Form No. 3383-658 Rev A CT2240 Compact Triple 4-Wheel Drive Turf Mower Model No. 30654—Serial No. 314000001 and Up G025163 Register at www.Toro.com.
This product complies with all relevant European directives, for details please see the separate product specific Declaration of Conformity (DOC) sheet. Introduction This machine is a ride-on, cutterhead-blade lawn mower intended to be used by professional, hired operators in commercial applications. It is primarily designed for cutting grass on parks, sports fields, caravan parks, cemeteries and commercial grounds. It is not designed for cutting brush or for agricultural use.
Contents Electrical System Maintenance ....................................38 Check Electrical System ..........................................38 Check Battery Condition .........................................38 Inspect Transmission Control Cable and Operating Mechanism ........................................................38 Servicing the Battery...............................................39 Drive System Maintenance .........................................39 Changing the Transmission Oil Filter .
Safety • This machine meets or exceeds standard EN ISO 5395-3:2013 specifications in effect at time of production. 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 symbol, which means Caution, Warning, or Danger—personal safety instruction. Failure to comply with the instruction may result in personal injury or death.
• • • equipment with a portable container, rather than from a fuel dispenser nozzle. Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. Do not use a nozzle lock open device. If fuel is spilled on clothing, change clothing immediately. Never overfill fuel tank. Replace fuel cap and tighten securely. • Operation • Do not operate the engine in a confined space where • • • • • • • • • • • • dangerous carbon monoxide fumes can collect.
• Lower a folding ROPS temporarily only when absolutely • • • • • • • • • Use care when checking the cylinders/cutterheads. Wear necessary. Do not wear the seat belt when folded down. Be aware there is no rollover protection when a folded ROPS is in the down position. Be certain that the seat belt can be released quickly in the event of an emergency. Check the area to be mowed and never fold down a folding ROPS in areas where there are slopes, drop offs or water.
Sound Power Level – When near or crossing roads, always yield the right-of-way. This unit has a measured sound power level of 105 dB(A), which includes an Uncertainty Value of 1 dB(A). – Apply the service brakes when going downhill to keep forward speed slow and to maintain control of the machine. Sound power level was determined according to the procedures outlined in ISO 11094. • Raise and latch the cutting units when driving from one work area to another.
Operators Daily Personal Vibration Exposure Employers of personnel using this machine are advised to read the 'Physical Agents Vibration Directive' as the operator's daily personal exposure level could be above the 'Daily exposure action value'. The Toro Company has no control over site conditions, duration of use, state of maintenance or adjustment of the mower. All of these factors will affect the operator's daily personal vibration exposure level.
111-3902 1. Warning—cutting hazard of hand, fan. 2. Hot surfaces—read the Operator's Manual for more information. 111-3344 1. Ignition switch indicating different positions of key switch 111-3562 111-0936 1. Press pedal to adjust steering wheel tilt. 1. Tipping hazard—slow machine before turning. 2. Tipping hazard—operate on slopes less than 16 degrees, do not operate on slopes greater than 16 degrees. 3.
111-7249 1. 24 hour service interval 6. Check hydraulic oil level 2. 50 hour service interval 7. Check fuel level 3. Check the tire pressure 8. Check engine oil level 4. Check all nuts and bolts for proper tightness 9. Check operation of seat switch 5. Check all hoses for leaks 10. Check air filter element 11. Check cutter head setting 16. Lubrication points for 24 hour interval 12. Check engine coolant level 17. Lubrication points for 50 hour interval 13. Check cleanliness of radiator 14.
Setup Media and Additional Parts Description Qty. Use Operator's Manual 1 Read the Operator's Manual before operating the machine Engine Operator's Manual 1 Reference engine information Parts Catalog 1 Reference part numbers Store all documentation in a safe place for future use. Note: Determine the left and right sides of the machine from the normal operating position. Checking the Tyre Pressure Check the air pressure in the front and rear tyres. See the chart below for the correct pressure.
Controls Product Overview Control Panel Components 13 16 14 17 8 5 2 3 4 19 11 1 6 1 18 10 5 2 6 9 3 G025164 7 Figure 2 1. Front cutting units 4. Operator's seat 2. Control arm 5. Engine hood 3. Steering wheel 6. Rear cutting unit 4 15 12 G014418 Figure 3 1. Parking brake switch 11. Horn button 2. Limited lift in reverse switch 12. Auxiliary 12 volt socket (supplied with a 12V kit) 3. Hazard warning switch (supplied with lighting kit) 13. Engine oil pressure indicator 4.
