Form No. 3328-186 Groundsmaster 455-D Traction Unit and Cutting Unit Model No. 30450—Serial No. 220000201 and Up Model No. 30455—Serial No.
Page Warning Introduction The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. 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.
– Do not smoke while handling fuel. Safety – Fill fuel tank outdoors and only to within an inch from the top of the tank, not the filler neck. Do not overfill. The GROUNDSMASTER 455-D was tested and certified by TORO for compliance with the B71.4-1990 specifications of the American National Standards Institute.
• Keep body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid. Use cardboard or paper to find hydraulic leaks. Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result. • Operator must be skilled and trained in how to drive on hillsides.
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.
85-6410 76-8780 86-0700 83-9150 86-0710 86-0720 86-0730 84-1470 6
88-8950 86-0740 92-1370 86-0750 93-6681 1. Cutting/dismemberment hazard, fan—stay away from moving parts.
106-1005 93-7242 93-7243 8
Specifications Traction Unit Engine Cooling System Fuel System 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—3000 RPM Capacity is 3.5 gallons (13.2 l) of 50/50 mixture of Peugeot recommended anti-freeze (Part No. 93-7213) Capacity is 12 gallons (45.4 l) of #1 or #2 diesel fuel. Hydraulic System Reservoir capacity is 6.5 gallons (24.
Cutting Unit Type Mowing Rate Trimability 126 in. (320 cm) width of cut, seven blade, front mounted rotary; 54 in. (137 cm) width of cut, three blade center section; two 36 in. (91 cm) width of cut wings, 90 in. (229 cm) width of cut with one wing up; rear discharge with even dispersion over the entire width of cut Mows up to 8 acres/hr (32,375 m2) at 6.5 MPH (10.5 km/h) Trims on both sides Height-of-Cut Adjustable from 1 to 5 in. (2.5 to 12.7 cm) in 1/2 in. (1.
Before Operating Note: Determine the left and right sides of the machine from the normal operating position. Description Qty. Use Ignition key 1 Parts catalog 1 Commercial product setup card 1 Operator’s Manual 2 Read before operating the machine. Registration card 1 Fill out and return to Toro. Checking the Cooling System Caution Capacity of system is 3.5 gallons (13.3 l) Before servicing or making adjustments to the machine, stop engine and remove key from the switch. 1.
Multi-grade Hydraulic Fluid – ISO VG 46 1 Normal Climate: 0 (–18 C) to 110 F (43 C) Mobil DTE 15M Amoco Chevron Rykon Premium ISO 46 Rykon Premium Oil ISO 46 Conoco Hydroclear AW MV46 Exxon Univis N46 Pennzoil AWX MV46 Shell Figure 3 Tellus T 46 Texaco 1. Fuel tank cap Rando HDZ 46 Important The ISO VG 46 Multi-grade fluid has been found to offer optimal performance in a wide range of temperature conditions.
3. Install reservoir cap, close hood, and secure latch. 4. Screw dipstick filler cap finger–tight onto filler neck. It is not necessary to tighten cap with a wrench. Checking the Front Axle Oil Level Checking the Rear Axle Lubricant (Model 30455 Only) The front axle is shipped from the factory filled with SAE 80–90 wt. gear lube. However, check level before engine is first started and every 50 hours thereafter. Capacity is 128 oz. Check daily for signs of oil loss.
Checking the 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 (138 kPa). Important Maintain even pressure in all tires to assure a good quality-of-cut and proper machine performance. Do not under-inflate. Checking the Torque of the Wheel Nuts or Bolts 1 Figure 8 Warning 1.
Adjusting the Height-of-Cut 2. Push castor spindle through front castor arm, install remaining spacers onto spindle, and install HOC cap to secure assembly (Fig. 11). The height-of-cut is adjustable from 1 to 5 inches (2.5 to 12.7 cm) in 1/2 inch (13 mm) increments. Positioning the castor wheel axles in the top holes of the castor forks or pivots (see chart below) allows low range height-of-cut settings from 1 to 3-1/2 in. (2.5 to 8.
