Toro 30455TS, groundsmaster 455-d Operator's Manual

Form No. 3327-466

Operator’s Manual

®

Groundsmaster®455-D

Traction Unit

Model No. 30455TS—Serial No. 220000201 and Up

English (GB)

1

Table of Contents

Table of Contents 1

Introduction 2

Safety 3

Sound & Vibration Levels 5

Symbol Glossary 6

Specifications 9

Before Operating 11

Check the Engine Oil 11
Check the Cooling System 11
Fill the Fuel Tank 11
Check Hydraulic Circuit Oil 12
Check the Front Axle Oil Level 13
Check the Rear Axle Lubricant 13
Check Bi-Directional Clutch Lubricant 14
Check Tire Pressure 14
Check the Torque of Wheel Nuts Or Bolts 14

Controls 15

Operation 17

Starting and Stopping 17
Priming the Fuel System 17
Checking the Interlock System 17
Operating Characteristics 18
Operating Tips 19

Maintenance 21

Greasing (Fig. 18–26) 21
Minimum Recommended Maintenance Intervals 23
General Air Cleaner Maintenance 24
Servicing the Air Cleaner 24
Engine Oil and Filter 25
Fuel System 25
Engine Fan Belt 27
Engine Timing Belt 27
Changing Hydraulic Oil 27
Replacing the Hydraulic Filter 28
Checking Hydraulic Lines and Hoses 28
Hydraulic System Test Ports 29
Adjusting the Traction Drive for Neutral 29
Changing Front Axle Lubricant 30
Changing Rear Axle Lubricant 30
Changing Bi-Directional Clutch Lubricant 31
Rear Wheel Toe In 31
Adjusting Service Brakes 31
Adjusting the PTO Belt 32
Adjusting the Clutch 32
Battery Care 33
Fuses 33
Preparation for Seasonal Storage 33

2

Introduction

Read this manual carefully to learn how to operate and
maintain your product correctly. 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.

Whenever you need service, genuine Toro parts, or
additional information, contact an Authorized Service
Dealer or Toro Customer Service and have the model
and serial numbers of your product ready.

Write the product model and serial numbers in the space
below.

This manual identifies potential hazards and has special
safety messages that help you and others avoid personal
injury, even death. Danger, Warning and Caution are
signal words used to identify the level of hazard.
However, regardless of the hazard, be extremely careful.

Danger signals an extreme hazard that will cause
serious injury or death if you do not follow the
recommended precautions.

Warning signals a hazard that may cause serious injury
or death if the recommended precautions are not
followed.

Caution signals a hazard that may cause minor or
moderate injury if the recommended precautions are not
followed.

The manual uses two other words to highlight
information. calls attention to special
mechanical information and Note: emphasizes general
information worthy of special attention.

Important

Model No: __________________________

Serial No.: __________________________

3

Safety

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.

Before Operating

1. Read and understand the contents of this manual

before starting and operating the machine. Become
familiar with the controls and know how to stop the
machine and engine quickly.

A free replacement manual is available by sending
the complete model and serial number to:

The Toro Company
8111 Lyndale Avenue South
Minneapolis, Minnesota 55420.

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.

3. Never operate the machine when under the

influence of drugs or alcohol.

4. Keep all shields, safety devices and decals in place.

If a shield, safety device or decal is defective,
illegible or damaged, repair or replace it before
operating the machine. Also tighten any loose nuts,
bolts or screws to ensure machine is in safe
operating condition.

5. Always wear substantial shoes. Do not operate

machine while wearing sandals, tennis shoes,
sneakers or when barefoot. Do not wear loose
fitting clothing that could get caught in moving
parts and possibly cause personal injury. Wearing
safety glasses, safety shoes, long pants and a
helmet is advisable and required by some local
ordinances and insurance regulations.

6. Assure interlock switches are adjusted correctly so

engine cannot be started unless traction pedal is in
NEUTRAL and cutting unit is DISENGAGED.

7. Remove all debris or other objects that might be

picked up and thrown by the blades or fast moving
components from other attached implements. Keep
all bystanders away from operating area.

8. Since diesel fuel is highly flammable, handle it

carefully:

A. Use an approved fuel container.

B. Do not remove fuel tank cap while engine is

hot or running.

C. Do not smoke while handling fuel.

D. Fill fuel tank outdoors and only to within an

inch from the top of the tank, not the filler
neck. Do not overfill.

E. Wipe up any spilled fuel.

While Operaing

9. Sit on the seat when starting and operating the

machine.

10. Before starting the engine:

A. Engage the parking brake.

B. Make sure traction pedal is in NEUTRAL and

cutting decks are DISENGAGED. Move axle
shift to HI or LO position.

