Tensioning rod jam nut

3. Tension adjusting bolt

PTO Clutch Adjustment

The power take off electric clutch can be adjusted by following the following procedure:

PTO Belt

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.

2. Loosen the tensioning rod jam nut (Fig. 48).

3. Use a 1/2” wrench to tighten or loosen the belt

tensioning spring (Fig. 48). Adjust spring to a length of 2-7/8” (73 mm).

4. Tighten jam nut. To Replace Belt:

1. Turn off the engine and remove the ignition key. Set the

parking brake. Raise the hood and allow the engine to cool.

2. Loosen the tensioning rod jam nut (Fig. 48).

3. Using a 1/2” wrench, loosen the belt tensioning spring

(Fig. 48) all the way.

4. Rotate PTO pulley toward the engine and remove the

belt (Fig. NO TAG).

1. Turn engine off and remove the ignition key. Set the

parking brake. Raise the engine hood and allow the engine to cool.

2. Remove bolt, washer and nut securing nylon block and

remove nylon block (Fig. 49).

Figure 49

1. Clutch

2. .015” air gap (3)

3. Adjusting nut (3)

4. Nylon block

5. Electrical connector

6. PTO Belt

Page 38

3. Unplug clutch electric connector (Fig. 49).

4. Adjust the air gap so that a .015 inch feeler gauge slides

in between the clutch lining and friction plate with light pressure (Fig. 49). The gap can be decreased by turning the adjusting nut clockwise (Fig. 49).

5. Rotate the clutch by hand and adjust all three air gaps.

After all three gaps have been set, check all three again. Adjusting one gap can alter the other gaps.

6. Reinstall nylon block with nut, washer and bolt.

Reconnect the clutch electrical connector.

Adjusting Transmission For Neutral

The machine must not creep when traction pedal is released. If it does creep, an adjustment is required.

1. Park machine on a level surface and shut engine off.

Depress only the right brake pedal and engage the parking brake.

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.

3. Lift seat. Visually inspect traction linkage for possible

binding condition, correct if necessary and check machine operation. if condition still exists, repeat steps 1 and 2 and proceed to step 4.

4. Loosen two locknut securing pump plate so plate is free

to move (Fig. 50).

5. Start engine and rotate pump plate (Fig. 50) in either direction until wheel ceases rotation.

6. Stop engine and tighten locknuts to secure pump plate (Fig. 50).

7. Start engine and check adjustment. Repeat adjustment, if necessary.

8. Stop the engine and release right brake. Remove jack stands and lower machine to the shop floor. Test drive the machine to be sure it does not creep.

Adjusting the Parking Brake Interlock Switch

1. Turn engine off and remove the ignition key. Do not engage the parking brake.

2. Remove knob from parking brake rod and screws from steering tower cover (Fig. 51).

3. Slide cover up steering shaft to expose parking brake switch (Fig. 52).

Figure 50

1. Pump plate 2. Locknut

Figure 51

1. Steering tower cover

2. Parking brake knob/rod

4. Loosen screws and nuts securing parking brake switch to left side of steering tower (Fig. 51).

5. Align parking brake rod paddle with switch plunger (Fig. 52)

3. Switch mounting screws

4. Cover mounting screws

Page 39

Changing Hydraulic Oil And Filter

Initially, replace the hydraulic system filter after the first

.030”

full day’s operation — NOT TO EXCEED 10 HOURS. Replace the filter after every 200 hours and oil after every 1000 hours.

Figure 52

1. 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. 52, inset) . This the distance between the brake rod paddle and switch plunger housing.

7. Tighten switch mounting screws and nuts.

8. With parking brake disengaged, the switch circuit should have continuity. If there is no continuity, move

switch down slightly until there is continuity.

9. Check adjustment as follows:

• Engage the parking brake. Depress the traction pedal while engine is running and the PTO lever is disengaged. The engine should stop within 2 seconds. If engine stops, the switch is operating correctly; thus, continue operation. If engine does not stop, there is a malfunction in the interlock system.

10.Install steering tower cover and brake rod knob.

2. Parking brake rod paddle

the engine is first started and daily thereafter.

Appropriate hydraulic fluids are listed below. The following list is not assumed to be all–inclusive.