4 1 2 3 1 2 Figure 13 1. Rear deck straps Figure 14 2. Lift arm brackets 1. Safety door 2. Door guide 2. Remove hairpin cotter and H.O.C. pin securing rear deck strap to H.O.C. bracket on deck. 3. Slide deck strap forward or backward until holes in strap are aligned with selected height-of-cut bracket holes in the deck frame, install H.O.C. pin and secure with hairpin cotter. 3. Ball joint 4.
Controls Key Switch Cutting Unit Engagement Switch The key switch (Fig. 15) has three positions: OFF, ON and START. Rotate key to START and release key when engine begins running. To stop engine, rotate key to OFF. The cutting unit engagement switch (Fig. 15) is 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. Throttle Control Move the throttle control (Fig.
Seat Axle Shift Lever Seat adjusting lever on left side of seat (Fig. 16) allows 4 inch (10.2 cm) fore and aft adjustment. Seat adjusting knob on front of seat, adjusts seat for operator’s weight. The axle shift lever ,located on right side of console (Fig. 17), 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 Starting and Stopping A knob on the left side of console (Fig. 18) actuates parking brake lock. To engage parking brake, connect pedals with locking pin, push down on both pedals and pull parking brake latch out. To release parking brake, depress both pedals until parking brake latch retracts. 1. Sit on the seat, keep foot off traction pedal. Ensure that the parking brake is engaged, traction pedal is in NEUTRAL, and cutting unit engagement switch is in the DISENGAGED position. 2.
Note: Note: It may be necessary to bleed the air out of the fuel line between the fuel filter / water separator and the injection pump. To do this, loosen the fitting on the injection pump (Fig. 21) and repeat bleeding procedure. switch is operating correctly; thus, proceed to step 5. If engine does not stop, there is a malfunction in the interlock system. 5. Engage parking brake and depress the traction pedal while engine is running and the cutting unit engagement switch is DISENGAGED.
Operating Tips 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 cutting units. Mow When Grass is Dry Mow either in the late morning to avoid the dew, which causes grass clumping or in late afternoon to avoid the damage that can be caused by direct sunlight on the sensitive, freshly mowed grass.
After Operating To ensure optimum performance, clean underside of mower housings and under belt covers after each use. Use low psi compressed air only. Do not use water. If residue is allowed to buildup in mower housings, cutting performance will decrease.
Maintenance Recommended Maintenance Schedule Maintenance Service Interval 1If Maintenance Procedure After first 10 hours • Inspect the PTO and cutting unit belts. • Torque the wheel lug nuts. • Inspect the engine fan belt. After first 50 hours • • • • • Change the engine oil and filter. Check the electric deck clutches adjustment. Check the electric PTO clutch adjustment. Check the engine RPM (at idle and full throttle). Change the hydraulic oil filter.
Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Maintenance Check Item Mon. Tues. Wed. Thurs. Check the safety interlock system. Check the brake operation. Check the engine oil level. Check the fuel level. Check the cooling system fluid level. Drain the water/fuel separator. Check the air filter restriction indicator. Check the radiator and screen for debris.1 Check for unusual engine noises.2 Check for unusual operating noises. Check the hydraulic system oil level.
SERVICE INTERVAL CHARTS 2 Wheel Drive 4 Wheel Drive DTE 15M DTE 15M 25
Lubricating the Machine 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. The grease fittings that must be lubricated are: lift arm pivot (2), lift cylinder (4), brake arm pivots (2) (Fig.
Important Failure to lubricate the hydro pump drive fitting will result in a failure.
Figure 30 Figure 32 1 Figure 33 Figure 31 1.
