Form No. 3327–462 Groundsmaster 455–D Traction Unit & Cutting Unit Model No. 30455TS—Serial No.
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 - Schematics - Operating Instructions - Seasonal Storage This manual emphasizes safety, mechanical and general product information. DANGER, WARNING and CAUTION identify safety messages.
TABLE OF CONTENTS IDENTIFICATION AND ORDERING . . . . . . . . . . . . . 2 ENGINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 24 SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 3 Engine and Oil Filter . . . . . . . . . . . . . . . . . . . . . . . 24 SAFETY AND INSTRUCTION DECALS . . . . . . . . . . 6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Engine Cooling System . . . .
SAFETY INSTRUCTIONS 11. Seating capacity is one person. Therefore, never carry passengers. 2. Never allow children to operate the machine. Do not allow adults to operate machine without proper instruction. Only trained operators who have read this manual should operate this machine. 12. Do not run engine in a confined area without adequate ventilation. Exhaust fumes are hazardous and could possibly be deadly. 3. Never operate the machine when under the influence of drugs or alcohol. 13.
SAFETY INSTRUCTIONS 34. Do not overspeed the engine by changing governor setting. To assure safety and accuracy, have an Authorized Toro Distributor check maximum engine speed. 22. Do not touch engine, muffler or exhaust pipe while engine is running or soon after it is stopped. These areas could be hot enough to cause burns. 23. If cutting deck strikes a solid object or vibrates abnormally, stop immediately, turn engine off, set parking brake and wait for all motion to stop. Inspect for damage.
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. ON RIGHT HAND CONSOLE ( Part No. 84-1450 ) Key Switch - Off, On & Start; Cutting Unit Engagement Switch - Stop & Start ON RIGHT HAND CONSOLE ( Part No.
SAFETY AND INSTRUCTION DECALS ON REAR OF TOWER ( Part No. 84-1470 )* Operating & Safety Instructions ON RIGHT HAND CONSOLE FRONT Part No. 93-7342 Quick Reference Aid ON Access Panel (Part No. 93-9426) High Pressure Hydraulic Hoses ON AIR CLEANER SUPPORT (Part No. 83-9150) Do Not Use Starting Fluid ON LEFT FLOOR PLATE (Part No. 92-1370) Parking Requirements ON Lower PTO Pulley (Part No.
SPECIFICATIONS TRACTION UNIT Warning Lights: Glow plug indicator Engine oil pressure warning Engine coolant temperature warning Charge indicator Water in fuel Low water indicator Engine: Peugeot, four-cycle, four cylinder, 1.9 liter (1900 cc) displacement, liquid cooled diesel engine. 23.5:1 compression ratio. Low idle - 1600 rpm, high idle - 2800 ± 30 rpm. Oil capacity is 5.3 qts. with filter. Cooling System: Capacity is 3.5 gal. of 50/50 mixture of Peugeot recommended anti-freeze.
LOOSE PARTS CHART Description Qty. Ignition keys 2 Operator’s Manual 2 Parts Catalog 1 Use Read before operating the machine. BEFORE OPERATING CAUTION 1 Before servicing or making adjustments to the machine, stop engine and remove key from the switch. CHECK ENGINE OIL (Fig. 1 & 2) Crankcase capacity is 5.3 qt. with filter. 1. Park machine on a level surface. Release hood latch and open hood. Figure 1 1. Dipstick / Tube Cap CHECK COOLING SYSTEM (Fig. 2) Capacity of system is 3.5 gal. 1 1.
BEFORE OPERATING CHECK HYDRAULIC CIRCUIT OIL (Fig. 4) 3. If coolant is low, remove degasser tank cap and add a 50/50 mixture of water and Peugeot recommended anti-freeze (Toro Part No. 93-7213). DO NOT USE WATER ONLY OR ALCOHOL/METHANOL BASE COOLANTS. The machines reservoir is filled at the factory with approximately 6.5 gallons of high quality hydraulic fluid. Check the level of hydraulic fluid before the engine is first started and daily thereafter. Appropriate hydraulic oils are listed below.
BEFORE OPERATING groove mark. DO NOT OVERFILL by more than 1/2 inch above groove. 1. Park machine on a level surface and stop engine. 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 level is sufficient. 1 2. If oil level is not visible in gauge, remove cap from hydraulic oil reservoir and slowly add a high quality hydraulic oil until level reaches middle (maximum) of sight gauge.
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 quality-of-cut and proper machine performance. DO NOT UNDER INFLATE. CHECK TORQUE OF WHEEL NUTS OR BOLTS 1 WARNING Figure 8 1.
KNOW YOUR CONTROLS Cutting Unit Engagement Switch (Fig. 10) - Used to start and stop cutting unit operation. Lift switch and move forward to actuate cutting unit. Center deck will engage first followed by wing decks engaging approximately one second later. Engine Coolant Temperature Warning Light (Fig. 10) -The red light illuminates and the engine stops when temperature of coolant exceeds 230 F. Water in Fuel Indicator (Fig. 10) - Indicates when there is water in fuel. Seat (Fig.
