Toro 30654 Operator'S Manual Download

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Daily Maintenance Checklist

Duplicate this page for routine use.

For the week of:

Maintenance Check Item

Mon.

Tues.

Wed.

Thurs.

Fri.

Sat.

Sun.

Check the safety interlock operation.

Check the brake operation.

Check the engine-oil and fuel levels.

Check the air-filter restriction indicator.

Check the radiator and screen for debris.

Check unusual engine noises.

Check unusual operating noises.

Check the hydraulic system fluid level.

Check hydraulic hoses for damage.

Check for fluid leaks.

Check the tire pressure.

Check the instrument operation.

Check the cylinder-to-bedknife adjustment.

Check the height-of-cut adjustment.

Check all grease fittings for lubrication.

Touch up damaged paint.

1. Check the glow plug and injector nozzles if hard starting, excess smoke, or rough running is noted.

2. Immediately after every washing, regardless of the interval listed

Notation for Areas of Concern

Inspection performed by:

Item

Date

Information

Important:

Refer to your engine operator’s manual for additional maintenance procedures.

Summary of Contents for 30654

Page 1: ...Form No 3439 307 Rev B CT2240 Compact Triple 4 Wheel Drive Turf Mower Model No 30654 Serial No 405600000 and Up Register at www Toro com Original Instructions EN 3439 307 ...

Page 2: ...r or to register your product 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 Figure 1 identifies the location of the model and serial numbers on the product Write the numbers in the space provided g320033 Figure 1 1 Model and serial number location Model...

Page 3: ...37 Engine Maintenance 38 Engine Safety 38 Checking the Engine Overheat Warning System 38 Servicing the Air Cleaner 38 Servicing the Engine Oil and Filter 39 Fuel System Maintenance 40 Draining the Fuel Tank 40 Checking the Fuel Lines and Connections 40 Bleeding the Fuel System 40 Replacing the Fuel Filter 41 Electrical System Maintenance 41 Electrical System Safety 41 Checking the Electrical Syste...

Page 4: ...ne Do not operate the machine without all guards and other safety protective devices in place and functioning properly on the machine Keep bystanders and children out of the operating area Never allow children to operate the machine Shut off the engine remove the key and wait for all movement to stop before you leave the operator s position Allow the machine to cool before adjusting servicing clea...

Page 5: ... 13 077 70 13 077 1 Warning shut off the engine and remove the ignition key before releasing or operating the safety latches decal950832 950832 1 Tire pressure decal950889 950889 1 Warning hot surfaces decal111 0773 111 0773 1 Warning crushing of fingers force applied from side decal111 3344 111 3344 1 Ignition switch indicating different positions of key switch decal111 3562 111 3562 1 Press the ...

Page 6: ... operating decal111 3567 111 3567 1 Pedal operation to control machine direction decal111 3658 111 3658 1 Cutterhead 3 Unlatch 2 Latch decal111 3901 111 3901 1 Transmission fluid read the Operator s Manual decal111 3902 111 3902 1 The fan can cut your hand warning 2 Hot surfaces read the Operator s Manual 6 ...

Page 7: ...ecal134 1807 134 1807 1 Slope indicator 7 Raise 2 Right cutting unit controls 8 Fast 3 Center cutting unit controls 9 Engine speed 4 Left cutting unit controls 10 Slow 5 Lower float 11 Horn 6 Transport 7 ...

Page 8: ...lt in a change in slope operation for the machine If possible keep the cutting units lowered to the ground while operating the machine on slopes Raising the cutting units while operating on slopes can cause the machine to become unstable 1 Tipping hazard drive slowly when turning or going up slopes 4 Warning read the Operator s Manual remove the key from the ignition before servicing or performing...

Page 9: ...gine coolant level 17 Lubrication points for 50 hour interval 3 Check the tire pressure 8 Check engine oil level 13 Check cleanliness of radiator 4 Check all nuts and bolts for proper tightness 9 Check operation of seat switch 14 Clean and inspect the machine 5 Check all hoses for leaks 10 Check air filter element 15 Check wheel nut tightness using a torque wrench front wheels 200 N m rear wheels ...