Figure 36 Figure 34 Figure 35 29
2. Gently slide primary filter (Fig. 39) out of air cleaner body to reduce the amount of dust dislodged. Avoid knocking filter against air cleaner body. Do not remove safety filter. Caution Before servicing or making adjustments to the machine, stop engine and remove key from the switch. 1 Servicing the Air Cleaner Checking the Air Cleaner 1. Check air cleaner body for damage which could possibly cause an air leak. Replace a damaged air cleaner body. 2.
Servicing the Engine Oil and Filter Servicing the Fuel System Change oil and filter initially after the first 50 hours of operation, thereafter change oil and filter every 100 hours. 1. Remove drain plug (Fig. 40) and let oil flow into drain pan. When oil stops, install drain plug and new plug seal. 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.
3. Tighten drain screw. 3. Unscrew knobs and pivot oil cooler rearward. Clean both sides of oil cooler and radiator area thoroughly with low pressure compressed air. Open hood and blow debris out toward back of machine. Pivot oil cooler back into position and tighten knobs. Changing the Fuel Filter Replace fuel filter if fuel flow becomes restricted, after every 400 hours of operation or annually, whichever comes first.
2. If deflection exceeds 1/4 in. (6 mm), loosen alternator mounting bolts. Adjust alternator belt tension by adjusting tension screw (Fig. 45). Check deflection of belt again to assure tension is correct. 1 1 2 Figure 46 1. Hydraulic reservoir drain Figure 45 1. Fan belt 2. Adjusting screw 4. Install reservoir cap, lower hood, and latch. Start engine and use all hydraulic controls to distribute hydraulic oil throughout the system. Also check for leaks. Then stop the engine.
Replacing the Hydraulic Filter Warning Initially, change filter after the first 50 operating hours, thereafter, every 800 operating hours or annually, whichever comes first. Keep body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid. Use cardboard or paper to find hydraulic leaks. Hydraulic fluid escaping under pressure can penetrate skin and cause injury.
Adjusting the Traction Drive 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, shut engine off and move shift lever to “HI” position. Depress only the left brake pedal and engage the parking brake. 2. Jack up right side of machine until front tire is off the shop floor. Support machine with jack stands to prevent it from falling accidentally. 1 3.
Changing the Front Axle Lubricant After every 800 hours of operation the oil in the front axle must be changed. 1. Position machine on a level surface. 2. Clean area around the drain plug (Fig. 54). 1 Figure 55 1. Drain plugs (3) Changing the Bidirectional Clutch Lubricant 1 (Model 30455 Only) Figure 54 1. Front axle drain plug After every 800 hours of operation the oil in the clutch housing must be changed. 3. Remove plug allowing oil to drain into drain pans. 1.
Adjusting Rear Wheel Toe-In After every 800 operating hours or annually, check rear wheel toe-in. 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. (3 mm) of each other. Adjusting 2-Wheel Drive Models 1. Loosen clamps at both ends of tie rods (Fig. 57). 1 2. Rotate tie rod to move front of tire inward or outward. Figure 58 3. Tighten tie rod clamps when adjustment is correct. 1.
1. Remove 2 screws securing PTO belt cover to adapter plate (Fig. 60) and 1 screw securing belt cover to tab on spring anchor. Remove cover. 1. To adjust clutch, tighten or loosen locknuts on flange studs. 2. Check adjustment by inserting feeler gauge through slots next to flange studs (Fig. 62). 3. The proper disengaged clearance between the clutch plates is 0.011–0.021 inches (0.28–0.53 mm).
2 4 1 1 3 2 3 Figure 64 1. Hydraulic line couplers 2. Wire harness Figure 63 1. ACC fuse 2. Relay fuse 3. Deck fuse 4. Run fuse ACC 5 amp. Relay 5 amp. Deck 30 amp. Run 15 amp. 3. Rear deck straps 4. Remove hairpin cotters and height-of-cut pins securing rear deck straps to height-of-cut brackets on deck (Fig. 64). 5. Start engine and lower center cutting unit to the ground. Stop engine after cutting unit is lowered. 6.