KNOW YOUR CONTROLS Axle Shift Lever (Fig.12) - Located on right side of console, lever selects front drive mode. Pull out lockout knob, move lever rearward for mowing operation and forward for transport operation, then release knob to lock selection. Lever must be in LO position to mow. Middle position (N) is for towing. Parking Brake Latch (Fig. 13) - A knob on the left side of console actuates parking brake lock.
OPERATING INSTRUCTIONS STARTING AND STOPPING 1. Sit on the seat, keep foot off traction pedal. Assure parking brake is engaged, traction pedal is in NEUTRAL and cutting unit engagement switch is in the DISENGAGED position. 1 2. Turn ignition switch to ON position. When glow plug indicator light goes off, engine is ready to START. 3. Turn ignition key to START. Release key when engine starts. 4. To stop, disengage and move all controls to NEUTRAL and set parking brake.
OPERATING INSTRUCTIONS 6. Engage parking brake and depress the traction pedal while engine is running and the cutting unit engagement switch 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. 7. Raise off the seat and depress the traction pedal while engine is running and the cutting unit engagement switch is DISENGAGED.
OPERATING INSTRUCTIONS OPERATING TIPS Mow At Proper Intervals - Under most normal conditions you'll need to mow approximately every 4-5 days. But remember, grass grows at different rates at different times. This means that in order to maintain the same height-of-cut, which is a good practice, you'll need to cut more frequently in early spring; as the grass growth rate slows in mid summer, cut only every 8-10 days.
SERVICE INTERVAL CHART DTE 15M 18
LUBRICATION GREASING (Fig. 17-25) The traction unit and cutting unit have grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. If machine is operated under normal conditions, lubricate all grease fittings after every 25 hours of operation. Lubricate all grease fittings immediately after every washing, regardless of interval listed. 1. The grease fittings that must be lubricated are: Lift arm pivot (2), lift cylinder (4), brake arm pivots (2) (Fig.
LUBRICATION Figure 24 Figure 22 Figure 23 Figure 25 20
DAILY MAINTENANCE CHECKLIST Daily Maintenance: (duplicate this page for routine use) Check proper section of Operator's Manual for fluid specifications Daily Maintenance Check For Week Of _________________ Maintenance Check Item MON Safety Interlock Operation Brake Operation Engine Oil Level Fuel Level Cooling System Fluid Level TUES WED THURS FRI SAT SUN Drain Water/Fuel Separator Air Filter Restriction Indicator Radiator & Screen for Debris1 Unusual Engine Noises2
MAINTENANCE SCHEDULE Minimum Recommended Maintenance Intervals Maintenance Procedure Inspect Air Filter, Dust Cup and Baffle Lubricate All Grease Fittings Check Cutting Unit Gear Box Oil Level Maintenance Interval & Service Every 50hrs Every 100hrs Every 200hrs Every 400hrs Every 800hrs Change Engine Oil and Filter Check Battery Level/Cable Connections Inspect Cooling System Hoses Inspect PTO and Cutting Unit Belts Check Electric Deck Clutches Adjustment Check Electric PTO Clutch Adjustment
AIR CLEANER MAINTENANCE CAUTION Before servicing or making adjustments to the machine, stop engine and remove key from the switch. 1 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 filters when ever air cleaner indicator (Fig. 26) shows red or every 400 hours (more frequently in extreme dusty or dirty conditions). Do not over service air filter. Figure 28 1.
ENGINE MAINTENANCE FUEL SYSTEM (Fig. 31) CAUTION Fuel Tank Drain and clean fuel tank every 800 hours of 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 fuel to flush out the tank. Before servicing or making adjustments to the machine, stop engine and remove key from the switch. ENGINE OIL AND FILTER (Fig.
ENGINE MAINTENANCE 1. Unscrew bottom filter cap from filter assembly. Remove cap, gaskets, o ring and filter from assembly. Note position of gaskets and o ring when disassembling from filter. D. Install rear screen and tighten knobs. IMPORTANT: Do not use water to clean engine, as damage may occur. 2. Maintaining Cooling System - Capacity of the system is 3.5 gal. Always protect cooling system with a 50/50 solution of water and Peugeot recommended anti-freeze. DO NOT USE WATER ONLY IN COOLING SYSTEM. A.
HYDRAULIC MAINTENANCE CAUTION Before servicing or making adjustments to the machine, stop engine and remove key from the switch. CHANGING HYDRAULIC OIL (Fig. 35 & 36) 1 Change hydraulic oil filter initially after the first 50 hours of operation, thereafter change hydraulic oil and filter after every 800 operating hours. If oil becomes contaminated, contact your local TORO distributor because the system must be flushed. Contaminated oil looks milky or black when compared to clean oil. 1. Sight Gauge 1.