Hydraulic fluids produced by other manufacturers may be used if they can cross reference to find an equivalent to the products listed. Toro will not assume responsibility for damage caused by improper substitutions, so use only products from reputable manufacturers who will stand behind their recommendation.

Universal Tractor Hydraulic Fluid

Mobil Mobil Fluid 424 Amoco 1000 Fluid Chevron Tractor Hydraulic Fluid Conoco Power-after 3 Exxon Torque Fluid Pennzoil Hydra–Tranz Shell Donax TD Texaco TDH

Note: Fluid to operate the power steering is supplied by the hydraulic system transmission charge pump.

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.

Page 40

1. Lower cutting unit to shop floor, set parking brake, and

turn engine OFF. Block the two rear wheels.

2. Jack up both sides of the front axle and support it with

jack stands.

3. Clean the area around the hydraulic oil filter and

remove the filter (Fig. 53).

Figure 53

1. Filter

2. Return line

3. Suction line

4. Remove the tube that connects the axle housing to the

transmission and allow the oil to flow into a drain pan.

5. Install new hydraulic oil filter and connect the tube

between axle housing and transmission. Fill axle (reservoir) to proper level (approx. 5 qt); refer to Check Hydraulic System Fluid. Remove jack stands.

Figure 54

1. Traction pedal stop

3. If more adjustment is required, adjust traction rod

(Fig. 55) as follows:

• Remove capscrew and nut securing traction rod end

to pedal.

• Loosen jam nut securing rod end to traction rod.

• Rotate rod until desired length is attained.

• Tighten jam nut and secure rod end to traction pedal

with capscrew and nut removed to lock the angle of the foot pedal.

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.

7. After two minutes, check level of transmission fluid;

refer to Check Hydraulic System Fluid.

Adjusting Traction Pedal

The traction pedal can be adjusted for operator comfort or to reduce the maximum reverse speed of the machine.

1. Check the traction pedal stop adjustment. The pedal

stop (Fig. 54) should contact the frame slightly before the pump reaches full stroke.

2. To adjust pedal stop, loosen jam nuts, push down on

traction pedal and tighten jam nuts when adjustment is attained.

Figure 55

1. Rod end

2. Jam nut

3. Traction rod

4. To reduce rear speed,

Adjusting Service Brakes

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.

Page 41

The brakes should be checked for adjustment after the first 25 hours of operation and should only need adjusting after considerable use thereafter. These periodic adjustments can be performed where the brake cable connect to the bottom of the brake pedals. When the cable is no longer adjustable, the star nut on inside of the brake drum must be adjusted to move the brake shoes outward. However, the brake cables must be adjusted again to compensate for this adjustment.

1. Disengage lock arm from right brake pedal so both pedals work independently of each other.

2. To reduce free travel of brake pedals — tighten the brakes — loosen front nut on threaded end of brake cable (Fig. 56). Then tighten rear nut to move cable backward until brake pedals have 1/2 to 1 inch (13 mm to 25 mm) of free travel. Tighten front nut after brakes are adjusted correctly.

Figure 57

1. Parking brake knob 2. Mounting screw (4)

2. Slide cover up steering shaft to expose pivot bracket

(Fig. 58).

Figure 56

1. Brake cable jam nuts

Adjusting the Tilt Steering Control

If steering wheel tilt control lever must be adjusted, proceed as follows:

1. Remove knob from parking brake and screws from steering column cover (Fig. 57).

Figure 58

1. Pivot plate

2. Small nut

3. Loosen small nut, rotate pivot bracket until it tightens

large nut below (Fig. 58). Retighten small nut.

4. Reinstall steering column cover and parking brake

knob.

3. Large nut

Page 42

Changing Rear Axle Lubricant

(Model 30242 only)

After every 400 hours of operation the oil in the rear axle must be changed.

1. Position machine on a level surface.

2. Clean area around the (3) drain plugs, (1) on each end

and (1) in the center (Fig. 59).

Figure 60

1. Bidirectional clutch 2. Check plug

4. Remove check plug allowing all lubricant to flow into

drain pan.

Figure 59

1. Drain plugs (3) 2. Tie rod

3. Remove plugs allowing oil to drain into drain pans.

4. After oil is drained, apply thread locking compound on

drain plug threads and reinstall in axle.