Page 10: ... Qty Use Operator s Manual 1 Engine owner s manual 1 Read the manuals before operating the machine 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 10 ...

Page 11: ...azard warning switch supplied with lighting kit 13 Engine oil pressure indicator 4 Warning beacon switch supplied with beacon kit 14 Transmission temperature indicator 5 Cutting units position controls 15 Hour meter 6 Throttle control lever 16 Battery warning indicator 7 Ignition switch 17 Engine temperature warning indicator 8 Cutting units drive switch 18 Glow plug indicator 9 Lighting switch su...

Page 12: ... operates on the front wheels only Do not park the mower on a slope g014421 Figure 7 1 Parking brake Emergency Brake In the event of service brake failure turn the ignition off to bring the mower to a standstill WARNING Application of the emergency brake activates front wheel brakes of the mower while traveling a sudden stop may cause ejection from the mower Remain seated and hold on to the steeri...

Page 13: ...units to the transport position and secure with the transport latches and safety locks when travelling between work areas Figure 10 g014548 Figure 10 Cutting Unit Drive Switch Always put the cutting unit drive switch in the OFF position when travelling between work areas Adjustable Steering Column WARNING A damaged steering column adjuster may cause the steering column to become loose which may ca...

Page 14: ... securely in position once adjusted and locked Adjust the seat only 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 12 Operator weight adjustment Rotate the handle clockwise to increase the suspension stiffness and counter clockwise to decrease the stiffness Figure 12 g014550 Fi...

Page 15: ...Warning Light The battery charge warning light illuminates when low battery charge occurs Figure 15 g014553 Figure 15 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 16 g014554 Figure 16 1 Low engine oil pressure warning light Disengagement of Reels The reels disengage when the operat...

Page 16: ...t a cold engine before using the pre heat can cause unnecessary wear to the battery g014557 Figure 19 1 Engine pre heat indicator light Fuel Gauge The fuel gauge shows the amount of fuel in the tank Figure 20 g014558 Figure 20 Hour Meter The hour meter shows the total hours that the machine has been operated Figure 21 g014559 Figure 21 1 Hour meter Transmission Neutral Indicator Light This light i...

Page 17: ...Indicator Light This light illuminates when the cutting unit drive switch is in the FORWARD REVERSE position and the ignition key is turned to position I Figure 23 g014561 Figure 23 1 Cutting unit drive switch indicator light 17 ...

Page 18: ... 9 US gallons Transport speed 22 km h 13 7 mph Mowing speed 11 km h 6 8 mph Hydraulic system capacity 32 L 8 5 US gallons Attachments Accessories A selection of Toro approved attachments and accessories is available for use with the machine to enhance and expand its capabilities Contact your Authorized Service Dealer or authorized Toro distributor or go to www toro com en gb for a list of all appr...

Page 19: ...ater or other appliance If you spill fuel do not attempt to start the engine avoid creating any source of ignition until the fuel vapors have dissipated Performing Daily Maintenance Service Interval Before each use or daily Before starting the machine each day perform the Each Use Daily procedures listed in Maintenance page 33 Checking the Engine Oil Level Service Interval Before each use or daily...

Page 20: ...n the radiator cap when the engine is running Use a rag when opening the radiator cap and open the cap slowly to allow steam to escape The cooling system is filled with a 50 50 solution of water and permanent ethylene glycol antifreeze 1 Clean debris off of the screen oil cooler and front of the radiator daily and more often if conditions are extremely dusty and dirty Refer to Removing Debris from...

Page 21: ...k outdoors in an open area when the engine is cold Wipe up any fuel that spills Never fill the fuel tank inside an enclosed trailer Never smoke when handling fuel and stay away from an open flame or where fuel fumes may be ignited by a spark Store fuel in an approved container and keep it out of the reach of children Never buy more than a 180 day supply of fuel Do not operate the machine without t...

Page 22: ...iscosity ASTM D445 cSt 40 C 104 F 44 to 48 Viscosity Index ASTM D2270 140 or higher Pour Point ASTM D97 37 C to 45 C 34 F to 49 F Industry Specifications Eaton Vickers 694 I 286 S M 2950 S 35VQ25 or M 2952 S Note Many hydraulic fluids are almost colorless making it difficult to spot leaks A red dye additive for the hydraulic fluid is available in 20 ml 0 67 fl oz bottles A bottle is sufficient for...