C. After engine is started, release parking brake

and keep foot off traction pedal. Machine must
not move. If movement is evident, the neutral
return mechanism is adjusted incorrectly;
therefore, shut engine off and adjust until
machine does not move when traction pedal is
released. Refer to Adjusting Traction Drive for
Neutral, page 29.

11. Seating capacity is one person. Therefore, never

carry passengers.

12. Do not run engine in a confined area without

adequate ventilation. Exhaust fumes are hazardous
and could possibly be deadly.

13. Check interlock switches daily for proper

operation. Do not rely entirely on safety switches—
use common sense. If a switch fails, replace it
before operating the machine. The interlock system
is for your protection, so do not bypass it. Replace
all interlock switches every two years.

4

14. Using the machine demands attention and to

prevent loss of control:

A. Operate only in daylight or when there is good

artificial light.

B. Drive slowly. Avoid sudden stops and starts.

C. Watch for holes or other hidden hazards.

D. Look behind machine before backing up.

E. Do not drive close to a sand trap, ditch, creek

or other hazard.

F. Reduce speed when making sharp turns and

turning on a hillside.

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.

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. This product may exceed noise levels of 85 dB(A)

at the operator position. Ear protectors are
recommended, for prolonged exposure, to reduce
the potential of permanent hearing damage.

18. When operating 4-wheel drive machine, always use

the seat belt and roll-over protection system
together and have seat pivot retaining pin installed.

19. If engine stalls or loses headway and cannot make

it to the top of a slope, do not turn machine around.
Always back slowly straight down the slope.

20. Raise cutting decks and latch securely in transport

position before driving from one work area to
another.

21. DON' T TAKE AN INJURY RISK! When a

person or pet appears unexpectedly in or near the
mowing area, STOP MOWING. Careless
operation, combined with terrain angles, ricochets,
or improperly positioned guards can lead to thrown
object injuries. Do not resume mowing until area is
cleared.

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. If damaged, repair or replace
any components before operating.

24. Before getting off the seat:

A. Set parking brake.

B. Move traction pedal to neutral and axle shift to

HI or LO position.

C. Disengage cutting decks and wait for blades to

stop.

D. Stop engine and remove key from switch.

E. Do not park on slopes unless wheels are

chocked or blocked.

25. Use only a rigid tow bar if it becomes necessary to

tow machine. Use trailer for normal transport.

Maintenance

26. Before servicing or making adjustments, stop

engine and remove key from the switch.

27. Make sure machine is in safe operating condition

by keeping all nuts, bolts and screws tight.

28. Make sure all hydraulic line connectors are tight,

and all hydraulic hoses and lines are in good
condition before applying pressure to the system.

29. 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.

30. Before disconnecting or performing any work on

the hydraulic system, all pressure in system must
be relieved by lowering cutting units to the ground
and stopping engine.

31. If major repairs are ever needed or assistance is

desired, contact an authorized Toro distributor.

5

32. To reduce potential fire hazard, keep engine area

free of excessive grease, grass, leaves and dirt.
Clean protective screen on back of machine
frequently. Never wash a warm engine or electrical
connections with water.

33. If engine must be running to perform maintenance

or an adjustment, keep hands, feet, clothing and
other parts of the body away from cutting units and
other moving parts. Keep all bystanders away.

34. Do not overspeed the engine by changing governor

setting. To assure safety and accuracy, have an
Authorized Toro Distributor check maximum
engine speed.

35. Shut engine off before checking or adding oil to the

crankcase.

36. Disconnect battery before servicing the machine. If

battery voltage is required for troubleshooting or
test procedures, temporarily connect the battery.

37. At the time of manufacture, the machine

conformed to the safety standards for riding
mower. Ballast weight, mounted to rear of traction
unit, is required for machine to conform to safety
standard. DO NOT remove ballast weight at any
time. To assure optimum performance and
continued safety certification of the machine, use
genuine Toro replacement parts and accessories.
Replacement parts and accessories made by other
manufacturers may result in non-conformance with
the safety standards, and the warranty may be
voided.

Sound Pressure Level

This unit has an equivalent continuous A-weighted
sound pressure at the operator ear of: 89 dB(A), based
on measurements of identical machines per Directive
98/37/EC and amendments.

Sound Power Level

This unit has a guaranteed sound power level of: 105
dB(A)/1pW, based on measurements of identical
machines per Directive 2000/14/EC and amendments.

Vibration level

Hand-Arm

This unit does not exceed a vibration level of 2.5 m/s2at
the hands based on measurements of identical machines
per ISO 5349 procedures.

