Toro CT2120 30655, Operator'S Manual

Page 1: ... CT2140 Compact Triple 4 Wheel Drive Turf Mower Model No 30655 Serial No 310000001 and Up Model No 30656 Serial No 310000001 and Up g014494 To register your product or download an Operator s Manual or Parts Catalog at no charge go to www Toro com Original Instructions EN ...

Page 2: ...artment Spellbrook Bishops Stortford CM23 4BU England 44 0 1279 603019 Email uk service toro com 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 The model and serial numbers are on a plate mounted on the left side of the frame under the foot rest Write th...

Page 3: ...nance 35 Check the Engine Overheat Warning System 35 Servicing the Air Cleaner 35 Servicing the Engine Oil and Filter 36 Fuel System Maintenance 37 Draining the Fuel Tank 37 Checking the Fuel Lines and Connections 37 Bleeding the Fuel System 37 Electrical System Maintenance 38 Check Electrical System 38 Check Battery Condition 38 Inspect Transmission Control Cable and Operating Mechanism 38 Servic...

Page 4: ...ys wear substantial footwear long trousers hard hat safety glasses and ear protection Long hair loose clothing or jewelry may get tangled in moving parts Do not operate the equipment when barefoot or wearing open sandals Thoroughly inspect the area where the equipment is to be used and remove all objects which may be thrown by the machine Warning Fuel is highly flammable Take the following precaut...

Page 5: ...e transport position engage the transport latches and safety locking rings stop the engine and remove the key When driving the mower between work sites it is important to ensure that the cutterheads cannot be inadvertently lowered and started disengage the drive to the cutterheads raise the cutterheads to the transport position engage the transport latches and safety locking rings Stop the engine ...

Page 6: ...er Safety The following list contains safety information specific to Toro products or other safety information that you must know that is not included in the safety standards This product is capable of amputating hands and feet and throwing objects Always follow all safety instructions to avoid serious injury or death Use of this product for purposes other than its intended use could prove dangero...

Page 7: ...overned engine speed should be 3000 RPM If major repairs are ever needed or if assistance is desired contact an Authorized Toro Distributor Use only Toro approved attachments and replacement parts The warranty may be voided if used with unapproved attachments Sound Power Level This unit has a guaranteed sound power level of 105 dBA which includes an Uncertainty Value K of 1 dBA Sound power level w...

Page 8: ...eater than 16 degrees 3 Tipping hazard always wear the seat belt when a roll over protection system ROPS is in use do not wear a seat belt when the ROPS bar is lowered 4 Warning read the Operator s Manual remove the ignition key before performing any maintenance 5 Thrown object hazard keep bystanders a safe distance from the machine 111 3277 1 Horn 5 Fast 2 Cutters lower 6 Engine speed 3 Cutters h...

Page 9: ...shing hazard ensure platform latch in engaged before operating 111 3567 1 Pedal operation 111 3901 1 Transmission oil read the Operator s Manual for more information 111 3902 1 Warning cutting hazard of hand fan 2 Hot surfaces read the Operator s Manual for more information 9 ...

Page 10: ...olant level 17 Lubrication points for 50 hour interval 3 Check the tyre 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 hose for leaks 10 Check air filter element 15 Check wheel nut tightness using a torque wrench Front wheels 200 N m Rear wheels 54 N m 1...

Page 11: ...and rear tyres See the chart below for the correct pressure Important Maintain correct tyre pressures in all tyres to ensure correct contact with the turf Tyres Tyre Type Recommended Tyre Pressures Turf Conditions Road Conditions Max Pressure Front Axle 23 x 10 5 12 BKT turf pattern 0 7 bar 10 psi 1 4 bar 20 psi 1 7 bar 25 psi Rear Axle 18 x 9 5 8 6 BKT turf pattern 0 7 bar 10 psi 1 4 bar 20 psi 1...

Page 12: ...iliary 12 volt socket supplied with a 12V kit 3 Warning beacon switch supplied with beacon kit 13 Oil pressure indicator 4 Hazard warning switch supplied with lighting kit 14 Transmission temperature indicator 5 Cutterheads position controls 15 Hour meter 6 Throttle control lever 16 Battery warning indicator 7 Ignition key 17 Engine temperature warning indicator 8 Cutterheads drive switch 18 Glow ...

Page 13: ... 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 WARNING The service braking system will not hold the mower at a standstill ALWAYS ensure the parking brake is engaged to park the mower at a standstill Emergency Brake In the e...