Page 23: ... the platform carefully Note The gas spring will provide assistance 2 Move the locking latch handle toward the front of the mower as the platform nears the fully lowered position Note This ensures that the latch hooks clear the locking bar 3 Fully lower the platform and move the locking handle toward the rear of the mower until the latch hooks fully engage the locking bar g014422 Figure 28 Underst...

Page 24: ...bility to avoid holes or hidden hazards Avoid mowing on wet grass Reduced traction could cause the machine to slide Keep your hands and feet away from the cutting units Look behind and down before backing up to be sure of a clear path Use care when approaching blind corners shrubs trees or other objects that may obscure your vision Stop the cutting units whenever you are not mowing Slow down and u...

Page 25: ... offs ditches embankments water hazards or other hazards The machine could suddenly roll over if a wheel goes over the edge or the edge caves in Establish a safety area between the machine and any hazard Identify hazards at the base of the slope If there are hazards mow the slope with a pedestrian controlled machine If possible keep the cutting units lowered to the ground while operating on slopes...

Page 26: ...d engine 2 Let the engine idle for 5 minutes 3 Turn the ignition key to position 0 If the engine fails to shut off when the ignition key is turned to 0 operate the engine shutoff lever in the forward direction Figure 30 WARNING Contact with hot or moving parts can result in personal injury Keep all body parts away from any hot or moving parts of the engine g014563 Figure 30 Adjusting the Center Cu...

Page 27: ...g approximately 150 mm 6 inches above ground level This operates with the cutting units lowered and rotating Auto limited lift in reverse causes the cutting units to rise automatically to the limited lift position when reversing They return to the floating position when returning to forward travel The cutting units continue to rotate during this operation Engaging the Cutting Unit Drive g014434 Fi...

Page 28: ...action assistance Hydraulic pressure in the cutting unit lift system provides a lifting force which reduces the weight of the cutting units on the ground and transfers the weight as a downward force onto the tires of the machine This action is known as weight transfer To engage weight transfer The amount of weight transfer can be varied to suit operating conditions by rotating the weight transfer ...

Page 29: ...e operating the machine in an open area Start and shut off the engine Operate in forward and reverse Lower and raise the cutting units and engage and disengage the cutting units When you feel familiar with the machine practice operating up and down slopes at different speeds Understanding the Warning System If a warning light comes on during operation stop the machine immediately and correct the p...

Page 30: ...ow the machine to cool before adjusting servicing cleaning or storing it Clean grass and debris from the cutting units drives mufflers cooling screens and engine compartment to help prevent fires Clean up oil or fuel spills Disengage the drive to the attachment whenever you are hauling or not using the machine Maintain and clean the seat belt s as necessary Do not store the machine or fuel contain...

Page 31: ...s 1 Connect a rigid tow bar between the towing eye on the front of the mower and a suitable towing vehicle 2 Identify the right hand front wheel motor disc brake assembly and remove the hex plug Figure 36 g014448 Figure 36 1 Hex plug 3 Locate the M12 x 40 mm setscrew and washer stored underneath the operator platform one in each of the platform support rails 4 Install a M12 x 40 mm long setscrew w...

Page 32: ...ht hand front wheel motor disc brake assembly B Rotate the setscrew counterclockwise and remove together with the washer C Assemble the hex plug into the motor end plate Figure 39 g014451 Figure 39 1 Front wheel motor 3 Washer M12 2 Hex plug 4 Setscrew M12 x 40 mm D Identify the left front wheel motor disc brake assembly and repeat the previous procedure E Remove the wheel chocks F Disconnect the ...

Page 33: ...tension of the alternator belt After the first 50 hours Change the engine oil and filter Change the transmission oil filter Change the hydraulic return filter Check the engine speed idle and full throttle Before each use or daily Inspect the seat belt s for wear cuts and other damage Replace the seat belt s if any component does not operate properly Check the engine oil level Check the cooling sys...

