Toro 30612 Operator's Manual

Groundsmaster 120

Groundsmaster Traction Unit

Model No. 30612—Serial No. 220000001 and Up

Form No. 3327-100

Operator ’s Manual

English (EN)

Warning

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

Important This engine is not equipped with a spark

arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate this engine on any forest-covered, brush-covered, or grass-covered land. Other states or federal areas may have similar laws.

This spark ignition system complies with Canadian ICES-002.

Ce système d’allumage par étincelle de véhicule est conforme à la norme NMB-002 du Canada.

The enclosed Engine Owner’s Manual is supplied for information regarding The U.S. Environmental Protection Agency (EPA) and the California Emission Control Regulation of emission systems, maintenance and warranty.

Keep this engine Owner’s Manual with your unit. Should this engine Owner’s Manual become damaged or illegible, replace immediately. Replacements may be ordered through the engine manufacturer.

Contents

Page

Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safe Operating Practices 3. . . . . . . . . . . . . . . . . . . .

Toro Mower Safety 4. . . . . . . . . . . . . . . . . . . . . . . .

Slope Chart 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety and Instruction Decals 9. . . . . . . . . . . . . . . .

Gasoline and Oil 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Gasoline 12. . . . . . . . . . . . . . . . . . . .

Using Stabilizer/Conditioner 12. . . . . . . . . . . . . . . .

Filling the Fuel Tank 12. . . . . . . . . . . . . . . . . . . . . .

Checking the Engine Oil Level 12. . . . . . . . . . . . . .

Assembly 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loose Parts 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Seat 13. . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Steering Wheel 14. . . . . . . . . . . . . . . .

Activating the Battery 14. . . . . . . . . . . . . . . . . . . . . .

Installing the Battery 15. . . . . . . . . . . . . . . . . . . . . .

Checking the Engine Oil 15. . . . . . . . . . . . . . . . . . .

Checking the Hydraulic System Fluid 15. . . . . . . . .

Operation 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Think Safety First 15. . . . . . . . . . . . . . . . . . . . . . . . .

 2002 by The Toro Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196

Page

Starting and Stopping the Engine 15. . . . . . . . . . . . .

Operating the Power Take Off (PTO) 16. . . . . . . . . .

Driving Forward or Backward 16. . . . . . . . . . . . . . .

Parking Brake 17. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Implement Lift Lever 17. . . . . . . . . . . . . . . . . . . . . .

The Safety Interlock System 17. . . . . . . . . . . . . . . .

Positioning the Seat 18. . . . . . . . . . . . . . . . . . . . . . .

Pushing or Towing the Machine 18. . . . . . . . . . . . . .

Maintenance 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Maintenance Schedule 19. . . . . . . . .

Servicing the Air Cleaner 20. . . . . . . . . . . . . . . . . . .

Engine Oil Service 21. . . . . . . . . . . . . . . . . . . . . . . .

Spark Plug Service 22. . . . . . . . . . . . . . . . . . . . . . . .

Greasing and Lubrication 23. . . . . . . . . . . . . . . . . . .

Brake Service 24. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Fuel Filter 24. . . . . . . . . . . . . . . . . . .

Tire Pressure Service 25. . . . . . . . . . . . . . . . . . . . . .

Cleaning the Cooling System 25. . . . . . . . . . . . . . . .

Adjusting the Belts 25. . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Belts 25. . . . . . . . . . . . . . . . . . . . . . . .

Adjusting the Lift Cylinder and Counterbalance Springs

Adjusting the Transmission Neutral 26. . . . . . . . . . .

Adjusting the Electric Clutch 27. . . . . . . . . . . . . . . .

Checking the Hydraulic System Fluid 27. . . . . . . . .

Changing the Hydraulic System Oil 28. . . . . . . . . . .

Changing the Hydraulic Oil Filter 28. . . . . . . . . . . .

Adjusting the Steering 29. . . . . . . . . . . . . . . . . . . . .

Changing the Front Axle Oil 29. . . . . . . . . . . . . . . .

Servicing the Battery 29. . . . . . . . . . . . . . . . . . . . . .

Servicing the Wire Harness 30. . . . . . . . . . . . . . . . .

Waste Disposal 30. . . . . . . . . . . . . . . . . . . . . . . . . . .

Transporting Machines 30. . . . . . . . . . . . . . . . . . . . .

Hydraulic Schematic 31. . . . . . . . . . . . . . . . . . . . . .

Wiring Diagram 32. . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning and Storage 33. . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The Toro Total Coverage Guarantee 36. . . . . . . . . . . . .

Introduction

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.

Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and

Printed in the USA

serial numbers of your product ready. Figure 1 illustrates the location of the model and serial numbers on the product.

m–2196

Figure 1

1. Location of the model and serial numbers

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

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.

Safe Operating Practices

The following instructions are from ANSI standard B71.4—1999.

Training

• Read the Operator’s Manual and other training material.

If the operator(s) or mechanic(s) can not read English it is the owner’s responsibility to explain this material to them.

Model No.

Serial No.

This manual identifies potential hazards and has special safety messages that help you and others avoid personal injury and 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 you do not follow the recommended precautions.

Caution signals a hazard that may cause minor or moderate injury if you do not follow the recommended precautions.

This manual uses two other words to highlight information.

Important calls attention to special mechanical

information and Note: emphasizes general information worthy of special attention.

• Become familiar with the safe operation of the

equipment, operator controls, and safety signs.

• All operators and mechanics should be trained. The

owner is responsible for training the users.

• Never let children or untrained people operate or

service the equipment. Local regulations may restrict the age of the operator.

• The owner/user can prevent and is responsible for

accidents or injuries occurring to himself or herself, other people or property.

Preparation

• Evaluate the terrain to determine what accessories and

attachments are needed to properly and safely perform the job. Only use accessories and attachments approved by the manufacturer.

• Wear appropriate clothing including hard hat, safety

glasses and ear protection. Long hair, loose clothing or jewelry may get tangled in moving parts.

• Inspect the area where the equipment is to be used and

remove all objects such as rocks, toys and wire which can be thrown by the machine.

Safety

This machine meets or exceeds the B71.4 1999 specifications of the American National Standards Institute, in effect at time of production.

Note: The addition of attachments made by other

manufacturers that do not meet American National Standards Institute certification will cause noncompliance of this machine.

• Use extra care when handling gasoline and other fuels.

They are flammable and vapors are explosive.

• Use only an approved container

• Never remove gas cap or add fuel with engine

running. Allow engine to cool before refueling. Do not smoke.

• Never refuel or drain the machine indoors.

• Check that operator’s presence controls, safety switches

and shields are attached and functioning properly. Do not operate unless they are functioning properly.

Operation

• Never run an engine in an enclosed area.

• Only operate in good light, keeping away from holes

and hidden hazards.

• Be sure all drives are in neutral and parking brake is

engaged before starting engine. Only start engine from the operator’s position. Use seat belts if provided.

• Slow down and use extra care on hillsides. Be sure to

travel in the recommended direction on hillsides. Turf conditions can affect the machine’s stability. Use caution while operating near drop–offs.

• Use care when approaching blind corners, shrubs, trees,

or other objects that may obscure vision.

Maintenance and storage

• Disengage drives, lower implement, set parking brake,

stop engine and remove key or disconnect spark plug wire. Wait for all movement to stop before adjusting, cleaning or repairing.

• Clean grass and debris from cutting units, drives,

mufflers, and engine to help prevent fires. Clean up oil or fuel spillage.

• Let engine cool before storing and do not store near

flame.

• Shut off fuel while storing or transporting. Do not store

fuel near flames or drain indoors.

• Slow down and use caution when making turns and

when changing directions on slopes.

• Never raise deck with the blades running.

• Never operate with the PTO shield, or other guards not

securely in place. Be sure all interlocks are attached, adjusted properly, and functioning property.

• Never operate with the discharge deflector raised,

removed or altered, unless using a grass catcher.

• Do not change the engine governor setting or overspeed

the engine.

• Stop on level ground, lower implements, disengage

drives, engage parking brake (if provided), shut off engine before leaving the operator’s position for any reason including emptying the catchers or unclogging the chute.

• Stop equipment and inspect blades after striking objects

or if an abnormal vibration occurs. Make necessary repairs before resuming operations.

• Keep hands and feet away from the cutting units.

• Look behind and down before backing up to be sure of

a clear path.

• Never carry passengers and keep pets and bystanders

away.

• Slow down and use caution when making turns and

crossing roads and sidewalks. Stop blades if not mowing.

• Be aware of the mower discharge direction and do not

point it at anyone.

• Do not operate the mower under the influence of

alcohol or drugs

• Use care when loading or unloading the machine into a

trailer or truck

• Park machine on level ground. Never allow untrained

personnel to service machine.

• Use jack stands to support components when required.

• Carefully release pressure from components with stored

energy.

• Disconnect battery or remove spark plug wire before

making any repairs. Disconnect the negative terminal first and the positive last. Reconnect positive first and negative last.

• Use care when checking blades. Wrap the blade(s) or

wear gloves, and use caution when servicing them. Only replace blades. Never straighten or weld them.