Pivoting the Cutting Unit Down into the Operating Position 6. Roll the cutting unit away from the traction unit. 1. Sit on seat, start the engine, and slowly lower the cutting units to the ground; then raise center cutting unit slightly, so rear deck straps can be mounted to lift arm brackets. Stop engine after cutting unit is raised. Set parking brake. Alternate Method 1. Lower center and wing cutting units to the ground, set parking brake and stop engine. 2.
Adjusting the Safety Door Adjusting the Blade On each side of the center deck is a safety door that opens and closes as the wing decks are lowered and raised (Fig. 68). The doors open to provide overlap of the cutting blades when the wing units are down. The doors close to provide safety and protection when the wing units are raised. Check to make sure the forward, lower edge of door (Fig. 68) is even or 1/4 in.
Adjusting the Belt Tension Replacing the Drive Belts Each cutting unit drive belt is individually tensioned by a self tensioning spring loaded idler. When the idlers are properly adjusted, the black plastic sleeve should be 0.12 to 0.25 in. (3 to 6 mm) from the edge of the idler support. When 0.50 in. (13 mm) of the plastic sleeve is exposed, an adjustment is required.
6. Raise front of gear box support and remove old belt from around gear box pulley and remaining pulleys. 2 7. Route new belt around appropriate pulleys as shown in Figure 75. 1 Figure 73 1. Clutch rod 2. Clutch wire Figure 75 Removing the Center Deck Belt 8. Remount gear box support to deck channels with capscrews and nuts previously removed. Warning 9. Reinstall drive shaft cover to gear box support with the 4 flange head screws previously removed.
1 1 2 2 Figure 76 1. Clutch Figure 77 2. Flange studs 1. Front castor arm tube 2. Bushings Servicing the Front Bushings in the Castor Arms Servicing Castor Wheels and Bearings The castor arms have bushings pressed into the top and bottom of the tube and after many hours of operation, the bushings will wear. To check the bushings, move castor fork back and forth and from side to side. If castor spindle is loose inside the bushings, bushings are worn and must be replaced. 1.
4. To assemble the castor wheel, push bearing into wheel hub. Slide bearing spacer into wheel hub. Push other bearing into open end of wheel hub to captivate the bearing spacer inside the wheel hub. 5. Install castor wheel assembly between castor fork and secure in place with capscrew and locknut. 3 2 2 4 1 1 Figure 80 1. Blade bolt Figure 79 1. Castor wheel 2. Rear castor pivot arm 2. Anti-scalp cup Inspecting and Sharpening the Blade 3. Bearing (2) 4. Bearing spacer 1.
Engine 3. Inspect cutting 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. 82). The blade will remain balanced if same amount of metal is removed from both cutting edges. 1. Drain the engine oil from the oil pan and replace the drain plug. 2. Remove and discard the oil filter. Install a new oil filter. 3. Refill oil pan with 5.3 U.S. quarts (5.
TEST PORT 32.8/15.4 FRONT AXLE TEST PORT 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) 3.95 GPM (14.93 LITERS/MIN) O I 100 MESH STRAINER .31 IN 3 /REV (5.08 CC/REV) TEST PORTS 2000 PSI (138 BAR) 1200 PSI (83 BAR) 3.95 GPM (14.93 LITERS/MIN) 120 PSI OPERATING TEMP. (8.16 BAR) F E D C B A .039 ONE–WAY ORIFICE RIGHT UNIT LIFT .
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.
+ RED B S 49 TERMINAL I TERMINAL S TERMINAL B TERMINAL Y TERMINAL A OR 85 GLOW BK 30 RELAY STARTER BK 6 4 (–) YEL 85 IGINITION SWITCH W B I Y X 87 (NC) (NC) 2 VIO/R Y W W ’C’ ’D’ 3 C.U.
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.