Page 34: ... hours Check the engine overheat warning system Replace the primary air filter more frequently in extreme dusty or dirty conditions Check the electrical system Change the transmission oil filter Change the hydraulic return filter Check the rear wheel alignment Service the hydraulic system Check the hydraulic fluid overheat warning system Replace the fuel filter Every 800 hours Drain and clean the ...

Page 35: ...fluid level Check hydraulic hoses for damage Check for fluid leaks Check the tire pressure Check the instrument operation Check the cylinder to bedknife adjustment Check the height of cut adjustment Check all grease fittings for lubrication 2 Touch up damaged paint 1 Check the glow plug and injector nozzles if hard starting excess smoke or rough running is noted 2 Immediately after every washing r...

Page 36: ...Service Interval Chart g025069 Figure 40 36 ...

Page 37: ...g regardless of the interval listed Replace any damaged grease fittings Grease all cutting unit 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 and debris and ensures maximum working life The grease fitting locations and quantities are as foll...

Page 38: ...ose hose clamps Service the primary air cleaner filter only when the service indicator Figure 43 requires it Changing the air filter before it is necessary only increases the chance of dirt entering the engine when the filter is removed Important Be sure that the cover is seated correctly and seals with the air cleaner body 1 Check the filter blockage indicator If the indicator is red replace the ...

Page 39: ...e 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 Every 150 hours 1 Remove the drain plug Figure 45 and let the oil flow into a drain pan g008911 Figure ...

Page 40: ...ns have occurred Initial start up of a new machine Engine has ceased running due to lack of fuel Maintenance has been performed upon fuel system components i e filter replaced separator serviced etc 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 ...

Page 41: ... protective clothing and use insulated tools Checking the 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 Checking the Battery Condition Service Interval Every 250 hours Note When removing the battery always disconn...

Page 42: ...ear the battery and keep sparks and flames away from it Check the battery condition Keep the terminals and the entire battery case clean because a dirty battery discharges slowly To clean the battery wash the entire case with a solution of baking soda and water Rinse it with clear water Drive System Maintenance Changing the Transmission Oil Filter Service Interval After the first 50 hours Every 50...

Page 43: ...12 to 0 31 inch 1 Set the rear wheels in the straight ahead position 2 Measure and compare the distance between the front sidewalls and the rear sidewalls at the wheel center height Note The distance between the front sidewalls must be set 3 to 8 mm 0 12 to 0 31 inch less than the distance between the rear sidewalls g014442 Figure 50 1 Wheel center height 3 Direction of forward travel 2 Tire 4 Tra...

Page 44: ... range and ensure that the mechanism moves smoothly and freely to the NEUTRAL position without sticking or hanging up g014571 Figure 51 1 Outer cover 3 Sleeve 2 Rubber seal 4 Rod end Cooling System Maintenance Cooling System Safety Swallowing engine coolant can cause poisoning keep out of reach from children and pets Discharge of hot pressurized coolant or touching a hot radiator and surrounding p...

Page 45: ...bris with low pressure 50 psi compressed air do not use water Repeat the step from the front of the radiator and again from the fan side Thoroughly clean both sides of the oil cooler 8 After the radiator and oil coolers are thoroughly cleaned clean out any debris that may have collected on other parts of the machine Figure 54 with compressed air g004137 Figure 54 1 Radiator 9 Pivot the oil cooler ...

Page 46: ...stment Controls System Maintenance Checking the Forward Reverse Travel Pedal Action With the engine shut 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 Checking the Operator Presence Seat Switch Service Interval Before each use or daily 1 Sit on the operator seat and start the engine 2 Lo...

Page 47: ... Note Use extreme care to ensure that the area around the machine is clear before checking that the engine does not start under this condition Hydraulic System Maintenance Hydraulic System Safety Seek immediate medical attention if fluid is injected into skin Injected fluid must be surgically removed within a few hours by a doctor Ensure that all hydraulic fluid hoses and lines are in good conditi...