5. Fill axle with lubricant; refer to Check Rear Axle

Lubricant.

Changing Bidirectional Clutch Lubricant

(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. Rotate clutch so check plug is positioned downward

(Fig. 60).

5. Rotate clutch so check plug is positioned at 4 O’clock.

6. Add Mobil Fluid 424 until lubricant level is up to hole

in clutch. Clutch should be approximately 1/3 full.

7. Install check plug. Note: Do not use engine oil (i.e. 10W30) in bidirectional

clutch. Anti–wear and extreme pressure additives will cause undesirable clutch performance.

Rear Wheel Toe–in

(Model 30242 only)

The rear wheels should not toe–in or toe–out when they are adjusted correctly. To check the rear wheel toe–in, measure the center–to–center distance at wheel hub height, in front and in back of the rear tires. If the wheels toe–in or toe–out, an adjustment is required.

1. Rotate the steering wheel so rear wheels are straight

ahead.

2. Remove nuts securing one tie rod ball joint to mounting

bracket on axle and disconnect ball joint from axle (Fig. 59).

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.

Page 43

Servicing Battery

Warning

CALIFORNIA

Proposition 65 Warning

Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after

handling.

The battery electrolyte level must be properly maintained and the top of the battery kept clean. lf the machine is stored in a location where temperatures are extremely high, the battery will run down more rapidly than if the machine is stored in a location where temperatures are cool.

Check the electrolyte level every 25 operating hours or, if the machine is in storage, every 30 days.

Maintain the cell level with distilled or demineralized water. Do not fill the cells above the bottom of the split ring inside each cell.

Danger

Battery terminals or metal tools could short against metal tractor components causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury.

• When removing or installing the battery, do not

allow the battery terminals to touch any metal parts of the tractor.

• Do not allow metal tools to short between the

battery terminals and metal parts of the tractor.

Warning

Incorrect battery cable routing could damage the tractor and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury.

• Always disconnect the negative (black) battery

cable before disconnecting the positive (red) cable.

• Always connect the positive (red) battery cable

before connecting the negative (black) cable.

Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns.

• Do not drink electrolyte and avoid contact with

skin, eyes or clothing. Wear safety glasses to shield your eyes and rubber gloves to protect your hands.

• Fill the battery where clean water is always

available for flushing the skin.

Keep the top of the battery clean by washing it periodically with a brush dipped in ammonia or bicarbonate of soda solution. Flush the top surface with water after cleaning it. Do not remove the fill caps while cleaning the battery.

The battery cables must be tight on the terminals to provide good electrical contact.

If corrosion occurs at the terminals, disconnect the cables, negative (–) cable first, and scrape the clamps and terminals separately. Reconnect the cables, positive (+) cable first, and coat the terminals with petroleum jelly.

Storing the Battery

If the machine will be stored more than 30 days, remove the battery and charge it fully. Either store it on the shelf on the machine. Leave the cables disconnected if it is stored on the machine. Store the battery in a cool atmosphere to avoid quick deterioration of the charge in the battery. To prevent the battery from freezing, make sure it is fully charged. The specific gravity of a fully charged battery is

1.265–1.299.

Wiring Harness Service

Prevent corrosion of wiring terminals by applying Grafo 112X (Skin-over) grease, Toro Part No. 505-47, to the inside of all harness connectors whenever the harness is replaced.

Whenever working with the electrical system, always disconnect battery cables, negative (–) cable first, to prevent possible wiring damage from short-outs.

Page 44

Fuses

Fuses are accessible under seat plate (Fig. 61).

