Form No. 3325-463 Groundsmaster 120 Groundsmaster Traction Unit Model No.
Warning Starting and Stopping the Engine . . . . . . . . . . . . . Operating the Power Take Off (PTO) . . . . . . . . . . Driving Forward or Backward . . . . . . . . . . . . . . . Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . Implement Lift Lever . . . . . . . . . . . . . . . . . . . . . . The Safety Interlock System . . . . . . . . . . . . . . . . Positioning the Seat . . . . . . . . . . . . . . . . . . . . . . . Pushing or Towing the Machine . . . . . . . . . . . . . .
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. serial numbers of your product ready. Figure 1 illustrates the location of the model and serial numbers on the product.
• Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision. • Check that operator’s presence controls, safety switches and shields are attached and functioning properly. Do not operate unless they are functioning properly. Maintenance and storage Operation • 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.
• Follow the manufacturer’s recommendations for wheel weights or counterweights to improve stability. General Operation • Allow only responsible adults who are familiar with the instructions to operate the machine. • Use extra care with grass catchers or other attachments. These can change the stability of the machine. • Be sure the area is clear of other people before mowing. Stop the machine if anyone enters the area. • Keep all movement on slopes slow and gradual.
• 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 7
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. 92-6288 92-6291 92-6277 54-0910 77-3100 1. Fingers can be severed in the fan blade.
54-0900 55-4300 53-4430 61-3610 26-7390 98-4387 63-8440 54-0880 10
Gasoline and Oil Warning Recommended Gasoline Gasoline is harmful or fatal if swallowed. Long–term exposure to vapors can cause serious injury and illness. Use unleaded Regular Gasoline suitable for automotive use (85 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available. • Avoid prolonged breathing of vapors. • Keep face away from nozzle and gas tank or conditioner opening. • Keep gas away from eyes and skin.
Assembly Note: Determine the left and right sides of the machine from the normal operating position. Loose Parts Note: Use the chart below to verify that all parts have been shipped. Description Qty. Use Spacer 1 Steering wheel 1 Roll pin, 1/4 x 2-1/2 in.(64 mm) 1 Seat 1 Bolt, 5/16-18 x 1 in. (25 mm) 4 Lock nut, 5/16 4 R-clamp 1 Weight 2 Bolt, 1/2 x 3-1/2 in. (89 mm) 4 Washer, 1/2 in. (13 mm) 4 Lock washer, 1/2 in. (13 mm) 4 Nut, 1/2 in. 4 Carriage bolt, 1/4-20 x 3/4 in.
Installing the Steering Wheel 1 1. Move the rear wheels so that they point straight ahead. 2. Slide the spacer and steering wheel onto the steering shaft, aligning the mounting holes. Check that the logo on the steering cap points forward. 3. Secure the steering wheel to the shaft with a roll pin (Fig. 2). 2 2 3 1262 Figure 3 1 1. Filler caps 2. Electrolyte 3 3. Lower part of the tube M-4263 3. Leave the covers off and connect a 3 to 4 amp battery charger to the battery posts (Fig. 4).
5. Slowly pour electrolyte into each cell until the level is up to the lower part of the tube (Fig. 3) and install the covers. Checking the Hydraulic System Fluid 6. Install the battery into the holder. The hydraulic system is shipped with approximately 5 quarts of 10W-30 engine oil; however, the oil level must be checked before the engine is first started. Check the oil level; refer to Checking the Hydraulic System Fluid, page 26.
Operating the Power Take Off (PTO) 2. Move the traction pedal to neutral, set the parking brake, and move the PTO switch to “OFF.” 3. Move the choke control to the “CHOKE” position before starting a cold engine. The power take off (PTO) switch engages and disengages power to the electric clutch. Note: A warm or hot engine may not require any choking. 4. Rotate the ignition key to “START.
