FORM NO. 3315127 MODEL NO. 30450 20001 & UP s MODEL NO. 30455~ 20001 & UP OPERATOR'S MODEL NO. 30401 20001 & UP MANUAL TOR 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 it means CAUTION, WARNING or DANGER personal safety instruction. Failure 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 — Maintenance — Before Operating — Operating Instructions ~ Schematics Seasonal Storage This manual emphasizes safety, mechanical and general product information, DANGER, WARNING and CAUTION identify safety messages.
TABLE OF CONTENTS PRODUCT IDENTIFICATION .. TABLE OF CONTENTS .. .3 SAFETY INSTRUCTIONS SAFETY AND INSTRUCTION DECALS .. 6-8 SPECIFICATIONS LOOSE PARTS CHART BEFORE OPERATING 10-14 Check Engine Ol 10 Check Cooling System . .. 11 Fill Fuel Tank vies 11 Check Hydraulic Circuit Oit "M Check Front Axle Qi Level 12 Check Rear Axle Lubricant {Model 30455 only} 12 Check Tire Pressure 13 Check Torque whereof Nuts .. 13 Check Lubricant in Gear Box . 13 Adjusting 13 Safety Doors KNOW YOUR CONTROLS .
A SAFETY INSTRUCTIONS The GROUNDS MASTER 455-D was tested and certified by TOR 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 axis when moving. Machine must be on a flat surface and / or brakes must be engaged to prevent freewheeling, 16, 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. RIGHT HAND CONSOLE (Part No, 84-1450) Koy Switch — Off, On & Star; Cutting Unit Engagement Switch Stop & Start ON FAN SHROUD (Part No. 76--8750) Esp Hands Away From Rotating Fan ON RIGHT HAND CONSOLE ( Part No.
A SAFETY AND INSTRUCTION DECALS HEIGHT OF CUT HEIGHT OF CUT ON LEFT CASTOR ARM ON RIGHT CASTOR ARM {Part No. 860720} {Part No. 86-0730} Adjusting Procedures Adjusting Procedures SPACERS it £ DANGER -, high SPEED PULLEYS AND BELTS CAN SERIOUSLY INJURE. LOW el 3152 25 335 +DO NOT OPERATE THIS UNIT UNLESS ALL SHIELDS ARE 4.4 SECURELY FASTENED. suite RANGE HEIGHT OF CUT : UNDER DECK HOVERS Replace Cover Be tore Operating ON LEFT CASTOR ARM (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 idle — 1500 rpm, high die — 3000 rpm. Oil capacity is 5.3 gts. with filter. Cooling System: Capacity is 3.5 gal. of 50/50 mixture of Peugeot recommended anti—freeze. Fuel System: 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, Squealer Width: Transport 75in. Mowing 127 in. Height: Bin. With TOPS installed 82in. Wheel Tread: (Front} 52in {Rear) 44in. Wheel Tread: 56in. Dry Weight: 2 Wheel Drive 3,450 lbs. 4 Wheel Drive 3,550 Ibs.
BEFORE OPERATING CHECK COOLING SYSTEM (Fig. 3) Capacity of system is 3.5 gal. 1. Park machine on a revel surface, Release hood latch and open heed. 2. Coolant level should above mounting tabs on degassed tank, when engine is veld. Figure ¥ 1. Degassed Tank 2. Mounting Tabs 3. H coolant is low, remove degassed tank cap and add a 50/50 mixture of water and Peugeot recommended anti-freeze. DO NOT USE WATER ONLY OR ALCOHOL/METHANOL BASE COOLANTS. IMPORTANT: Do not remove black plastic cap on degassed tank.
BEFORE OPERATING 1. Park machine on a level surface. Make sure machine has been operated so oil is warm. Release hood latch and open hood. Check level of oil by viewing sight gauge. If oil is visible in gauge, oil levels sufficient. 2. Foil levels not visible in gauge, remove cap from hydraulic oil reservoir and slowly add Mobil DTE 26 or equivalent hydraulic oil unfit level reaches middies {maximum) of sight gauge. DO NOT OVER Fill. Figure § 1. Sight Gauge 2.