Figure 61

1. Fuse block

Page 45

Hydraulic Schematic

HYDROSTATIC TRANSMISSION & CHARGE PUMP

800 PSI PSI

70-150

LIFT CYLINDERS

4 GAL/MIN

STEERING VALVE

.3 CID

OIL COOLER

LIFT VALVE

STEERING CYLINER

Page 46

Electrical Schematic

(D1)

DIODE

Start

B+

PROTECTION

BU BK

STARTER

B+ TO FUSIBLE LINK HARNESS

GY+BK

87a

VIO

P22–G

BKR/BK

FUEL PUMP

(D2)

LOGIC

DIODE

(HOLD)

(START)

RUN SOLENOID

R/BK

878687a

RUN ENABLE

OVER

TEMP

PKPK

OIL

ALT

PRES

L I

FUEL

L I

TEMP

YBU

GLOW

P22–F

CLUSTER GAUGE

P22–C

P22–EP22–K

YBU

OIL PRESSURE SWITCH

(LOW PRESSURE)

ENGINE

FUEL

SENDER

BKENGINE

SENDER

TEMPERATURE

IN CONTROL PANEL HARNESS

TO HIGHTEMP OVERRIDE SWITCH

(CONNECTED TO GROUND ON OVER TEMP CONDIITION)

878687a

OVER TEMP SHUT DOWN

PK GN

7.5 A F 4

OFF

RUN

15 A

F 1

VIO

START

7.5 A F 2

–7+8

N.C.

VIOORPK

GLOW

THERMO

LAMP

START

(–)

BK BK

143

GND

+ 12V

RPKW

P22–J

P22–B

ALTERNATOR

8586

(TEMPERATURE OK)

ENGINE OVER TEMP.

ENGINE

GLOW PLUGS (3)

GLOW RELAY

GN = GREEN

GY = GRAY

OR = ORANGE

PK = PINK

VIO = VIOLET

(+)

PK PK PK

(OFF)

(MOMENTARY)

KUBOTA

GLOW PLUG

CONTROLER

VIOPK

GROUNDGROUND

THE ENGINE GROUND

MARKED AS BLACK WIRE ARE

CONNECTED TOGETHER AND TO

ALL MAIN HARNESS GROUND POINTS

BATTERY

PARKING BRAKE SWITCH

878687a

PKPK

P11–A

(OFF)

SEAT SWITCH

P11–B

TIE POINTB+ON STARTER

FL3

BKGYGY

POSITIVE BATTERY CABLE

(ON)

SEAT DELAY RELAY

CAPACITOR

SEAT DELAY

NEGATIVE BATTERY CABLE

HIGHTEMP OVERRIDE

P22–A

TO OVERTEMP SHUT DOWN RELAY

CONTROL PANEL HARNESS

P22–D P22–H

PK VIO

FRAME

ENGINE

(+) (–)

(NEUTRAL) START ENABLE

NEUTRAL SWITCH

GN Y Y

PTO

(D3)

DIODE

CLUTCH

(OFF)

PTO SWITCH

/ FUSE BLOCK

OPTIONAL LIGHT

FUSIBLE LINK HARNESS

15 A

F 3

PROTECTION

SEAT SWITCH HARNESS

FL1

FL2

KEY TO WIRE COLORS

BR = BROWN

BU = BLUE

R = RED

BK = BLACK

R = RED

Y = YELLOW

W = WHITE

T = TAN

Page 47

Storage

Traction Unit

1. Thoroughly clean the traction unit, cutting unit and the engine, paying special attention to these areas:

• radiator and radiator screen

• underneath the cutting unit

• under the cutting unit belt covers

• counterbalance springs

• P.T.O. Shaft Assembly

• all grease fittings and pivot points

• remove control panel and clean out inside of the control

box

• beneath seat plate and top of transmission

2. Check the tire pressure. Inflate all traction unit tires to 20 psi.

3. Remove, sharpen and balance the cutting unit’s blades. Reinstall the blades and torque the blade fasteners to 85-110 ft-lb (115-149 Nm).

Engine

1. Drain the engine oil from the oil pan and replace the

drain plug.

2. Remove and discard the oil filter. Install a new filter.

3. Refill the engine with 4 quarts (3.8 l) of recommended

motor oil. Refer to Changing Crankcase Oil.

4. Start the engine and run at idle speed for two minutes.

5. Drain diesel fuel from the fuel tank, fuel lines, pump,

filter and separator. Flush fuel tank with clean diesel fuel and connect all fuel lines.

6. Thoroughly clean and service the air cleaner assembly.

7. Seal the air cleaner inlet and the exhaust outlet with

weather proof masking tape.

8. Check the oil filler cap and fuel tank cap to ensure they

are securely in place.

4. Check all fasteners for looseness; tighten as necessary.

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 paint on painted areas that are scratched, chipped or rusted. Repair any dents in the metal body.

