MODEL NO. 30450— 40001 & UP MODEL NO. 30455— 40001 & UP MODEL NO. 30401~ 40001 & UP FORM NO. 3316248 OPERATOR’S MANUAL To understand this product, and for safety and optimum performance, read this manual before starting the engine. Pay special attention to SAFETY INSTRUCTIONS highlighted by this symbol. A 1t means CAUTION, WARNING or DANGER personal safety instruction. Allure to comply with the instruction may result in personal injury.
FOREWORD This operator's manual has instructions on safety, proper set—up and operation, adjustments and maintenance. Therefore, anyone involved with the product, including the operator, should read and understand this manual. Major sections are; — Safety Instructions Before Operating ~ Operating Instructions Maintenance — Schematics — Seasonal Storage This manual emphasizes safety, mechanical and general product information.
TABLE OF CONTENTS PRODUCT IDENTIFICATION TABLE OF CONTENTS PPN SAFETY INSTRUCTIONS SAFETY AND INSTRUCTION DECALS SPECIFICATIONS underpinned LOOSE PARTS CHART .. BEFORE OPERATING . Check Engine Ol .. Check Cooling System Fill Fuel Tank . Check Hydraulic Circuit Oil Heck Front Axis Ol Level Check Rear Axle Lubricant (Model 30455 only} 12 Check Tire Pressure Check Morgue of Wheel Nuts Check Lubricant in Gear Bok Adjusting .. Safety Doors i, KNOW YOUR CONTROLS OPERATING INSTRUCTIONS .
A SAFETY INSTRUCTIONS The GROUNDS MASTER 455-D was tested and certified by ROTOR for compliance with the specifications of the American National Standards institute. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern, and proper training of the personnel involved in the operation, transport, maintenance, and storage of the machine.
A SAFETY INSTRUCTIONS 15. Traverse slopes carefully. Do not start or stop suddenly when traveling uphill or downhill. Never shift axle when moving. Machine must be on a flat surface and / or brakes must be engaged to prevent freewheeling. 18. Operator must be skilled and trained in how to drive on hillsides, Failure to use caution on slopes or hills may cause loss of control and vehicle to tip or roll possibly resulting in personal injury or death. 17.
A SAFETY AND INSTRUCTION DECALS The following safety and instruction decals are affixed to the traction unit. If any decal becomes illegible or damaged, install a new decal, Part numbers are listed below and in your Parts Catalog. CENTER HOT LEFT RIGHT HAND CONSOLE ON RIGHT HAND CONSOLE ( Part No. 84-1450 ) { Part No.
A SAFETY AND INSTRUCTION DECALS HEIGHT OF CUT HEIGHT OF CUT ON LEFT CASTOR ARM {Part Na. 88—0720) Height-of-cut Adjusting Procedure SPACERS g 2gaafr : MOPES 4 8 | LOW e 115225335 HIGH RANGE HEIGHT OF CUT i ON LEFT CASTOR ARM (Part No. 860780} Thought-of-Cut Adjusting Procedure ON RIGHT CASTOR ARM (Part No. 86-0730) Height—of Cut Adjusting Procedure £ DANGER »HIGH SPEED PULLEYS AND BELTS CAN SERIOUSLY INJURE »DO NOT OPERATE THIS UNIT UNLESS ALL SHIELDS ARE SECURELY FASTENED. UNDER DECK COVERS {Part No.
SPECIFICATIONS TRACTION UNIT Engine: Peugeot, four—cycle, four cylinder, 1.9 liter: {1900 cc) displacement, liquid cooled diesel engine. 23.5:1 compression ratio. Low die — 1800 rpm, high idle ~ 3000 rpm. Oil capacity is 5.3 gts. with filter. Cooling System: Capacity is 3.5 gal. of50/50 mixture of Peugeot recommended anti—freeze. Fuel Stern: Capacity is 14 gal. diesel fuel. Hydraulic System: Reservoir capacity is 6.5 gal. Replaceable spin—on filter element, Traction System: Ground speed: Low Range; 0 -6.