BEFORE OPERATING CHECK TIRE PRESSURE The tires are over—inflated for shipping. Therefore, release some of the air to reduce the pressure, Correct air pressure in the front and rear tires is 20 psi. IMPORTANT: Maintain even pressure in all tires to assure a good and proper machine performance. DO NOT UNDER INFLATE. CHECK TORQUE OF WHEEL NUTS OR BOLTS Torque front wheel nuts to 45.
BEFORE OPERATING Figure 10" 1. Front Castor Whale 2. Lynch Pin 3. Spacers 2. Push castor spindle through front castor arm install remaining spacers onto spindle and install lynch pin to secure assembly, REAR CASTOR WHEELS 1. Remove hairpin cotter and H.O.C. pin securing rear castor pivot arm to deck bracket, Fugues 13 1. Rear Castor Pivot 2. Align the pivot arm holes with selected bracket holes in the deck frame, install H.O.L. 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 nave forward to actuate cutting unit. Center deck will engage first followed by wing decks engaging approximate wingding altar Figure 14 1. Cutting Unit Engagement 7. Coolant Temperature Switch 2. Glow Plug Indicator 3. Charge Indicator 4. Koy Switch Gauge 8. Fuel Gauge 3. Out Mater 10, Engine OH Pressure 5. Throttle Control Warning Light 8, Cutting Unit Lit 1%.
KNOW YOUR CONTROLS Axle Shift Lever (Fig.16) ~ Located on right aids of console, lever selects front drive mode. Pull knockout knob, move lever rearward for mowing operation and forward for transport operation, then release knob to lock selection. Lever must be in LO position 10 mow. Middle position (N} is for towing. IMPORTANT: On model 30455, lever must be in LO position to operate in 4—wheel drive. CAUTION: Machine must be on a flat surface and brakes engaged when shifting axle rom Hi to LO Figure 17 1.
OPERATING INSTRUCTIONS 4. Pump priming plunger until resistance is fat. Try to start engine. if engine does not start repeat step 3. Figure 19 1. Primer Plunger 2. Bleed Screw Note: It may be necessary to breed the air out of the fuel fine 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. Injection Pump Fitting CHECKING INTERLOCK SYSTEM.
OPERATING INSTRUCTIONS Warning System — |fa warning light comes on 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 at 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.
SERVICE INTERVAL CHARTS 2 Wheel Drive GM 455-D 2WD Q REFERENCE AID SERVICEABLE. L O GELLED T GREASE ROTS e s 2 HYDRAULIC OIL VERSAILLES 8 RADIATOR ACRE 3.FRONT AXLE 04 LEVEL FILL 9. AIF CLEANER. SPARSELY 10 HATER SEPARATION FILTER 5. COOLANTLEVELFRL M. BATTERY 6. FUEL DIESEL ORLY 12 TIRE PRESSURE (113 BAR13:29 95 FLUID SPECIFICATIONS/CHANGE INTERVALS.
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 it iris cracked or punctured. 2. Check air cleaner body for dents and other damage which could possibly cause an air leak.
AIR CLEANER MAINTENANCE C. Dry fighter element using warm, flowing air {160°F max}, or allow element to air-dry. Do not use compressed air or a light bulb to dry the filter element because damage could result. Compressed Air Method IMPORTANT: Do not remove plastic fin assembly because back-blowing with compressed air removes dust from beneath fins. A. Blow compressed air from inside to the outside of dry filter element. Do not exceed 100 psi to prevent damage to the element.
ENGINE MAINTENANCE DANGER Because diesel fuel is highly flammable, use caution when storing or handling 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. Sorta fueling 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. Note: Do not use water to clean engine, as damage may occur, 2. Maintaining Cooling System — Capacity of the system is 8.5 gal. Always protect cooling system with 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.