Page 14: ...ty locks when travelling between work areas Figure 9 G014548 Figure 9 Cutterhead Drive Switch Always put the cutterhead drive switch in the Off position when travelling between work areas Adjustable Steering Column WARNING Never operate the mower without first checking that the steering column adjuster mechanism is in good working order and that once adjusted and locked the steering wheel remains ...

Page 15: ... 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 you to adjust the seat fore and aft Figure 11 Operator weight adjustment Rotate handle clockwise as shown to increase suspension stiffness and counter clockwise to decrease Figure 11 1 G014550 CW CCW 2 Figure 11 1 Seat adjustment le...

Page 16: ...ery charge warning light illuminates when low battery charge occurs Figure 14 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 1 G014554 Figure 15 1 Low engine oil pressure warning light Disengagement of Cutting Cylinders The cutting cylinders will disengage when...

Page 17: ...pting to start a cold engine before the pre heat is used can cause unnecessary wear to the battery 1 G014557 Figure 18 1 Engine pre heat indicator light Fuel Gauge The fuel gauge shows the amount of fuel in the tank Figure 19 G014558 FUEL E F Figure 19 Hour Meter The hour meter shows the total hours that the machine has been operated Figure 20 1 G014559 000 0 Figure 20 1 Hour meter Transmission Ne...

Page 18: ...th R O P S folded 2290mm 90 15 inches with R O P S in its vertical operating position 1681mm 66 2 inches with R O P S folded 2290mm 90 15 inches with R O P S in its vertical operating position Weight 1 150 kg 2 536 lb 1 200 kg 2 645 lb Engine Kubota 19 4kw 26hp at 3000 rpm DIN 70020 Kubota 19 4kw 26hp at 3000 rpm DIN 70020 Fuel tank capacity 45 7 litres 45 7 litres Transport speed 22km h 13 7mph 2...

Page 19: ... all temperatures Toro Premium Engine oil is available from your distributor in either 15W 40 or 10W 30 viscosity Note The best time to check the engine oil is when the engine is cool before it has been started for the day If it has already been run allow the oil to drain back down to the sump for at least 10 minutes before checking If the oil level is at or below the add mark on the dipstick add ...

Page 20: ... D at temperatures above 7 C 20 F and winter grade No 1 D or No 1 D 2 D blend below that temperature Use of winter grade fuel at lower temperatures provides lower flash point and cold flow characteristics which will ease starting and reduce fuel filter plugging Use of summer grade fuel above 7 C 20 F will contribute toward longer fuel pump life and increased power compared to winter grade fuel Imp...

Page 21: ...sed provided they meet all the following material properties and industry specifications We do not recommend the use of synthetic fluid Consult with your lubricant distributor to identify a satisfactory product Note Toro will not assume responsibility for damage caused by improper substitutions so use only products from reputable manufacturers who will stand behind their recommendation High Viscos...

Page 22: ...ont of the mower as the platform nears the fully lowered position This will ensure that the latch hooks clear the locking bar 3 Fully lower the platform and move the locking handle towards the rear of the mower until the latch hooks fully engage the locking bar G014422 Figure 27 Operator Presence Control Note The engine will cut out if the operator leaves the seat without engaging the parking brak...

Page 23: ...ottle position 2 Turn the ignition key to the ignition on position I and check that the engine oil pressure and battery charge warning lights illuminate 3 Turn the ignition key to the preheat position II so that the pre heat indicator light is on Hold it for 5 seconds to heat the glow plugs 4 After preheating the glow plugs turn key to the start position III and hold to crank the engine Crank the ...

Page 24: ...ing edges are kept sharp to ensure good cutting performance minimum power consumption and prolonged life for the cutting edges refer to Cutterheads Maintenance page 46 MK3 Fixed cutterhead 8 inch 20 cm When the mower is set up with fixed cutterheads the height of cut is gauged by the rear roller and the cutterhead is allowed to pivot laterally to follow ground contours This arrangement is recommen...

Page 25: ...cm Pivot knuckle fixing Secure the bolt in the front fixed hole position in Figure 34 as shown 1 G014427 Figure 34 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 2 1 G014428 Figure 35 1 Adjusting nut...

Page 26: ...to decrease height of cut or anti clockwise to increase height of cut Figure 38 3 2 1 G014431 4 Figure 38 1 Adjusting nut assembly 3 Height of cut 2 Adjusting nuts 4 Indicator rings Important Do not attempt to unlock the nut assemblies To alter the front roller position loosen bolts Release and turn adjusting nuts both ends clockwise to increase the height of cut or anti clockwise to decrease the ...