• Keep hands and feet away from moving parts. If

possible, do not make adjustments with the engine running.

• Charge batteries in an open well ventilated area, away

from spark and flames. Unplug charger before connecting or disconnecting from battery. Wear protective clothing and use insulated tools.

• Keep all parts in good working condition and all

hardware tightened. Replace all worn or damaged decals.

Toro Mower 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 ANSI standards.

This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death.

This product is designed for cutting and recycling grass or, when equipped with a grass bagger, for catching cut grass. Any use for purposes other than these could prove dangerous to user and bystanders.

General Operation

• Allow only responsible adults who are familiar with the

instructions to operate the machine.

• Be sure the area is clear of other people before mowing.

Stop the machine if anyone enters the area.

• Do not mow in reverse unless absolutely necessary.

Always look down and behind before and while backing.

• Be aware of the mower discharge direction and do not

point it at anyone. Do not operate the mower without either the entire grass catcher or the guard in place.

• Slow down before turning. Sharp turns on any terrain

may cause loss of control.

• Turn off blades when not mowing.

• Keep hands, feet, hair and loose clothing away from

attachment discharge area, underside of mower and any moving parts while engine is running.

• Stop the engine before removing the grass catcher or

unclogging the chute.

• Mow only in daylight or good artificial light.

• Watch for traffic when operating near or crossing

roadways.

• Do not touch equipment or attachment parts which may

be hot from operation. Allow to cool before attempting to maintain, adjust or service.

• Before operating a machine with ROPS (roll over

protection) be certain the seat belts are attached to prevent the seat from pivoting forward.

• Use only Toro-approved attachments. Warranty may be

voided if used with unapproved attachments.

Slope Operation

• Follow the manufacturer’s recommendations for wheel

weights or counterweights to improve stability.

• Use extra care with grass catchers or other attachments.

These can change the stability of the machine.

• Keep all movement on slopes slow and gradual. Do not

make sudden changes in speed or direction.

• Avoid starting or stopping on a slope. If tires lose

traction, disengage the blades and proceed slowly straight down the slope.

• When operating machine on slopes, banks or near drop

offs, always have ROPS (roll over protection) installed.

• When operating a machine with ROPS (roll over

protection) always use seat belt.

• Be certain that the seat belt can be released quickly if

the machine is driven or rolls into ponds or water.

• Check carefully for overhead clearances (i.e. branches,

doorways, electrical wires) before driving under any objects and do not contact them.

DO NOT

• Do not mow slopes exceeding 15 degrees.

• Avoid turning on slopes. If you must turn, turn slowly

and gradually downhill, if possible.

• Do not mow near drop-offs, ditches, or embankments.

The machine could suddenly turn over if a wheel goes over the edge of a cliff or ditch, or if an edge caves in.

• Do not mow on wet grass. Reduced traction could cause

sliding.

• Do not try to stabilize the machine by putting your foot

on the ground.

• Do not use a grass catcher on steep slopes. Heavy grass

bags could cause loss of control or overturn the machine.

Slopes and ramps are a major factor related to loss-of-control and tip-over accidents, which can result in severe injury or death. All slopes and ramps require extra caution. If you cannot back up the slope or if you feel uneasy on it, do not mow it.

• If a steep slope must be ascended, back up the hill, and

drive forward down the hill, keeping the machine in gear.

• Remove obstacles such as rocks, tree limbs, etc. from

the mowing area. Watch for holes, ruts or bumps, as uneven terrain could overturn the machine. Tall grass can hide obstacles.

• Use slow speed so that you will not have to stop while

on the slope.

Service

• Never store the machine or fuel container inside where

there is an open flame, such as near a water heater or furnace.

• Keep nuts and bolts tight, especially the blade

attachment bolts. Keep equipment in good condition.

• Never tamper with safety devices. Check safety systems

for proper operation before each use.

• Use only genuine replacement parts to ensure that

original standards are maintained.

• Check brake operation frequently. Adjust and service as

required.

• Battery acid is poisonous and can cause burns. Avoid

contact with skin, eyes and clothing. Protect your face, eyes and clothing when working with a battery.

• Battery gases can explode. Keep cigarettes, sparks and

flames away from battery.

• Hydraulic fluid escaping under pressure can penetrate

the skin and cause injury. Use cardboard or paper to find hydraulic leaks. Never use your hands.

Slope Chart

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.

92-6278

26-7390

92-6288

53-4430

54-0880

54-0900

54-0910

61-3610

63-8440

1. Hot surface

77-3100

1. Spinning blades can cut off fingers.

54-0920

55-4300

92-6277

92-6291

98-4387

1. Warning—wear hearing protection.

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