1 P G014421 Figure 6 1 1. Parking brake g014419 Figure 4 Service Brake 1. Weight transfer control 1 Service braking is achieved by the hydraulic transmission system. When the forward or reverse travel pedals are released or the engine speed reduced, service braking becomes effective and travel speed is automatically reduced. To increase the braking effect, push the transmission pedal into the neutral position. Service braking is effective on the front wheels only.
Transport Latches Always raise the cutterheads to the transport position and secure with the transport latches and safety locks when travelling between work areas (Figure 9). 1 G014547 Figure 7 1. Throttle control lever Travel Forward travel: Depress the forward travel pedal to increase forward travel speed. Release the pedal to reduce speed (Figure 8). G014548 Figure 9 Reverse travel: Depress the reverse travel pedal to increase reverse travel speed. Release the pedal to reduce speed (Figure 8).
G014549 Figure 10 Operator Seat WARNING Never operate the mower without first checking that the operator seat mechanisms are in good working order and that, once adjusted and locked, the seat remains securely in position. 1 Adjustment of the seat mechanisms should only be carried out when the mower is at a standstill with the parking brake engaged. Fore/Aft adjustment: The seat adjusting lever allows the operator to adjust the seat fore and aft (Figure 11).
Warning Systems Low Battery Charge Warning Light Engine Coolant Overheating Warning Light The battery charge warning light illuminates when low battery charge occurs (Figure 14). The engine coolant warning light illuminates, the horn is actuated and the cutters stop (Figure 12). 1 1 G014553 Figure 14 1. Low battery charge warning light Low Engine Oil Pressure Warning Light The engine oil pressure warning light illuminates when the oil pressure is too low (Figure 15). G014551 Figure 12 1 1.
Ignition Key Fuel Gauge 0 = Engine off. The fuel gauge shows the amount of fuel in the tank (Figure 19). I = Engine run/Auxiliary on. II = Engine pre-heat. III = Engine start. FUEL E F WARNING Always remove the ignition key when the mower is not in use. G014558 Figure 19 Important: Always install the protective cap when the ignition key is removed to prevent ingress of dirt and moisture damaging the mechanism.
Cutterhead Drive Switch Indicator Light 1 This light illuminates when the cutterhead drive switch is in the forward/reverse position and the ignition key is turned to position I (Figure 22). G0014561 Figure 22 1. Cutterhead Drive Switch Indicator Light Specifications Note: Specifications and design are subject to change without notice. Specification CT 2240 Transport Width 1380 mm (54.3 inches) Width of cut 2120 mm (83.5 inches) Length 2860 mm (112.6 inches) Height 1681 mm (66.2 inches) with R.
Operation Note: Determine the left and right sides of the machine from the normal operating position. CAUTION If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Lower the cutting units to the ground, set the parking brake and remove the key from the ignition switch before servicing or making adjustments to the machine. Figure 23 1. Dipstick Checking the Engine Oil Level 4. Remove dipstick and check oil level on dipstick.
Checking the Cooling System Adding Fuel Service Interval: Before each use or daily Service Interval: Before each use or daily Use only clean, fresh diesel fuel with low (<50 ppm) or ultra low (<15 ppm) sulfur content. The minimum cetane rating should be 40. Purchase fuel in quantities that can be used within 180 days to ensure fuel freshness. CAUTION If the engine has been running, the pressurized, hot coolant can escape and cause burns.
High Viscosity Index/Low Pour Point Anti-wear Hydraulic Fluid, ISO VG 46 Material Properties: Viscosity, ASTM D445 cSt @ 40°C 44 to 48 cSt @ 100°C 7.9 to 8.5 140 to 160 Viscosity Index ASTM D2270 Pour Point, ASTM D97 -34°F to -49°F DANGER In certain conditions during fueling, static electricity can be released causing a spark which can ignite the fuel vapors. A fire or explosion from fuel can burn you and others and can damage property.
