Form No. 3327–756 Rev A Groundsmaster 120 Groundsmaster Traction Unit Model No. 30612TE– Serial No.
This spark ignition system complies with Canadian ICES-002. Positioning the Seat . . . . . . . . . . . . . . . . . . . . . . . Pushing or Towing the Machine . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Maintenance Schedule . . . . . . . . Removing and Installing the Belt Guard . . . . . . . Servicing the Air Cleaner . . . . . . . . . . . . . . . . . . Servicing the Engine Oil . . . . . . . . . . . . . . . . . . .
alert symbol, which means CAUTION, WARNING, or DANGER—“personal safety instruction.” Failure to comply with the instruction may result in personal injury or death. 1 Safe Operating Practices m–2196 The following instructions are from the CEN standard EN 836:1997. Figure 1 1. Location of the model and serial numbers This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death.
• never mow across the face of the slope, unless the lawnmower is designed for this purpose. • Thoroughly inspect the area where the equipment is to be used and remove all objects which may be thrown by the machine. • Use care when pulling loads or using heavy equipment. • WARNING – Fuel is highly flammable. • Use only approved drawbar hitch points. • Store fuel in containers specifically designed for this purpose. • Limit loads to those you can safely control.
• Reduce the throttle setting during engine run-out and, if the engine is provided with a shut-off valve, turn the fuel off at the conclusion of mowing. Toro Riding 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 CEN standard. Maintenance and Storage • Use only Toro-approved attachments. Warranty may be voided if used with unapproved attachments.
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 93-7276 1. Explosion hazard—wear eye protection. 2. Caustic liquid/chemical burn hazard—to perform first aid, flush with water. 93-6668 1. Battery 2. Read the instructions before servicing or performing maintenance. 3. Contains lead; do not discard. 93-7272 1.
93-7300 1. Lower 2. Raise 93-7281 1. 2. 3. 4. Choke On Off Disengage the parking brake 5. Engage the power take-off (PTO) 6. Fast 7. Continuous variable setting 8. Slow 93-7306 1. Warning—read the Operator’s Manual. 2. Cutting hazard of hands or feet—stay away from moving parts. 3. Tipping hazard—when driving down slopes less than 10 degrees, lower the cutting unit. 4. Thrown object hazard—keep bystanders a safe distance from the machine. 5. Warning—wait for moving parts to stop. 6.
93-7822 1. Warning—fill the fuel tank to no more than 25 mm (1 in.) from the top of the fuel tank; read the Operator’s Manual. 93-7823 1. Engine oil 2. Read the Operator’s Manual 93-8069 1. Hot surface/burn hazard—stay a safe distance from the hot surface. 98-4387 1. Warning—wear hearing protection.
Gasoline and Oil Recommended Gasoline Warning Use UNLEADED Regular Gasoline suitable for automotive use (85 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available. Gasoline is harmful or fatal if swallowed. Long–term exposure to vapors can cause serious injury and illness. Important Never use methanol, gasoline containing methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged. Do not mix oil with gasoline.
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 all parts have been shipped. DESCRIPTION QTY. Seat 1 Bolt, 5/16 x 1 in. 4 Lock nut, 5/16 in. 4 R-clamp 1 Spacer 1 Steering wheel 1 Roll pin, 1/4 x 2-1/2 in. 1 Weight 2 Bolt, 1/2 x 3-1/2 in. 4 Washer, 1/2 in. 4 Nut, 1/2 in. 4 Carriage bolt, 1/4 x 3/4 in. 2 Wing nut, 1/4 in.
Installing the Steering Wheel Activating the Battery 1. Move rear wheels so they point straight ahead. Bulk electrolyte with 1.260 specific gravity must be purchased from a local battery supply outlet. 2. Slide spacer and steering wheel onto steering shaft aligning mounting holes. Check that logo on steering cap points forward. 1. If already installed, remove the battery from the holder. 3. Secure steering wheel to shaft with roll pin (Fig. 3).
3. Slide the red terminal boot onto the red battery cable (Fig. 7). 4 4. Install the positive battery cable to positive (+) battery terminal and the negative battery cable to the negative (–) battery terminal and secure with carriage bolts and lock nuts (Fig. 7). 2 3 5 1 7 3 3 4 6 2 1 1254 Figure 6 1. Positive post 2. Negative post M–4282 3. Charger red (+) wire 4. Charger black (–) wire Figure 7 1. 2. 3. 4. Warning Charging battery produces gasses that can explode and cause serious injury.