Page 48: ...d level and top up as necessary to the upper mark on the sight level gauge g014452 Figure 56 1 Fluid tank filler cap 3 Filler strainer 2 Suction strainer Checking the Hydraulic Fluid Overheat Warning System Service Interval Every 500 hours g022285 Figure 57 1 Temperature switch 2 Hydraulic fluid tank 1 Turn the ignition key to the ignition on position I 2 Disconnect the red yellow wire terminal fr...

Page 49: ... the component parts and have them ground again 1 Ensure that the mower engine is shut off and that the parking brake is engaged 2 Adjust the reels to the bedknives to obtain light contact 3 Apply a medium grade detergent based carborundum paste to the cutting edges of the reels with a long handled brush 80 grade carborundum paste Part No 0 45 kg 1 lb 63 07 088 11 3 kg 25 lb 63 07 086 g014445 Figu...

Page 50: ... to be used is in good condition and capable of supporting the weight of the mower securely Minimum lift capacity 2 000 kg 4 409 lb 1 Park the machine on a level surface 2 Engage the parking brake 3 Shut off the engine and remove the ignition key 4 Ensure that the ground under the lifting device is level and firm 5 Align and ensure the lifting device is secure against one of the lifting points on ...

Page 51: ...eaning or storing it Do not store the machine or fuel container where there is an open flame spark or pilot light such as on a water heater or other appliance Preparing the Traction Unit 1 Thoroughly clean the traction unit cutting units and engine 2 Check the tire pressure Refer to Checking the Tire Pressure page 22 3 Check all fasteners for looseness and tighten them as necessary 4 Grease all gr...

Page 52: ...ely 2 minutes 5 Shut off the engine 6 Thoroughly drain all fuel from the fuel tank lines and the fuel filter water separator assembly 7 Flush the fuel tank with fresh clean diesel fuel 8 Secure all fuel system fittings 9 Thoroughly clean and service the air cleaner assembly 10 Seal the air cleaner inlet and the exhaust outlet with weatherproof tape 11 Check the antifreeze protection and add antifr...

Page 53: ...the float position 3 There is no ground contact on 1 end of the cutting unit because of poorly routed hoses or wrongly positioned hydraulic adapters 3 Correct the hose routing and the position of the hydraulic adapters 4 There is no ground contact on 1 end of the cutting unit because of pivot pins seizing 4 Release and grease the pivot points There is a step in the cut grass height at the point of...

Page 54: ...nnection is loose or corroded 1 Clean and tighten the terminal connections Charge the battery 2 The alternator belt is loose or worn 2 Adjust the tension or replace the belt refer to engine operator s manual 3 The battery is discharged 3 Charge or replace the battery The battery has no power 4 There is an electrical short circuit 4 Locate the short circuit and fix it 1 There is a blocked screen 1 ...

Page 55: ... the hydraulic system 7 The hydraulic fluid level is low 7 Fill the hydraulic fluid reservoir to the correct level 1 A pump or motor is worn 1 Replace parts as necessary 2 The hydraulic fluid level is low 2 Fill hydraulic fluid tank to the correct level 3 The fluid in the hydraulic system has the wrong viscosity 3 Replace the fluid in the hydraulic tank with the correct viscosity grade fluid refer...

Page 56: ...witch is malfunctioning 1 Check the mechanical and electrical operation of the switch 2 The hydraulic fluid level is low 2 Fill the hydraulic fluid reservoir to the correct level 3 A driveshaft is sheared 3 Check the motor and reel driveshafts and replace them if necessary 4 The pressure relief valve is jammed open or wrongly set 4 Have the relief valve pressure checked Consult your authorized Tor...

Page 57: ...Notes ...

Page 58: ...Notes ...

Page 59: ... for marketing purposes Retention of your Personal Information Toro will keep your personal information as long as it is relevant for the above purposes and in accordance with legal requirements For more information about applicable retention periods please contact legal toro com Toro s Commitment to Security Your personal information may be processed in the US or another country which may have le...

Page 60: ...vered for the duration of the original product warranty and become the property of Toro Toro will make the final decision whether to repair any existing part or assembly or replace it Toro may use remanufactured parts for warranty repairs Deep Cycle and Lithium Ion Battery Warranty Deep cycle and Lithium Ion batteries have a specified total number of kilowatt hours they can deliver during their li...

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