SPECIFICATIONS GENERAL SPECIFICATIONS (approx.): Overall Length; With deck installed 134in: Overall Width: Transport 7S in. Mowing 127 in Height: 58in, With TOPS installed 82in. Wheel Tread: {Front) §2in. {Rear} 44in. Wheel Tread: 56in. Dry Weight: 2 Wheel Drive 3,450 fos. 4 Wheel Drive 3,550 Ibs.
CHECK COOLING SYSTEM (Fig. 3) Capacity of system is 3.5 gal. 1. Park machine on a level surface. Release hood latch and open had. 2. Check coolant level. Coolant level should above mounting tabs on degassed tank, when angina is cold: Figure 3 2. Mounting Tabs 3. If coolant is low, remove degassed tank cap and add a 50/80 mixture of water and Peugeot recommended anti—freeze. DO NOT USE WATER ONLY OR ALCOHOLICALLY BASE COOLANTS. IMPORTANT: Do not remove black plastic cap on degassed tank. 4.
BEFORE OPERATING 1. Park machine on a level surface. Make sure machine has been operated so off is warm. Release hood latch and open hood. Check level of oil by viewing sight gauge. f oil is visible in gauge, ol levels sufficient. 2. Foil level is not visible in gauge, remove cap from hydraulic oil reservoir and slowly add Mobil DTE 26 or equivalent hydraulic-lunatic level reaches middle {maximum) of sight gauge. DO NQT OVER FILL. Figure § 1. Sight Gauge 2.
BEFORE OPERATING CHECK TIRE PRESSURE ADJUSTING HEIGHT ~OF-CUT (Fig. 10-12) The height—of—cut is adjustable from 1 10 5 inches in incrementalists. Positioning the castor wheel axles in the top holes of the castor forks or pivots (See chart. IMPORTANT: Maintain even pressure in all fires to | below) allow slow range height—of—cut settings from 1 assure a good quality—of—cut and proper machine to positioning the castor wheel axles ir} the performance. DO NOT UNDER INFLATE.
Figure 10 3. Spacers 4. Washer {center deck only) 1. Front Castor Hoe! 2. Lynch Pin REAR CASTOR WHEELS 1. Remove hairpin cotter and H.O.C. pin securing rear castor pivot arm to deck bracket. Figure 11 1. Rear Castor Pivot 2. Align the pivot arm holes with selected height—of—cut bracket holes in the deck frame, install H.0.C. pin and secure with hairpin cotter. REAR DECK STRAPS 1.
KNOW YOUR CONTROLS Cutting Unit Engagement Switch (Fig. 14) — Used to start and stop cutting unit operation. Lift switch and move forward to-actuate cutting unit Center deck wilt engage first followed by wing decks engaging approximately ane second later. Figure 14 1. Cutting Unit Engagement 7. Coolant Temperature Switch Gauge 2. Glow Pius indicator 8. Fuel Gauge 3. Charge indicator 8. Hour Meter 4. Koy Switch 10, Engine Oil Pressure 8, Throttler Contort Warning Light 6, Cutting Unit Lift 11.
KNOW YOUR CONTROLS Axle Shift Lever (Fig.18) — Located on right side of Parking Brake Latch {Fig. 17) — Knob nonetheless console, lever selects front drive mode, Pull knockout of console actuates parking brake lock. To engage knob, move lever rearward for mowing operation and parking brake, connect pedals with locking pin, push forward for transport operation, then release knob to down on both pedals and pull parking brake latch out. lock selection. Lever must be in LO position fo mow.
& Pump priming plunger until resistance is felt: Try to start engine. If engine does not start repeat step 3. Figure 19 1. Primer Plunger 2. Bled Screw Note: It may be necessary fo bleed the air out of the fugal line between the fuel filter / water separator and the injection pump. To do this, loosen the fitting on the injection pump (Fig. 20} and repeat bleeding procedure. Figure 20 1. Inaction Pump Fitting CHECKING INTERLOCK SYSTEM.
OPERATING INSTRUCTIONS Warning System = {fa waning light comes o during operation, stop the machine immediately and correct the problem before continuing operation. Serious damage could occur if the machine Is operated with a malfunction, Mowing — When you are af the area to be mowed, release cutting unit transport latches. Move axle shift lever rearward to Mow position and throttle to FAST so engine is running at maximum speed. Lift engagement switch and move forward to engage curling units.