7. Service the battery and cables as follows: A. Remove the battery terminals from the battery posts. B. Clean the battery, terminals and posts with a wire

brush and baking soda solution.

C. Coat the cable terminals and battery posts with

Grafo 112X skin-over grease (Toro Part No. 505-47), or petroleum jelly to prevent corrosion.

D. Slowly recharge the battery for 24 hours every 60

days to prevent lead sulfation of the battery.

Page 48

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 Toro Commercial Product (“Product”) to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first. Where a warrantable condition exists, we will repair the Product at no cost to you including diagnosis, labor, parts, and transportation. This warranty begins on the date the Product is delivered to the original retail purchaser.

* Product equipped with hour meter

Instructions for Obtaining Warranty Service

You are responsible for notifying the Commercial Products Distributor or Authorized Commercial Products Dealer from whom you purchased the Product as soon as you believe a warrantable condition exists.

If you need help locating a Commercial Products Distributor or Authorized Dealer, or if you have questions regarding your warranty rights or responsibilities, you may contact us at:

Toro Commercial Products Service Department Toro Warranty Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196 952-888-8801 or 800-982-2740 E-mail: commercial.service@toro.com

Owner Responsibilities

As the Product owner, you are responsible for required maintenance and adjustments stated in your operator’s manual. Failure to perform required maintenance and adjustments can be grounds for disallowing a warranty claim.

Items and Conditions Not Covered

Not all product failures or malfunctions that occur during the warranty period are defects in materials or workmanship. This express warranty does not cover the following:

• Product failures which result from the use of non-Toro replacement parts, or from installation and use of add-on, modified, or unapproved accessories

• Product failures which result from failure to perform required maintenance and/or adjustments

• Product failures which result from operating the Product in an abusive, negligent or reckless manner

• Parts subject to consumption through use unless found to be defective. Examples of parts which are consumed, or used up, during normal Product operation include, but are not limited to, blades, reels, bedknives, tines, spark plugs, castor wheels, tires, filters, belts, etc.

• Failures caused by outside influence. Items considered to be outside influence include, but are not limited to, weather, storage practices, contamination, use of unapproved coolants, lubricants, additives, or chemicals, etc.

• Normal “wear and tear” items. Normal “wear and tear” includes, but is not limited to, damage to seats due to wear or abrasion, worn painted surfaces, scratched decals or windows, etc.

Parts

Parts scheduled for replacement as required maintenance are warranted for the period of time up to the scheduled replacement time for that part.

Parts replaced under this warranty become the property of Toro. Toro will make the final decision whether to repair any existing part or assembly or replace it. Toro may use factory remanufactured parts rather than new parts for some warranty repairs.

General Conditions

Repair by an Authorized Toro Distributor or Dealer is your sole remedy under this warranty.

Neither The Toro Company nor Toro Warranty Company is liable for indirect, incidental or consequential damages in connection with the use of the Toro Products covered by this warranty, including any cost or expense of providing substitute equipment or service during reasonable periods of malfunction or non-use pending completion of repairs under this warranty . Except for the Emissions warranty referenced below, if applicable, there is no other express warranty. All implied warranties of merchantability and fitness for use are limited to the duration of this express warranty.

Some states d o n o t a l l o w exclusions of incidental or consequential damages, or limitations on how long an implied warranty lasts, so the above exclusions and limitations may not apply to you.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

Note regarding engine warranty: The Emissions Control System on your Product may be covered by a separate warranty meeting requirements established by the U.S. Environmental Protection Agency (EPA) and/or the California Air Resources Board (CARB). The hour limitations set forth above do not apply to the Emissions Control System Warranty. Refer to the Engine Emission Control Warranty Statement printed in your operator’s manual or contained in the engine manufacturer’s documentation for details.

Countries Other than the United States or Canada

Customers who have purchased Toro products exported from the United States or Canada should contact their T oro Distributor (Dealer) to obtain guarantee policies for your country , province, or state. If for any reason you are dissatisfied with your Distributor’s service or have difficulty obtaining guarantee information, contact the Toro importer. If all other remedies fail, you may contact us at Toro Warranty Company.

Part No. 374-0031 Rev. a