5. Install the cap onto the tank. Check the Torque of the Wheel Nuts Service Interval: Before each use or daily Torque the wheel nuts to 200 N-m (148 ft-lb) for the front axle, and 54 N-m (40 ft-lb) for the rear axle. WARNING Failure to maintain proper torque of the wheel nuts could result in personal injury. G014422 Operator Platform Latching Mechanism Figure 27 Do not operate the mower without first checking that the operator platform latching mechanism is fully engaged and in good working order.
CAUTION If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. 1 • Do not tamper with the interlock switches. G014557 • Check the operation of the interlock switches daily and replace any damaged switches before operating the machine. Figure 28 1. Engine pre-heat indicator light Starting and Stopping the Engine WARNING When the engine is operating all warning lights should be off.
G014563 Figure 29 G014423 Figure 30 Checking the Cylinder to Bedknife Contact MK3 Floating cutterhead 8 inch (20 cm): When the mower is set up with floating cutterheads the height of cut is gauged by the front and rear rollers. The cutterhead is allowed to pivot fore and aft as well as laterally. This arrangement is recommended for high quality grass areas and performs well where grass is short and the ground undulations are severe (Figure 31).
MK3 Fixed cutterhead 20 cm (8 inch) Pivot knuckle fixing: Secure the bolt in the front fixed hole position in Figure 34 as shown. 1 G014427 Figure 34 G014425 Figure 32 1. Front fixed hole position Height of cut adjustment: The height of cut is gauged by the position of the rear roller. Turn the adjusting nut assembly both ends clockwise to decrease height of cut or anti-clockwise to increase height of cut (Figure 35).
1 Ensure that all cutterheads are set at the same height of cut by either referring to the indicator rings (Figure 36 ) or by using a height of cut gauge across the full width of each cutterhead for greater accuracy as shown. 2 4 3 2 G014431 1 Figure 38 3 = 3. Height-of-cut 2. Adjusting nuts 4. Indicator rings Important: Do not attempt to unlock the nut assemblies. G025165 Figure 36 1. Indicator rings 1. Adjusting nut assembly To alter the front roller position loosen bolts.
Centre Cutterhead Height of Cut Correction Adjustment With all cutterheads set at the same HOC via the indicator rings, it may be noticeable that the center unit produces a higher cut finish compared to the wing units. The center unit is pulled and the wing units are pushed, this presents marginally different cutting angles relative to the ground.
Forward rotation cutterhead drive engagement: Depress the top of the cutterhead drive switch to the forward position (Figure 41). Using Weight Transfer/Traction Assistance Reverse rotation cutterhead drive engagement: Depress the bottom of the cutterhead drive switch to the reverse position (Figure 41). A variable hydraulic weight transfer system is provided for improving tyre grip with the grass surface - traction assistance.
3. Carefully lower the frame downwards until it rests on the stops. when operating the mower. Lower the roll bar temporarily only when absolutely necessary. 4. Insert the retaining bolts in the lower holes and fully tighten the hand nuts to support the upper frame in its lowered position. Jacking Points 5. Note: Use jack stands to support the machine when required. To raise the frame, follow these instructions in reverse order. • Front—under the front arm mount. 1 • Rear—axle tube on the rear axle.
Operating Tips WARNING Take care when travelling over obstacles such as roadside kerbs. Always travel at slow speed over obstacles to prevent damage to the machines tyres, wheels and steering system. Ensure that tyres are inflated to the recommended pressures. Familiarization Before mowing grass, practice operating the machine in an open area. Start and stop the engine. Operate in forward and reverse. Lower and raise the cutting units and engage and disengage the cutterheads.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Note: Looking for an Electrical Schematic or Hydraulic Schematic for your machine? Download a free copy of the schematic by visiting www.Toro.com and searching for your machine from the Manuals link on the home page. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 8 hours • Check the condition and tension of the alternator belt.
Maintenance Service Interval Maintenance Procedure • Drain and clean the fuel tank • Adjust the engine valves (refer to the engine Operator's Manual) Every 800 hours Before storage • Drain and clean the fuel tank Every 2 years • Flush and replace the cooling system fluid. • Replace all moving hoses. • Replace the transmission cable Daily Maintenance Checklist Duplicate this page for routine use. Maintenance Check Item For the week of: Mon. Tues. Wed. Thurs. Fri.
Pre- Maintenance Before performing any maintenance ensure the engine is switched to off and the ignition key is removed, the parking brake is set, there is no pressure in the hydraulic system, the cutterheads are down on the ground and the safety precautions in this manual have been read and understood. 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 before you do any maintenance.