Page 27: ...e the lift control switches in an upward direction and hold in position 3 If the cutterhead drive switch is in the On position the cylinder drive will disengage immediately 3 Release the lift control switches when the cutterheads are at the required height The control switches will automatically return to position 2 neutral and the arms are hydraulically locked into position Adjusting the Cutterhe...

Page 28: ...machine on level ground 2 Apply the parking brake and disengage all drives 3 Lower the cutting units to the ground or securely lock in the designated transport positions 4 Stop the engine and remove the ignition key to isolate all power sources and check that they are stopped 5 Release all stored energy devices 6 Check that all moving parts are stationary 7 Using a suitable strong wooden instrumen...

Page 29: ...nsert the retaining bolts in the lower hole and fully tighten the hand nuts to support the upperframe in its lowered position 5 To raise the frame follow these instructions in reverse order WARNING When in the raised position both retaining bolt assemblies must be installed and fully tightened to ensure full R O P S protection WARNING Be careful lowering and raising the R O P S frame to prevent en...

Page 30: ...gly Engine Never let the engine labour Reduce the forward speed or increase the height of cut Check that the cutting cylinders are not in heavy contact with their bottom blades Transporting Always disengage the cutterhead drive when travelling across un grassed areas Grass will lubricate the cutting edges whilst mowing Excessive heat will build up if the cutting cylinders are run when not mowing a...

Page 31: ...ather deterioration and chemical deterioration Every 50 hours Grease the bearings bushings and pivots Grease them immediately after every washing regardless of the interval listed Check cutterhead rear bearing adjustment Check Rear Roller Scraper Wire Tension Every 100 hours Inspect the cooling system hoses Check the condition and tension of the alternator belt Every 150 hours Change the engine oi...

Page 32: ...eck unusual engine noises 1 Check unusual operating noises Check the hydraulic system oil level Check hydraulic hoses for damage Check for fluid leaks Check the tyre 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...

Page 33: ...se are accurately matched to the required duty Dirt and contamination are the enemies of any hydraulic system When carrying out maintenance procedures on the hydraulic system always ensure that the work area and the components are thoroughly clean before during and after refitting Ensure that all open hydraulic lines and ports etc are plugged during maintenance procedures The recommended service i...

Page 34: ... the interval listed Replace any grease zerks that become damaged 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 The grease fitting locations and quantities are as follows ...

Page 35: ...leaner body 1 Check the filter blockage indicator If the indicator is red the air filter needs to be replaced Figure 47 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 trac...

Page 36: ...ilters Servicing the Engine Oil and Filter Service Interval After the first 50 hours Every 150 hours 1 Remove the drain plug Figure 49 and let the oil flow into a drain pan Figure 49 1 Oil drain plug 2 When the oil stops install the drain plug 3 Remove the oil filter Figure 50 Figure 50 1 Oil filter 4 Apply a light coat of clean oil to the new filter seal 5 Install the replacement oil filter to th...

Page 37: ...tions 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 fi...

Page 38: ...necessary Inspect Transmission Control Cable and Operating Mechanism Service Interval Every 250 hours Check the condition and security of the cable and operating mechanism at the speed control pedals and transmission pump ends Remove build up of dirt grit and other deposits Ensure that the ball joints are securely anchored and check that mounting brackets and cable anchors are tight and free from ...

Page 39: ...nce Changing the Transmission Oil Filter Service Interval After the first 50 hours Every 500 hours g014438 1 2 Figure 52 Right hand side of machine 1 Transmission oil filter 2 Engine fuel filter 1 Unscrew and remove the bottom of the transmission oil filter housing 2 Withdraw the filter element and discard 3 Refit a new filter element Part no 924709 4 Install the housing Changing the Hydraulic Ret...

Page 40: ...sidewalls and the rear sidewalls at the wheel centre height The distance between the front sidewalls must be set 3 8 mm 0 12 0 31 inches less than the distance between the rear sidewalls 2 4 1 G014442 3 x 3 8mm x Figure 54 1 Wheel center height 3 Direction of forward travel 2 Tyre 4 Track rod assembly To adjust the alignment of the rear wheels first back off the left hand and right hand locknuts o...