The use of protective equipment for eyes, ears, feet and head is recommended. 3. Set the parking brake. 4. Pull wire off spark plug(s) to prevent possibility of accidental starting before storing machine. Caution 4 This machine produces sound levels in excess of 85dBA at the operator’s ear and can cause hearing loss through extended periods of exposure. 5 1 Wear hearing protection when operating this machine. 1 2 2 3 Figure 9 Figure 8 1. Caution M–3329 1. Traction pedal 2. PTO switch 3.
2. Release the parking brake. Releasing the Parking Brake 3. Slowly press on the upper pad of the traction pedal to move forward (Fig. 9). 1. Move the parking brake lever down to the released the parking brake (Fig. 10). 2 Driving Backward 1. To go backward, place your foot on the traction pedal (Fig. 9). 2. Release the parking brake. 3. Slowly press on the lower pad of the traction pedal to move rearward (Fig. 9).
Testing the Safety Interlock System 3. Push implement lift lever forward to lower attachment (Fig. 10). Test the safety interlock system before you use the machine each time. If the safety system does not operate as described below, have an Authorized Service Dealer repair the safety system immediately. 2 1. Switch the power take off (PTO) on. Now turn the key to start; the engine should not rotate. 2. Turn the power take off (PTO) off and move the motion control (forward or reverse).
1 M–4283 Figure 12 1. Seat adjustment lever Pushing or Towing the Machine In an emergency, the traction unit can be pushed or towed for a very short distance. Toro does not recommend this as standard procedure. Important Do not push or tow the traction unit faster than 2 to 3 mph because transmission may be damaged. If traction unit must be moved a considerable distance, transport on a truck or trailer. 1. To push or tow forward, the traction pedal must be fully depressed forward. 2.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position.
Removing and Installing the Belt Guard 2. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to off. Remove the key. You will have to remove the belt guard to perform maintenance under seat and engine cover. 3. Clean around the air cleaner to prevent dirt from getting into the engine and causing damage. Unscrew the knob and remove the air cleaner cover (Fig. 14). Removing Belt Guard 1 1. Raise seat and remove center bolt (Fig. 13). 2 2.
4. Reinstall belt guard. See Installing Belt Guard on page 21. 2 1 Servicing the Engine Oil Service Interval/Specification Change oil: m–1213 • After the first 8 operating hours. Figure 15 1. Foam element • After every 50 operating hours. 2. Oil Note: Change oil more frequently when operating conditions are extremely dusty or sandy. Cleaning the Paper Element Oil Type: Detergent oil (API service SF, SE/CC, CD or SE) 1. Lightly tap the element on a flat surface to remove dust and dirt (Fig. 16).
6. Reinstall belt guard. See Installing Belt Guard on page 21. 5. Slowly pour approximately 80% of the specified amount of oil into the filler tube (Fig. 17). Now check the oil level; refer to Checking the Engine Oil Level, page 22. Slowly add additional oil to bring to full mark on dipstick. 3 Changing the Engine Oil Filter Service Interval/Specification Replace the oil filter every 100 hours or every other oil change.
Type: Champion RC 12YC (or equivalent) Air Gap: 0.040 in. (1 mm) Checking the Spark Plug Removing the Spark Plugs 1. Look at the center of the spark plug(s) (Fig. 21). If you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means the air cleaner is dirty. 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to off. Remove the key. Important Never clean the spark plug(s).
Grease Type: General-purpose lithium base grease. Once a year, grease front wheel hub to prevent the formation of rust and to simplify future wheel removal. How to Grease 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to off. Remove the key. 2. Clean the grease fittings with a rag. Make sure to scrape any paint off the front of the fitting(s). 3. Connect a grease gun to the fitting. Pump grease into the fittings until grease begins to ooze out of the bearings. 4.
Servicing the Fuel Filter Important With the parking brake released, the drive wheels must rotate freely. If brake action and free wheel rotation cannot be achieved contact your service dealer immediately. Service Interval/Specification Replace the fuel filter after every 100 operating hours or yearly, whichever occurs first.