6

Symbol Glossary

Caustic liquids,
chemical burns to
fingers or hand

Poisonous
fumes or toxic
gases, asphyxiation

Electrical shock,
electrocution

High pressure
fluid, injection
into body

High pressure
spray, erosion of
flesh

High pressure
spray, erosion of
flesh

Crushing of
fingers

or hand,

force

applied from

above

Crushing of
toes or foot, force
applied from above

Crushing of
whole body,
applied from
above

Crushing of
torso, force
applied from side

Crushing of fingers
or hand/, force
applied from side

Crushing of
whole body

Crushing of
head, torso and
arms

Cutting of
fingers or hand

Cutting of footCrushing of leg,
force applied
from side

Severing of
fingers or hand,
mower blade

Severing of
toes or foot,
mower blade

Severing of
toes or fingers,
rotary mower
blade

Cutting or
entanglement of
foot, rotating auger

Severing of
foot, rotating
knives

Severing of
fingers or hand,
impeller blade

Dismember­ment, front engine
mower in forward
motion

Dismember­ment, front engine
mower in rearward
motion

Severing of
fingers or hand,
engine fan

Whole body entanglement,
implement input drive line

Fingers or
hand entangle­ment, chain
drive

Hand & arm
entanglement,
belt drive

Thrown or flying
objects, whole
body exposure

Thrown or
flying objects,
face exposure

Thrown or flying
objects, rotary
mover

Runover/back­over, vehicle

Machine
tipping, riding
mower

Machine rollover,
ROPS (rear
engine mower)

Stored energy
hazard, kickback
or upward motion

Hot surfaces,
burns to fingers
or hands

Explosion Fire or open

flame

Secure lifting
cylinder with locking
device before getting
in hazardous area

Do not step on
loading platform
if PTO is connect­ed to tractor &
engine is running

Do not step Wait until all

machine comp­onents have
completely
stopped before
touching them

Shut off engine
& remove key
before perform­ing maintenance
or repair work

Stay a safe
distance from
the machine

Stay clear of
articulation area
while engine is
running

Do not open
or remove safety
shields while
engine is
running

Riding on this
machine is allowed
only on a passen­ger seat & only if the
driver’s view is not
hindered

7

Consult technical
manual for proper
service
procedures

Fasten seat
belts

Safety alert
triangle

Outline safety
alert symbol

Read operator’s
manual

Fire, open light
and smoking
prohibited

Eye protection
must be worn

Head protection
must be worn

Brake system

Filter Temperature Failure/

Plus/increase/
positive polarity

Hearing
protection must
be worn

Oil Coolant (water) Intake air Exhaust gas Pressure Level indicator Liquid level

Minus/decrease/
negative polarity

Caution, toxic
risk

Malfunction

Horn

Flush with water Engine Transmission Hydraulic systemFirst aid

Start switch/
mechanism

Battery charging
condition

Hourmeter/
elapsed operating
hours

On/start Off/stop Engage

Fast Slow Continuous

Disengage

variable, linear

Volume empty Volume full Machine travel

Oil lubrication
point

Engine lubricating
oil temperature

Lift point Jack or

Engine coolant

direction,
forward/
rearward

support point

Engine coolant
pressure

Control lever
operating
direction, dual
direction

Draining/
emptying

Engine coolant
filter

Control lever
operating
direction, multiple
direction

Engine lubricat­ing oil

Engine coolant
temperature

Clockwise
rotation

Engine
lubricating
oil pressure

Engine intake/
combustion air

Counter-clock­wise rotation

Engine lubricating
oil level

Engine intake/com­bustion air pressure

Grease
lubrication
point

Engine lubricating
oil filter

Engine intake/air
filter

8

Engine start Engine stop Engine failure/

Transmission
oil pressure

Transmission
oil temperature

malfunction

Transmission
failure/malfunction

RP 2 31

Reverse

Park First gear

n/min

Engine rotational
speed/frequency

Choke Primer (start aid) Electrical preheat

(low temperature
start aid)

Transmission
oil

NHLF

Clutch Neutral High Low Forward

Second gear

Third gear (other #'s
may be used until the
maximum # of forward
gears is reached.)

Hydraulic oil

Hydraulic oil
pressure

Hydraulic oil
level

Hydraulic oil
filter

Power Take-Off,
rotational speed

Cutting unit,
transport
position

Hydraulic oil
temperature

Blade cutting
element

Cutting unit,
raise to transport
position

Hydraulic oil
failure/malfunction

Blade cutting
element, height
adjustment

Cutting unit,
lower to transport
position

Parking brake Fuel

Lock Unlock Differential lock 4-Wheel drive Power Take-OffDiesel fuel Unleaded fuel Headlights

Attachment
lower

Cutting unit Cutting unit,

raise

Attachment
raise

Fuel level

Cutting unit,
lower

Spacing distance Snow thrower,

Fuel filter Fuel system

Cutting unit,
hold

collector auger

failure/malfunction

Cutting unit,
float

Traction

Above working
temperature
range

Drilling Manual metal

arc welding

Manual Water pump Keep dry Weight Do not dispose

in the garbage

CE logo

9

Specifications

Traction Unit

Engine: Peugeot, four-cycle, four-cylinder, 1.9 liter
(1,900 cc) displacement, liquid-cooled diesel engine.