Page 41: ... area 4 Release the latch and open the engine cover Figure 55 2 3 1 G014567 Figure 55 1 Engine cover 3 Oil cooler release clip 2 Oil cooler 5 Clean the screen thoroughly with compressed air 6 Pivot the latch inward to release the oil cooler Figure 56 G014918 Figure 56 1 Oil cooler 2 Oil cooler latch 7 Thoroughly clean both sides of the oil cooler and the radiator Figure 57 with compressed air G014...

Page 42: ...lease bar and into the hole in the centre of the motor end plate 5 Tighten the setscrew into the threaded hole in the brake piston until the brake is released Figure 58 g014448 1 Figure 58 1 Hex plug 950639 6 Identify the left hand front wheel motor disc brake assembly and repeat the previous procedure Figure 59 1 2 3 G014449 Figure 59 1 Hex plug 950639 3 Setscrew M12 x 40 ZDH1L040U 2 Washer M12 0...

Page 43: ...ng the mower ensure that the braking system operates correctly Carry out initial checks with the mower at slow speed Do not operate the mower with a damaged braking system Do not operate the mower with the brakes de commissioned Belt Maintenance Check the condition and tension of the alternator belt after the first day of operation and every 100 operating hours thereafter Tensioning the Alternator...

Page 44: ...he switch to the forward position The indicator light should illuminate and the engine should not start when the ignition key is turned Repeat for the reverse position Parking Brake Interlock Switch 1 Stop the engine 2 Engage the parking brake 3 Turn the ignition key to position I The parking brake indicator light should illuminate 4 Disengage the parking brake The indicator light should go out an...

Page 45: ...emove the strainer and clean with paraffin or petrol before installing 3 Install the return line oil filter element 4 Install the transmission oil filter element refer to Changing the Transmission Oil Filter page 39 5 Install the drain plug and refill the hydraulic tank with fresh clean hydraulic oil of the recommended grade refer to Specifications page 18 6 Run the machine and operate all hydraul...

Page 46: ...t Grip the roller and move from side to side and up and down If excessive movement is detected proceed as follows Carefully tighten nuts Figure 65 at each end of the roller with the spanner provided just sufficiently to remove any end float 1 G014441 Figure 65 1 Nuts Note The roller should still rotate freely after adjustment Overtightening of nuts Figure 65 could lead to premature bearing damage ...

Page 47: ... maintenance costs escalating The quality of cut will also be seriously affected as will the health and growth of the grass An experienced operator will notice when a cutterhead starts to go out of adjustment when the grass ceases to be cut cleanly and the cut ends become ragged Carry out the following procedure before commencing work and check the settings every few hours G014443 90 0 Figure 67 1...

Page 48: ...sly worn or damaged it will be necessary to remove the component parts and have them reground 1 Check that the mower engine is switched off and the parking brake applied 2 Adjust the cutting cylinders to the bottom blades to obtain fleeting contact 3 Apply a medium grade detergent based carborundum paste to the cutting edges of the cylinders with a long handled brush 80 Grade Carborundum paste Par...

Page 49: ...nd and withdraw from the cutterheads 2 Remove the worn bottom blade and discard the countersunk screws and securing nuts 3 Fit the new blade to the holder and loosely assemble with new countersunk screws and securing nuts 4 Tighten the centre bolts to a torque of 40 N m 30 lb ft 5 Continue by tightening the remaining bolts to the same torque by working from the centre out towards the blade ends 6 ...

Page 50: ... any excess lubricant 5 Lightly sand and use touch up paint on painted areas that are scratched chipped or rusted Repair any dents in the metal body 6 Service the battery and cables as follows A Remove the battery terminals from the battery posts B Clean the battery terminals and posts with a wire brush and baking soda solution C Coat the cable terminals and battery posts with Grafo 112X skin over...

Page 51: ...aptors 3 Correct hose routing reposition hydraulic adaptors 4 No ground contact on one end of the cutter because pivot pins seizing 4 Release and grease pivot points Step in cut grass height at point of overlap between cutting cylinders 5 No ground contact on one end of the cutter because of grass build up under cutterhead 5 Remove grass 1 Cutting cylinder is partially out of contact with the bott...

Page 52: ...ocked oil cooler fins 2 Clean fins 3 Blocked engine radiator matrix 3 Clean matrix 4 Low relief valve setting 4 Have relief valve cleaned and pressure checked Consult your authorised dealer 5 Low oil level 5 Fill reservoir to correct level 6 Brakes engaged 6 Disengage brakes 7 Cutting cylinders tight on bottom 7 Adjust settings Hydraulic oil system overheating 8 Defective fan or fan drive 8 Check ...