SERVICE INTERVAL CHARTS 2 Wheel Drive GM 455-DOWDY Q%K REFERENCE AID SERVICEABLE. LIFELESSNESS RESPONDENTS remorse 2.0 OIL LEVEL, & RADIATOR SCREECH L PREFRONTAL O LEVELER % AR CLEANER Lr war 1 HATER SEPARKTGRFUELALTER COCLARTLEVELRRL PRESSURE s anus s FLUB OVERSIMPLIFICATION INTERVALS sk v |G RIPE [oioAi0y | Gt Seaside s onh, 210, 4 Wheel Drive GM 455-D 4WD QUICK REFERENCE AID SERVICEABLE s 3, ENGINE OiL Leveler 7 MEWS 2.
AIR CLEANER MAINTENANCE A CAUTION Before servicing or making adjustments to the machine, stop engine and remove key from the switch. GENERAL MAINTENANCE PRACTICES Inspect air cleaner and hose periodically to maintain maximum engine protection and to ensure maximum service life. 1. Assure hose between air cleaner and intake manifold is clamped securely in place. Replace the hose if it is cracked or punctured. 2. Check air cleaner body for dents and other damage which could possibly cause an air leak.
AIR CLEANER MAINTENANCE Compressed Air Method IMPORTANT: Do not remove plastic fin assembly because back—blowing with compressed air removes dust from beneath fins. A. Blow compressed alr 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 one inch from pleated paper, and move nozzle up and down while rotating the filter element. Inspect element when dust and dirt are removed; refer to Inspecting Filter Element, page 23.
ENGINE A DANGER Because diesel fuel is highly flammable, use caution when storing or handing it Do not smoke while filling the fuel tank. Do not fill fuel tank while engine Is running, hot, or when machine is in an enclosed area. Always fill fuel tank outside and wipe up any spilled diesel fuel before starting the engine. Store fuel ina clean, safety—approved container and keep cap in place. Use dies! fuel for the engine only; not for any other purpose.
ENGINE MAINTENANCE Note: Upper portion of fan shroud may be easily unbolted from machine to simplify cleaning. D. Install rear screen and tighten knobs, Nita: Do not use water to clean engine, as damage may occur 2. Maintaining Cooling System -~ Capacity of the systems 3.5 gal. Always protect cooling systematize 50/50 solution of water and Peugeot recommended anti—freeze. DO NOT USE WATER ONLY IN COOLING SYSTEM. A. After every 100 operating hours, tighten hose connections. Replace any deteriorated hoses. B.
HYDRAULIC MAINTENANCE 5 s Figure 42 1. Sight Gauge REPLACING HYDRAULIC FILTER (Fig. 43) Initially, change filter after the first 50 operating hours, thereafter, every 500 operating hours or annually, whichever comes first, Only the Toto replacement filter (Part No 863010} can be used in the hydraulic system. IMPORTANT: Use of any other filter may void the warranty on some components. 1. Turn engine off, release hood latch and raise hood. 2. Clean area around filter mounting area (Fig.
HYDRAULIC MAINTENANCE 6. Wing deck cutting unit Counterbalance normal setting is approximately 350400 psi @ high Idle and when oil is warm, Figure 45 . Charge Pressure Figure 46 1. Counterbalance/Lift Circuit 2. Tearing Circuit Figure 47 1. Counterbalance (Wing Docks) ADJUSTING TRACTION DRIVE FOR NEUTRAL (Fig. 48) 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, shut engine off and move shift lever to “HI" position.
AXLE MAINTENANCE A CAUTION & Before servicing or making adjustments to the machine, stop engine and remove key from the switch. CHANGING FRONT AXLE LUBRICANT (Fig. 49) After every 500 hours of operation the ofl in the front axis must be changed. 1. Position machine on a level surface. figure 5:) 2. Clean area around the drain plug (Fig. 49). 1. Drain Plugs (3) 3.
BRAKE MAINTENANCE ADJUSTING SERVICE BRAKES (Fig. 52) Adjust the service brakes when there is more than of “free travel” of the brake pedal, or when the brakes do not work effectively. Free travel is the distance the brake pedal moves before braking resistance is felt. 1. Storefront travel of brake pedals, tighten newton brake rod adjuster,1/2 turn at a time, until desired “free play” in pedal is achieved. PT.O.