Lubrication Replace any grease zerks that become damaged. Greasing the Bearings, Bushings and Pivots Grease all cutterhead grease points and ensure that sufficient grease is injected such that clean grease is seen to escape from the roller end caps. This provides visible evidence that the roller seals have been purged of grass debris etc. and will ensure maximum working life.
Engine Maintenance Check the Engine Overheat Warning System Service Interval: Every 500 hours G014565 Figure 47 2. Before removing the filter, use low pressure air (40 psi, clean and dry) to help remove large accumulations of debris packed between outside of the filter and the canister. Avoid using high pressure air which could force dirt through the filter into the intake tract. Remove the cover from the air cleaner body.
Servicing the Safety Filter The air filter has a secondary, safety filter element inside the primary air filter to prevent dislodged dust and other items from entering the engine while changing the main element. Replace the safety filter, never clean it. Important: Never attempt to clean the safety filter. If the safety filter is dirty, then the primary filter is damaged. Replace both filters. Servicing the Engine Oil and Filter Service Interval: After the first 50 hours Figure 50 Every 150 hours 1.
Fuel System Maintenance 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. 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.
Electrical System Maintenance Important: Before welding on the machine, disconnect both cables from the battery, both wire harness plugs from the electronic control module, and the terminal connector from the alternator to prevent damage to the electrical system. Check Electrical System Service Interval: Every 500 hours Inspect all electrical connections and cables and replace any which are damaged or corroded. Spray a good quality water inhibitor onto exposed connections to prevent moisture ingress.
Drive System Maintenance • Inspect end fittings for wear, corrosion, broken springs, • • • • and replace if necessary. Ensure that the rubber seals are correctly located and are in good condition. Ensure that the articulating sleeves supporting the inner cable are in good condition and firmly attached to the outer cable assembly at the crimped connections. If there are any signs of cracking or detachment install a new cable immediately.
Cooling System Maintenance Removing Debris from the Cooling System Service Interval: Before each use or daily Every 100 hours Every 2 years Note: To prevent the engine from overheating, the radiator and oil cooler must be kept clean. Normally, check daily and, if necessary,clean any debris off these parts. However,it will be necessary to check and clean more frequently in extremely dusty and dirty conditions. 1 g014491 1.
Brake Maintenance Towing the Mower Ensure that the towing vehicle specification is suited to braking the combined vehicle weight and able to remain in complete control at all times. Ensure the towing vehicle’s parking brake is applied. Chock the mower front wheels to prevent the mower rolling away. De-commission the front wheel motor disc brakes as follows : 1. Connect a rigid tow bar between the towing eye on the mower and a suitable towing vehicle. 2.
1 2 3 G014449 Figure 60 1. Hex plug 3. Setscrew M12 x 40 2. Washer M12 5. Tighten the setscrew into the threaded hole in the brake piston until the brake is released (Figure 60). 1 6. Identify the left hand front wheel motor disc brake assembly and repeat the previous procedure (Figure 60). G014450 Figure 61 1. Transmission Bypass Valves 7.
Belt Maintenance 1 Check the condition and tension of the alternator belt after the first day of operation and every 100 operating hours thereafter. 2 3 4 Tensioning the Alternator Belt Service Interval: After the first 8 hours Every 100 hours 1. Open the hood. 2. Check the tension of the alternator belt by depressing it (Figure 63) midway between the alternator and the crankshaft pulleys with 10 kg (22 lb) of force. g014451 Figure 62 1. Front wheel moto 2. Hex plug D. 3. Washer M12 4.
Transmission Neutral Interlock Switch Controls System Maintenance 1. Stop the mower engine. 2. Remove your foot from the forward/reverse travel pedals. Check Forward/Reverse Travel Pedal Action 3. Turn the ignition key to position I and the transmission neutral indicator light should illuminate. With the engine switched off, operate the forward and reverse travel pedals through the full range of articulation and ensure that the mechanism returns freely to the neutral position. 4.
Hydraulic System Maintenance 2 1 WARNING 3 Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • Make sure all hydraulic fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system. • Keep your body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid. G014452 Figure 64 • Use cardboard or paper to find hydraulic leaks. 1.
Checking the Hydraulic Lines and Hoses Cutterheads System Maintenance Daily, check hydraulic lines and hoses for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration, and chemical deterioration. Make all necessary repairs before operating.