HYDRAULIC MAINTENANCE 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 can be used in the hydraulic system, IMPORTANT: Using other filters may void the warranty, and could cause component failure or premature west. 1. Turn engine off, release hood latch and raise hood. 2. Clean area around filter mounting area (Fig. 43).
HYDRAULIC MAINTENANCE 6. Wing deck cutting unit Counterbalance normal setting is approximately 350400 psi @ high Die and when oit is warm. Figure & 1. Chars Treasure 1. Counterintelligence Circuit resting Circe 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 Conjugation 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 oil in the front axis must be changed. Figure 50 1, Drain Plugs {3) 1. Position machine on a level surface. 2. Clean area around the drain plug (Fig. 49). 3. Remove plugs allowing oil to drain into drain pans.
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. To reduce free travel of brake pedals, tighten newton brake rod adjuster, 1/2 turn at a time, until desired "Free play” in pedal is achieved.
ELECTRICAL MAINTENANCE 2 croon 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 1o 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. ACC Fuse 3.
CUTTING UNIT MA 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 5. Remove (2) cap screws, flat washers and flange nuts securing ball joint mounts to castor arms on cutting unit. Figure 8 3. Ball Joint Mount 4. Caps crows & Washers 1, Push Arm 2. Castor Arm €. Roll the cutting unit away from the traction unit. Alternate Method 1. Lower curling unit to the ground, sel parking brake and stop engine. 2. Disconnect (3) hydraulic lines (quick couplets) and wire harness at rear of deck. 3.
CUTTING UNIT MAINTENANCE % 2. Rotate threaded rod to raise or lower edge of door until is even or 1/4" higher then lower edge of door guide when wing decks are in the fully raised, transport position. 3. Tighten jams nuts to lock adjustment. CAUTION Check for proper operation of the safety doors sate 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 +.
CUTTING UNIT MAINTENANCE 6. Check adjustment on other adjusters and repeat procedure if required. REPLACING DRIVE BELTS (Fig. 65~ 68) The blade drive belts are very durable, but after many hours of use, the belts will show signs of wear. Signs of sworn belt are: squealing when belt is rotating, blades slipping when cutting grass, frayed edges, burn marks and cracks. Replace a belt if any of these conditions are evident, 1. Lower cutting unit to the shop floor.
CUTTING UNIT MAINTENANCE ADJUSTING DECK CLUTCH (Fig. 69) The deck clutches are adjustable to ensure proper engagement and blade braking. Check clutch adjustment after every 250 hours of operation and adjust if required. 1. To adjust clutch, tighten or loosen lockouts on flange studs. 2. Check adjustment by inserting feeler gauge thru slots next to flange studs. 3. The proper disengaged clearance between the clutch plates is .011 — .021 inches.
CUTTING UNIT MAINTENANCE Figure 72 1. Castor whale 3. Bearing (2) 2. Roar Castor Pivot Arm 4. Oaring Spacer 2. Remove bearing from wheel hub and allow bearing spacer to fail out. Remove bearing from apposite 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. Side bearing spacer into wheel hub.
CUTTING UNIT MAINTENANCE SHARPEN AT THIS ANGLE ONLY / END VIEW Figure 75 4, To check blade for being straight and parallel, lay blade on a level surface and check its ends, Ends of blade must be slightly lower than the center, and cutting edge must be lower than the heel of the blade, This blade will traduce good duality of cut and require minimal power from the engine.
The Jun Promise A ONE YEAR LIMITED WARRANTY The Toto Company promises 1o repair your TOR Product if defective in materials or workmanship. The following rime periods from the date of purchase apply. Commercial Products 1 Year The costs of pares and favor are included. but the customer pays the transportation costs on chalk rotary movers with crusting unit width of less than 25° % It you feel your TOR product is defective and wish to rely on The Toto Promise, the following procedure is recommended: 1.