Pressure: 103 kPa (15 psi) front and rear 3. Measure distance from bottom of spacer on pulley mounting screw to bottom of slot in idler adjustment link. Distance should be 1/4 inch (6 mm) or less (Fig. 29). 4. To adjust, remove cotter hair pin and washer securing to mounting pin (Fig. 29). 1 5. Slide tension bracket off mounting pin. Adjust and select new hole until bottom of spacer is within 1/4 inch from bottom of slot (Fig. 29). 6. Secure tension bracket with washer and cotter pin (Fig. 29).
Important To avoid damage reinstall clutch anchor bolt before connecting wire. 7. Adjust belt tension; refer to Adjust Belts page 27. 5 8. Reinstall belt guard. See Installing Belt Guard on page 21. 4 2194 3 Figure 30 1. 2. 3. 4. Jackshaft belt Traction belt Jackshaft pulley transmission pulley 2 1 M–4350 Figure 31 5. Idler pulley 6. Clutch pulley 7. Engine pulley 1. Jam nut 2. Cylinder pivot pin 3. Counterbalance spring 4. Adjustment nut 5. Lift arm T hook 5.
1. Park machine on a level surface, lower cutting unit and shut engine off. Disengage the PTO and engage the parking brake. 1 2 2. Raise seat and remove belt guard. See Removing Belt Guard on page 21. 3. Jack up front of machine until tires are off shop floor. Support machine with jack stands to prevent it from falling accidentally. Danger Mechanical or hydraulic jacks may fail to support machine and cause a serious injury. m–5179 • Use jack stand when supporting machine. • Do not use hydraulic jacks.
3. Remove dipstick cap from filler neck (Fig. 35) and wipe it with a clean rag. Insert dipstick cap onto filler neck; then remove it and check level of oil. 4. If level is not within 1/2 inch from full mark on dipstick, add SAE 10W–30 engine oil to raise level to FULL mark. Do not overfill. 5. Install dipstick filler cap onto filler neck (Fig. 35). 6. Run engine for approximately 1 minute, recheck reservoir oil level and add as required. 7. Reinstall belt guard. See Installing Belt Guard on page 21.
Adjusting the Steering 5. Install the tube assembly and hose assembly to reservoir (Fig. 36). 1. Measure toe-in distance (at axle height) at front and rear of steering tires. Front measurement must be 0–1/4 inch (6 mm) less than rear measurement. 2. Loosening jam nuts and rotating tie rod to adjust clearance (Fig. 37). 3. Turn steering wheel full left to achieve a full left turn (Fig. 37). 4. Check clearance between left tire and tie rod. There should be 25 mm (1 in.) ± 6 mm (1/4 in.
Hydraulic Schematic TRANSMISSION RESERVOIR FILTER VALVE CYLINDER T-0084 GM 1.9L (4PT.) 4.73L (5QT.) 18.93L (5GAL.) 14.9cl (44oz.
Changing the Front Axle Oil Checking the Electrolyte Level After every 500 hours of operation, change oil in the front axle. 1. Raise seat and remove belt guard. See Removing Belt Guard on page 21. 1. Run machine before changing oil to warm oil. Warm oil flows more freely and carries more contaminants than cold oil. 2. With the engine off, open the covers to see into the cells. The electrolyte must be up to the lower part of the tube (Fig. 39). Do not allow the electrolyte to get below the plates.
4. Remove the filler caps from the battery and connect a 3 to 4 amp battery charger to the battery posts. Charge the battery at a rate of 4 amperes or less for 4 hours (12 volts). Do not overcharge the battery. Install the filler caps after the battery is fully charged. Warning Charging battery produces gasses that can explode and cause serious injury. • Keep cigarettes, sparks and flames away from battery. • Make sure the ignition switch is off.
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 BLUE 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 Checking the Tire Pressure, page 26. 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to off. 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 Engine g will not start,, starts hard,, or f il tto kkeep running. fails i Engine g loses power. Engine g overheats. Abnormal vibration. Machine does not drive. POSSIBLE CAUSES CORRECTIVE ACTION 1. Operator is not seated. 1. Sit on seat. 2. Parking brake is off. 2. Move parking brake to on. 3. Fuel tank is empty. 3. Fill fuel tank with gasoline. 4. Choke is not on. 4. Move choke lever to on. 5. Air cleaner is dirty. 5. Clean or replace air cleaner element. 6.