Raising Attachments Caution 1. Remove pressure from traction pedal to stop the machine. Children or bystanders may be injured if they move or attempt to operate the tractor while it is unattended. 2. Pull implement lift lever (Fig. 8) rearward to raise attachment to the desired height. Always remove the ignition and set the parking brake when leaving the machine unattended, even if just for a few minutes. Lowering Attachments 1. Remove pressure from traction pedal to stop the machine.
Pushing or Towing the Machine 2. Set the parking brake, turn the power take off (PTO) “OFF” and move the motion control (forward or reverse). Now turn the ignition key to “START”; the engine should not rotate. In an emergency, the traction unit can be pushed or towed for a very short distance. We do not recommend this as standard procedure. 3. Move the power take off (PTO) to disengaged, motion control to neutral, do not set parking brake. Now turn the key to “START”; the engine should not rotate.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position.
Servicing the Air Cleaner 2 Foam Element: Clean and oil after every 25 operating hours. 1 Paper Element: Replace after every 100 operating hours. Note: Service the air cleaner more frequently (every few hours) if operating conditions are extremely dusty or sandy. m–1213 Figure 11 Removing the Foam and Paper Elements 1. Foam element 2. Oil 1. Raise the seat 2. Disengage the power take off (PTO), set the parking brake, stop the engine, and remove the key. Cleaning the Paper Element 3.
3. Install the air cleaner cover and secure it with the cover nut (Fig. 10). 3 Engine Oil Service Service Interval/Specification Change the oil: • After the first 5 operating hours • After every 50 operating hours M-4285 Note: Change the oil more frequently when operating conditions are extremely dusty or sandy. Figure 13 1. Oil dipstick 2. Oil fill Oil Type: Detergent oil (API service SF, SE/CC, CD, or SE) 3. Metal end Crankcase Capacity: w/filter, 4 pints (1.
Changing the Oil Filter Danger Replace the oil filter every 100 hours or every other oil change. In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property. Note: Change the oil filter more frequently when operating conditions are extremely dusty or sandy. 1. Drain the oil from the engine; refer to Changing and Draining the Oil, page 20. • Drain gasoline from the fuel tank when the engine is cold.
2 Where to Add Grease 3 1. Lubricate the wheel bearings (Fig. 18). 1 0.04 in. (1 mm) Figure 17 1. Center electrode insulator 2. Side electrode 3. Air gap (not to scale) M-4287 Figure 18 Installing the Spark Plug(s) 2. Lubricate the spindles, steering shaft, and pivot (Fig. 19). 1. Install the spark plug(s) and metal washer. Make sure that the air gap is set correctly. 2. Tighten the spark plug(s) to 12 ft.-lb. (17 N m). 3. Push the wire(s) onto the spark plug(s) (Fig. 16). 4.
4. Lubricate the traction pedal bushings and steering shaft with a few drops of SAE 10W-30 oil or dry spray lube (Fig. 21). 3. If the distance is greater than 1/4 in. (6 mm), tighten the locknut to decrease the distance between the actuating arm and stop pin (Fig. 22). 4. With the brake lever OFF, check the clearance between the brake pads and disc with a feeler gauge (Fig. 22). Proper clearance is approximately 0.01 in. (.25 mm). 5. The actuating arm should be no more than 3/8 in.
Adjusting the Belts 6. Move the hose clamps close to the filter and tighten them. If belt slippage occurs, the idler pulleys must be adjusted to increase the belt tension. 1 1. Disengage the power take off (PTO), set the parking brake, stop the engine, and remove the key. 2 2. Raise the seat. 3 3. Measure the distance from the bottom of the spacer on the pulley mounting screw to the bottom of the slot in the idler adjustment link. The distance should be 1/4 in. (6 mm) or less (Fig. 25).
5. Start the engine and raise the lift arms until the lift cylinder is fully retracted and lift (cutting unit) is fully raised. 5. Install the belts. Route the traction belt over the transmission as shown (Fig. 26). 6. Install the clutch anchor bolt and plug in the connector. Important To avoid damage, install the clutch anchor bolt before connecting the wire. 6. Check the distance between the clevis pin and bottom hooks of the springs (Fig. 25). The distance should be 1/4 in. (6 mm) or less. 7.