1 90 0 G014440 Figure 67 1. Scraper wire retaining nuts G014443 Note: Do not over tighten the scraper wires. Figure 68 Cutterhead Cylinder to Bottom Blade Adjustment 1. Check that the cutting cylinder is correctly set to the bottom blade by holding a thin piece of paper between the cutting cylinder and the bottom blade as shown.
80 Grade Carborundum paste Part No. 1 1 lb (0.45 kg) 63-07-088 25 lb (11.25 kg) 63-07-086 2 G014444 Figure 69 1. Hand wheel 2. Nut Cutterheads Back Lapping G014445 Figure 70 WARNING Contact with the cutterheads or other moving parts can result in personal injury. • Keep fingers, hands, and clothing away from the cutterheads or other moving parts. 4. Ensure that the area surrounding the cutterhead heads is clear of people.
1 7. Operate the cutterheads drive switch to the off position and switch off the mower engine when the grinding action has stopped. 2 8. Thoroughly clean the blade edges and adjust the cutting cylinders to the bottom blades. Check that a thin piece of paper can be cut cleanly at all points along the cutting edges while rotating the cylinders by hand. 9. If further back lapping is necessary repeat steps 2–8. 10.
Waste Disposal Storage Engine oil, batteries, hydraulic oil, and engine coolant are pollutants to the environment. Dispose of these according to your local regulations. Preparing the Traction Unit 1. Thoroughly clean the traction unit, cutting units, and engine. When disposing of hazardous waste products, take them to an authorized disposal site. Waste products must not be allowed to contaminate surface water, drains or sewage systems. 2. Check the tyre pressure.
Troubleshooting Problem Possible Cause Corrective Action 1. Turning too tightly 1. Reduce turning radius 2. Mower sliding sideways when travelling across face of slope 3. No ground contact on one end of the cutter because poorly routed hoses or wrongly positioned hydraulic adaptors 4. No ground contact on one end of the cutter because pivot pins seizing 5. No ground contact on one end of the cutter because of grass build up under cutterhead 2.
Problem Excessive bottom blade wear Engine will not start with ignition key Flat battery Hydraulic oil system overheating Possible Cause 1. Bottom blade in heavy ground contact 1. Raise height of cut 2. Cutting edges of the cutting cylinder/ bottom blade are rounded 3. Cylinder is in heavy contact with the bottom blade 4. Damaged cutting cylinder or bottom blade 5. Excessively abrasive ground conditions 2. Back lap or regrind to restore cutting edges 3.
Problem Excessive noise in hydraulic system Possible Cause 1. Faulty pump 1. Identify noisy pump and service or replace 2. Faulty motor 2. Identify noisy motor and service or replace 3. Tighten or replace hydraulic fittings particularly in suction lines 4. Clean and replace suction strainer or renew as necessary 5. Allow system to warm up 3. Air leaking into system 4. Suction strainer blocked or damaged 5. Excessive oil viscosity due to cold conditions 6. Low relief valve setting 7.
Problem Cutterheads fail to start up when lowered into work Possible Cause 1. Faulty seat sensor switch 1. Check mechanical and electrical operation of switch 2. Low oil level 2. Fill hydraulic oil reservoir to correct level 3. Check motor and cylinder drive shafts and replace if necessary 4. Have relief valve pressure checked. Consult your authorized dealer 5. Clear as necessary 6. Re adjust setting 7. Overhaul control valve 3. Sheared drive shaft 4. Pressure relief valve jammed open or wrongly set 5.
International Distributor List Distributor: Agrolanc Kft Balama Prima Engineering Equip. B-Ray Corporation Casco Sales Company Ceres S.A. CSSC Turf Equipment (pvt) Ltd. Cyril Johnston & Co. Cyril Johnston & Co. Equiver Femco S.A. ForGarder OU G.Y.K. Company Ltd. Geomechaniki of Athens Golf international Turizm Guandong Golden Star Hako Ground and Garden Hako Ground and Garden Hayter Limited (U.K.) Hydroturf Int. Co Dubai Hydroturf Egypt LLC Irrimac Irrigation Products Int'l Pvt Ltd. Jean Heybroek b.v.
The Toro Total Coverage Guarantee A 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. This warranty is applicable to all products with the exception of Aerators (refer to separate warranty statements for these products).