23.5:1 compression ratio. Low idle—1,600 rpm, high
idle—2,800±30 rpm. Oil capacity is 5 l (5.3 quarts) with
filter.

Cooling System: Capacity is 13.2 l (3.5 gal) of 50/50
mixture of Peugeot recommended anti-freeze.

Fuel System: Capacity is 45.2 liter (12 gallon) of #1 or
#2 diesel fuel.

Hydraulic System: Reservoir capacity is 24.6 liters
(6.5 gallon). Replaceable spin-on filter element.

Traction System: Ground speed: Low Range; 0–10.5
kmh, 0–6.5 mph (0–5.5 mph. with mechanical speed
limiter interlock) forward and 0–4.8 kmh, 0–3 mph
reverse. High Range: 0–24.1 kmh, 0–15 mph (0–20
kmh, 0–12.4 m.p.h. with mechanical speed limiter
interlock) forward and 0–8 kmh, (0–5 mph) reverse.

Front Axle: Two-speed axle is designed to withstand
heavy-duty slope operation and side loading. Separate
mowing and transport selections for faster and more
efficient machine operation. Neutral position allows
easy towing.

Rear Axles: Two-Wheel Drive—The large diameter
wheel spindles are designed for durability and long
wear, yet provide superior stability and maneuverability.
Four-Wheel Drive—Heavy-duty, agricultural type.
Hydraulic drive with “on demand” bi-directional clutch
and balanced weight distribution provides superior
traction on hillsides.

Tires/Wheels: High flotation turf tread tires on de­mountable rims. Front tires: (2) 26 x 12.0-12, 8 ply.
Rear tires: (2) 20 x 10.0-10, 6 ply. Tire pressure 138 kPa
(20 psi).

Seat: Adjustable fore and aft travel and weight.

Diagnostic System: Test ports for: forward and reverse

traction (2-wheel drive), front and rear axle motors (4
wheel drive), lift and counterbalance circuit, steering
circuit and charge circuit.

Steering System: Automotive type, full power.

Brakes: Totally enclosed, non asbestos, dry multi-disc

14.3 cm individual wheel and parking brakes on front
traction wheels. Brakes controlled by individual pedals
operated by the left foot. Dynamic braking through
closed-loop hydrostatic drive.

Electrical System: 12-volt battery with 650 cold
cranking Amps @ –18°C (0° F). 55-amp alternator,
ammeter, starter, key switch and automatic temperature
controlled glow plug controller. Separately-fused run,
deck and instrument/accessory circuits.

Interlock System: Stops the engine if operator gets off
the seat while the cutting deck drive switch is engaged
or the traction pedal is forward or reverse. Prevents the
engine from starting unless the traction pedal is in
neutral and the cutting deck is disengaged. Prevents the
cutting deck from operating unless the axle shift is in
LO range. The engine will stop if the machine comes
out of neutral with the parking brake set.

Warning Lights:

Glow plug indicator
Engine oil pressure warning
Engine coolant temperature warning
Charge indicator
Water in fuel
Low-water indicator

Indicators:

Engine coolant temperature gauge
Fuel gauge
Hour meter

General Specifications (approx.):

Overall Length:

With the deck installed 340 cm (134 in.)

Overall Width:

Transport 190.5 cm (75 in.)
Mowing 323 cm (127 in.)

Height:147 cm (58 in.)

With rollover protection
system installed 208 cm (82 in.)

Wheel Tread:

(Front) 129.5 cm (51 in.)
(Rear) 104 cm (41 in.)

10

Wheel Base: 132 cm (52 in.)

Dry Weight:

2-Wheel Drive 1,418 kg (3,800 lb)
4-Wheel Drive 1,455 kg (3,900 lb)

Optional Equipment

Broom Kit Contact Your Local Toro Distributor
Snowthrower Contact Your Local Toro Distributor
Roll-Over Protection Kit, Contact Your Local Toro

Distributor (Standard on Model 30455)
4-Post Canopy KitContact Your Local Toro Distributor
Spark Arrestor Muffler Part No. 94-5637
Segmented Wheel Kit, Part No. 76-1880
Brake Light Kit, Part No. 92-7763
Windshield Kit Contact Your Local Toro Distributor
Cruise Control Kit Model No. 30485
Road Light Kit Model No. 30471
Mulcher Kit Model No. 30475
Cab Contact your local Toro distributor
Additional Weights Contact your local Toro distributor
Low Seat Option Contact your local Toro distributor

Specifications and design subject to change without
notice.