Page 53: ...suction hose 7 Check and tighten fittings Replace hose if necessary 1 High spot on cylinder or bottom blade due to contact with foreign object 1 Remove high spot with a stone and back lap to restore cutting edges Serious damage will require re grinding Cylinder knocks while rotating 2 Worn cylinder bearings 2 Replace as necessary 1 Cutting cylinder bearing seized 1 Replace as necessary 2 Incorrect...

Page 54: ...r as necessary 6 Cutting cylinder tight on bottom blade 6 Re adjust setting 7 Cutterhead control valve in the off position caused by defective control valve 7 Overhaul control valve 8 Cutterhead control valve in the off position caused by electrical fault 8 Electrical fault Have electrical system checked Cutterheads fail to start up when lowered into work 9 Lift arm proximity switch incorrectly se...

Page 55: ...Schematics Showing Beacon Lights Aux Power Connector g014756 55 ...

Page 56: ...16222 83040 1 1 23 Switch Hydraulic Oil Temp 940852 1 1 24 Relay Hydraulic Oil Temp 111 0336 1 1 25 Controller Assembly 111 3763 1 1 26 L H Lower Pulley Take Up 111 3433 1 1 27 Centre Lower Pulley Take Up 111 3433 1 1 28 R H Lower Pulley Take Up 111 3433 1 1 29 Lift Enable Solenoid 111 3440 1 1 30 L H Lift Solenoid 111 3688 1 1 31 Centre Lift Solenoid 111 3688 1 1 32 R H Lift Solenoid 111 3688 1 1...

Page 57: ...R PB CP P TP P T A B C C R L T E P R L C A1 B1 A2 B2 A3 B3 A B D1 TPC DC 2 BAR T 33 32 32 32 14 15 16 17 18 19 21 20 11 12 8 9 10 7 13 1 2 3 4 5 6 37 38 39 40 41 42 43 44 45 46 47 48 49 34 31 23 22 24 25 26 27 28 29 30 35 36 57 ...

Page 58: ...ransfer valve 111 3439 22 Return filter 924865 23 Oil cooler 70 06 171 24 Steering cylinder 111 1956 25 Steering unit 111 2574 26 Check valve steering shock bypass LH 27 Check valve steering shock bypass RH 28 Relief valve 183 bar steering shock bypass LH 29 Relief valve 183 bar steering shock bypass RH 30 Pressure relief valve 115 bar 34 Solenoid valve fwd reverse check valve 4wd 924688 35 Hydrau...

Page 59: ... P TP P T A B C C R L T E P R L C A1 B1 A2 B2 A3 B3 A B D1 TPC DC RAR RBR D2 D1 RB 2 BAR 1 2 3 5 6 4 7 10 12 8 11 9 14 17 18 19 T 15 16 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 48 47 49 50 51 46 53 52 52 52 13 59 ...

Page 60: ...r 70 06 171 24 Steering cylinder 111 1956 25 Steering unit 111 2574 26 Check valve steering shock bypass LH 27 Check valve steering shock bypass RH 28 Relief valve 183 bar steering shock bypass LH 29 Relief valve 183 bar steering shock bypass RH 30 Pressure relief valve 115 bar 31 Hydraulic motor LH rear wheel 111 2260 32 Hydraulic motor RH rear wheel 111 2260 33 Rear transmission manifold 924687 ...

Page 61: ...Notes 61 ...

Page 62: ...Notes 62 ...

Page 63: ...08 Ibea S P A Italy 39 0331 853611 Irriamc Portugal 351 21 238 8260 Irrigation Products Int l Pvt Ltd India 86 22 83960789 Jean Heybroek b v Netherlands 31 30 639 4611 Lely U K Limited United Kingdom 44 1480 226 800 Maquiver S A Colombia 57 1 236 4079 Maruyama Mfg Co Inc Japan 81 3 3252 2285 Metra Kft Hungary 36 1 326 3880 Mountfield a s Czech Republic 420 255 704 220 Munditol S A Argentina 54 11 ...

Page 64: ...ited to weather storage practices contamination use of unapproved coolants lubricants additives fertilizers water or chemicals etc Normal noise vibration wear and tear and deterioration Normal wear and tear includes but is not limited to damage to seats due to wear or abrasion worn painted surfaces scratched decals or windows etc Parts Parts scheduled for replacement as required maintenance are wa...