A CAUTION Before servicing or making adjustments to the machine, stop engine and remove key from the switch. BATTERY CARE IMPORTANT: Before welding on the machine, disconnect ground cable from the battery to prevent damage to the electrical system. Note: Check battery condition weekly or after every 50 hours of operation. Keep terminals and entire battery case clean because a dirty battery will discharge Figure 56 slowly. To clean the battery, wash the entire case with 1.ACCFuse 3.
CUTTING UNIT MAINTENANCE A CAUTION ; To prevent accidental starting of the engine, while performing maintenance, shut engine off and remove key from ignition switch. GENERAL MAINTENANCE Note: Although not required for normal maintenance procedures, the cutting unit may be pivoted (stilted upright position, Should you desire to tilt:the cutting unit, use the following procedure: To Pivot (Tilt) Cutting Unit Upright: 1.
CUTTING UNIT MAINTENANCE 8. Remove (4) cap screws, flat washers and flange nuts securing ball joint mounts to castor arms on cutting unit. Figure 59 1. Push Arm 3. Baal Joint Mount 2, Castor Arm 4. Caps crows & Washers 6. Roll the cutting unit away from the traction unit. Alternate Method 1. Lower center and wing cutting units to the ground, set parking brake and stop engine. 2. Disconnect (3) hydraulic lines {quick couplets) and wire harness at rear of deck. 3.
CUTTING UNIT MAINTENANCE A CAUTION Check for proper operation of the safety doors each time the deck is cleaned and repair as needed, BLADE ADJUSTMENT (Fig. 62-63) To assure proper operation of the cutting unit, there must be .25 +.12" clearance between the tips of the wing and center cutting unit blades. 1. Raise cutting unit so blades are visible and bock center deck section so it cannot fall accidentally. Wing decks must be horizontal to center cutting unit. 2.
CUTTING UNIT MAINTENANCE To Remove Wing Deck Belts A WARNING dieter pulley spring goaded, use caution when relieving spring tension on wing belt, 2. To relieve tension on wing belt, pull back on idler pulley until holes in idler adjuster tube and tube sleeve are aligned. Thread a cap screw into holes retaining parts. Figure 65 1. Spring Loaded Tidier Pulley 2. Stationary Tidier Pulley 3. Remove hair pin cotter securing clutch rod to front of cutting deck and disconnect rod from deck.
CUTTING UNIT MAINTENANCE ADJUSTING DECK CLUTCH (Fig. 69) 8. Inspect castor spindle for wear and replace it if damaged. The deck clutches are adjustable to ensure proper engagement and blade braking. Check clutch 7. ‘Push castor spindle ‘through bushings and adjustment after every 250 hours of operation and mounting tube. Slide spacer(s) onto spindle, Install adjust if required. lyncher pin on castor spindle fo retain all parts in place. 1. To adjust clutch, tighten or loosen lockouts on flange studs. 2.
CUTTING UNIT MAINTENANCE Figure 72 3. Oaring (2) 4. Bearing $pacer 1, Castor whole 2, Rear Caster Pivot Arm 2. Remove bearing from whee! hub and allow bearing spacer to fall out. Remove bearing rom opposite side of wheel hub. 3. Check the bearings, spacer and inside of wheel hub for wear. Replace defective parts. 4. To assemble the castor wheel, push bearing into wheel hub. Slide bearing spacer into wheel hub.
CUTTING UNIT MAINTENANCE 2. Inspect curling edges of all blades, Sharpen the cutting edges if they are dull or nicked. Sharpen only the top of the cutting edge and maintain the original cutting angle to make sure of sharpness (Fig. 78). The blade will remain balanced if same amount of metal is removed from both cutting edges. SHARPEN AT THIS ANGLE ONLY. s END VIEW Figure 75 4.
ALY Bhe Cory Promise A LIMITED WARRANTY The Toto Company promises 1o repair your Model 30450 or 30455 TOR GROUNDSMASTER® MOWER, and its cutting unit, if defective in materials or workmanship. The following time periods from the date of purchase apply: Delta 30450 or 30455 .. Twe Years or 1500 operational hours, whichever comes first. The costs of parts, labor and transportation are included.