4. The proper disengaged clearance between the clutch plates is 0.012–0.018 in. (0.30–0.45 mm). It will be necessary to check this clearance at each of the three slots to ensure that the plates are parallel to each other. Warning Engine must be running so transmission neutral adjustment can be performed. Contact with moving parts or hot surfaces may cause personal injury. Keep hands, feet, face, clothing and other body parts away from rotating parts, muffler and other hot surfaces.
5. Install the tube assembly and hose assembly to the reservoir (Fig. 32). 2. Raise the seat. 3. Remove the dipstick cap from the filler neck (Fig. 31) and wipe it with a clean rag. Insert the dipstick cap onto the filler neck; then remove it and check the oil level. 4. If the level is not within 1/2 in. (13 mm) from the full mark on the dipstick, add SAE 10W-30 engine oil to raise the level to the FULL mark. Do not overfill. 5. Install the dipstick filler cap onto the filler neck (Fig. 31). 6.
Adjusting the Steering 4. Remove the fill plug and fill to the plug level with SAE EP-90 wt. oil (approximately 14.9cl [44 oz.]) (Fig. 34). 1. Measure the toe-in distance (at axle height) at the front and rear of the steering tires. The front measurement must be 0–1/4 in. (6 mm) less than the rear measurement. 2. Loosen the jam nuts and rotate the tie rod to adjust the clearance (Fig. 33). 3. Turn the steering wheel full left to achieve a full left turn (Fig. 33). 4.
1 2 Warning Charging battery produces gasses that can explode and cause serious injury. 3 • Keep cigarettes, sparks and flames away from battery. • Make sure the ignition switch is off. • Ventilate when charging or using battery in an enclosed space. 1262 Figure 35 1. Filler caps 2. Lower part of tube 3. Plates 5. Install the battery into the holder. Adding Water to the Battery Servicing the Wire Harness The best time to add distilled water to the battery is just before you operate the machine.
Hydraulic Schematic TRANSMISSION RESERVOIR FILTER VALVE CYLINDER T-0084 GM 1.9L (4PT.) 4.73L (5QT.) 18.93L (5GAL.) 14.9cl (44oz.
Wiring Diagram IGNITION SWITCH CIRCUITRY START B+S+I RUN A+B+I X+Y OPEN OFF DIODE MODULE CONNECTOR CLUTCH GREY WHITE BLACK BLACK ENGINE CONNECTOR N O HOUR METER GREEN C TO MAGNETO N C BLACK RELAY BLUE TO REGULATOR PTO SWITCH CIRCUITRY A+B ON OFF C+D BLUE BLU E A BROWN BC PTO SWITCH I X ORANGE D Y A VIOLET TO STARTER S B KEY SWITCH PARKING BRAKE CLOSED WHEN PARKING BRAKE IN OFF POSITION NEUTRAL CLOSED WHEN TRACTION PEDAL IS IN NEUTRAL STARTER SEAT OPEN WHEN OPERATOR IS NOT IN
Cleaning and Storage 9. Check the tire pressure; refer to Tire Pressure Service, page 24. 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key. 10. During long-term storage, either drain gasoline from the fuel tank (step 11) or add a fuel stabilizer/conditioner additive to a full tank of gasoline (step A). 2. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine.
Problem The engine g will not start, starts h d or ffails hard, il tto kkeep running. i The engine g loses power. The engine g overheats. There is abnormal vibration. The machine does not drive. Possible Causes Corrective Action 1. The operator is not seated. 1. Sit on the seat. 2. The parking brake is off. 2. Move the parking brake to ON. 3. The fuel tank is empty. 3. Fill the fuel tank with gasoline. 4. The choke is not on. 4. Move the choke lever to ON. 5. The air cleaner is dirty. 5.
The Toro Total Coverage Guarantee LCE A One-Year Limited Warranty Conditions and Products Covered Owner Responsibilities The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair any Toro Product used for commercial, institutional, or rental purposes if defective in materials or workmanship.