HYDRAULIC MAINTENANCE CHECKING HOSES HYDRAULIC LINES AND 6. Wing deck cutting unit Counterbalance normal setting is approximately 350-400 psi @ high Idle and when oil is warm. Check hydraulic lines and hoses daily for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration and chemical deterioration. Make all necessary repairs before operating. WARNING Keep body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid.
HYDRAULIC MAINTENANCE ADJUSTING TRACTION DRIVE FOR NEUTRAL (Fig. 42) 4. Start engine and rotate cam hex in either direction until wheel ceases rotation. The machine must not creep when traction pedal is released. If it does creep, an adjustment is required. WARNING 1. Park machine on a level surface, shut engine off and move shift lever to HI" position. Depress only the left brake pedal and engage the parking brake.
100 PSI 1.5 GPM (6.9 BAR) (5.66 LITERS/MIN) 12.6:1 REAR AXLE REAR MOTOR 3 2.01 IN /REV (32.9 CC/REV) OVER-RUNNING CLUTCH TEST PORT FRONT AXLE 32.8/15.4 TEST PORT T B P A ENGINE 3000/1600 RPM FRONT MOTOR 3 .913 IN /REV (15.0 CC/REV) 110 PSI (7.6 BAR) 6000 PSI (408 BAR) 6000 PSI (408 BAR) 3 1.50 IN /REV (25.0 CC/REV) FORWARD 16.2 GPM MAX (61 LITERS/MIN MAX) O I 100 MESH STRAINER 3 .31 IN /REV (5.08 CC/REV) (14.93 LITERS/MIN) 3.
AXLE MAINTENANCE CAUTION Before servicing or making adjustments to the machine, stop engine and remove key from the switch. CHANGING FRONT AXLE LUBRICANT (Fig. 43) 1 After every 800 hours of operation the oil in the front axle must be changed. Figure 44 1. Position machine on a level surface. 1. Drain Plugs (3) 2. Clean area around the drain plug (Fig. 43). CHANGING BIDIRECTIONAL CLUTCH LUBRICANT (Fig. 45) After every 800 hours of operation the oil in the clutch housing must be changed. 1.
AXLE MAINTENANCE REAR WHEEL TOE-IN (Fig. 46) E. Tighten clamp securing ball joint to tie rod. F. Torque ball joint nut to 40 ft-lb. and install cotter pin. After every 800 operating hours or annually, check rear wheel toe-in. 1. Measure center-to-center distance (at axle height) at front and rear of steering tires. Front and rear measurements must be within 1/8 in. of each other. 3. To adjust proceed as follows: A. Remove cotter pin and nut securing one of the tie rod ball joints to steering arm.
P.T.O. MAINTENANCE CAUTION Before servicing or making adjustments to the machine, stop engine and remove key from the switch. ADJUSTING P.T.O. BELT (Fig. 48-49) 1 Re-tension P.T.O. belt (Fig. 49) initially after the first 10 hours of operation, thereafter, check condition and tension of belt every 100 hours. It is recommended that belt be replaced after every 1500 hours of operation. 3 2 Figure 49 1. P.T.O. Belt 1. Remove (2) screws securing P.T.O.
ELECTRICAL MAINTENANCE FUSES (Fig. 51) CAUTION There are 4 fuses in the machines electrical system. They are located inside control panel. Before servicing or making adjustments to the machine, stop engine and remove key from the switch. 4 BATTERY CARE 3 2 1 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 100 hours of operation.
BK + 34 TERMINAL I TERMINAL S TERMINAL B TERMINAL Y TERMINAL A ALTERNATOR F B STARTER S B VIO RED OR 85 86 BN TERMINAL X DETAIL A 80A FUSE BLUE RED BATTERY - RED 30 GLOW BK 87A GREY OR OR BK RELAY 3 2 RELAY GLOW 4 1 6 5 STARTER PLUGS 87 FUSE-50A PINK RED SWITCH IGINITION W W (+) W BK 85 SEAT PINK S A SWITCH INJECTION PUMP I B Y X 2 VIO/R Y W (NO) 87 30 TEMP 3 W 'N.C.
PREPARATION FOR SEASONAL STORAGE Traction Unit Engine 1. Thoroughly clean the traction unit, cutting units and the engine. 1. Drain the engine oil from the oil pan and replace the drain plug. 2. Check the tire pressure. Inflate all tires to 20 psi. 2. Remove and discard the oil filter. Install a new oil filter. 3. Check all fasteners for looseness; tighten as necessary. 3. Refill oil pan with 5.3 quarts of SAE15W 40 CD motor oil. 4. Grease or oil all grease fittings and pivot points.
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 1996 or newer Toro Commercial Product (“Product”) purchased after January 1, 1997, to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first.
