Z–Master 250 Series
Z–255
FORM NO. 3319–786
Traction Unit
Model No. 74201–890001
Operator’s Manual
IMPORTANT: Read this manual carefully. It contains information about your
safety and the safety of others. Also become familiar with the controls and
their proper use before you operate the product.
Introduction
Thank you for purchasing a Toro product.
All of us at Toro want you to be completely satisfied
with your new product, so feel free to contact your
local Authorized Service Dealer for help with service,
genuine replacement parts, or other information you
may require.
Whenever you contact your Authorized Service
Dealer or the factory, always know the model and
serial numbers of your product. These numbers will
help the Service Dealer or Service Representative
provide exact information about your specific
product. You will find the model and serial number
plate located in a unique place on the product as
shown below.
1
Read this manual carefully to learn how to operate
and maintain your product correctly. Reading this
manual will help you and others avoid personal injury
and damage to the product. Although we design,
produce and market safe, state-of-the-art products,
you are responsible for using the product properly
and safely. You are also responsible for training
persons, who you allow to use the product, about safe
operation.
The warning system in this manual identifies
potential hazards and has special safety messages that
help you and others avoid personal injury, 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 the recommended
precautions are not followed.
WARNING signals a hazard that may cause serious
injury or death if the recommended precautions are
not followed.
1. Model and Serial Number Plate
For your convenience, write the product model and
serial numbers in the space below.
Model No:
Serial No.
CAUTION signals a hazard that may cause minor or
moderate injury if the recommended precautions are
not followed.
Two other words are also used to highlight
information. “Important” calls attention to special
mechanical information and “Note” emphasizes
general information worthy of special attention.
The left and right side of the machine is determined
by sitting on the seat in the normal operator’s
position.
The engine exhaust from this product
contains chemicals known to the State of
California to cause cancer, birth defects,
or other reproductive harm.
The Toro Company – 1997
All Rights Reserved
Contents
Safety 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Operating Practices 2. . . . . . . . . . . . . .
Slope Chart 5. . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 7. . . . . . . . . .
Gasoline and Oil 9. . . . . . . . . . . . . . . . . . . . . . . .
Recommended Gasoline 9. . . . . . . . . . . . . .
Stabilizer/Conditioner 9. . . . . . . . . . . . . . . .
Filling the Fuel Tank 9. . . . . . . . . . . . . . . . .
Check Engine Oil Level 9. . . . . . . . . . . . . . .
Assembly 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts 10. . . . . . . . . . . . . . . . . . . . . . . . .
Install Seat Retaining Rod 11. . . . . . . . . . . . .
Tire Pressure 11. . . . . . . . . . . . . . . . . . . . . . . .
Install Motion Control Levers 12. . . . . . . . . .
Activate the Battery 13. . . . . . . . . . . . . . . . . .
Install Battery 14. . . . . . . . . . . . . . . . . . . . . . .
Install Mower Mounts 15. . . . . . . . . . . . . . . .
Install Power Take Off (PTO) Spring 15. . . .
Operation 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Think Safety First 16. . . . . . . . . . . . . . . . . . .
Controls 16. . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake 16. . . . . . . . . . . . . . . . . . . . . . .
Starting and Stopping the Engine 17. . . . . . .
Operating the Power Take Off (PTO) 18. . . .
The Safety Interlock System 19. . . . . . . . . . .
Driving Forward or Backward 20. . . . . . . . . .
Page
Page
Stopping the Machine 20. . . . . . . . . . . . . . . .
Instruments 21. . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tanks 21. . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting Height-of-Cut 22. . . . . . . . . . . . . .
Positioning the Seat 22. . . . . . . . . . . . . . . . . .
Pushing the Machine by Hand 23. . . . . . . . . .
Maintenance 24. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Interval Chart 24. . . . . . . . . . . . . . . .
Air Cleaner 25. . . . . . . . . . . . . . . . . . . . . . . . .
Engine Oil 26. . . . . . . . . . . . . . . . . . . . . . . . .
Spark Plug 28. . . . . . . . . . . . . . . . . . . . . . . . .
Greasing and Lubrication 29. . . . . . . . . . . . . .
Cleaning the Cooling Systems 30. . . . . . . . . .
Tire Pressure 30. . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter 30. . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank 31. . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic System 32. . . . . . . . . . . . . . . . . . . .
Adjusting Motion Controls 34. . . . . . . . . . . .
Replacing the Pump Drive Belt 35. . . . . . . . .
Adjustment Parking Brake 36. . . . . . . . . . . . .
Fuse 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery 37. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagram 38. . . . . . . . . . . . . . . . . . . . .
Cleaning and Storage 39. . . . . . . . . . . . . . . . .
Troubleshooting 40. . . . . . . . . . . . . . . . . . . . . . . . .
Warranty Back Cover. . . . . . . . . . . . . . . . . . . . . . . . . .
1
Safety
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
This product is capable of amputating hands and feet
and throwing objects. Always follow all safety
instructions to avoid serious injury or death.
POTENTIAL HAZARD
• Engine exhaust contains carbon monoxide,
which is an odorless, deadly poison.
WHAT CAN HAPPEN
• Carbon monoxide can kill you and is also
known to the State of California to cause
birth defects.
HOW TO AVOID THE HAZARD
• Do not run engine indoors or in an enclosed
area.
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.
Note: This engine is NOT equipped with a
spark arrestor muffler. Use or operation
of this mower in the State of California
on any forest-covered or unimproved
grass-covered land, without an
approved spark arrester muffler, is a
violation of the law. Other states may
have similar laws.
General Operation
1. Read, understand, and follow all instructions in
the operator’s manual and on the machine before
starting.
2. Allow only responsible adults who are familiar
with the instructions to operate the machine.
3. Clear the area of objects such as rocks, toys,
wire, etc., which could be picked up and thrown
by the blade.
4. Be sure the area is clear of other people before
mowing. Stop the machine if anyone enters the
area.
5. Never carry passengers.
6. Do not mow in reverse unless absolutely
necessary. Always look down and behind before
and while backing.
7. 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.
8. Slow down before turning. Sharp turns on any
terrain may cause loss of control.
9. Never leave a running machine unattended.
Always turn off blades, set parking brake, stop
engine, and remove key before dismounting.
10. Turn off blades when not mowing.
11. Keep hands, feet, hair and loose clothing away
from attachment discharge area, underside of
mower and any moving parts while engine is
running.
12. Stop the engine before removing the grass
catcher or unclogging the chute.
13. Mow only in daylight or good artificial light.
2
Safety
14. Do not operate the machine while under the
influence of alcohol or drugs.
15. Watch for traffic when operating near or crossing
roadways.
16. Use extra care when loading or unloading the
machine onto a trailer or truck.
17. Do not touch equipment or attachment parts
which may be hot from operation. Allow to cool
before attempting to maintain, adjust or service.
18. Before operating a machine with ROPS (roll
over protection) be certain the seat belt retainers
are attached to prevent the seat from pivoting
forward.
Slope Operation
Slopes are a major factor related to loss-of-control
and tip-over accidents, which can result in severe
injury or death. All slopes require extra caution. If
you cannot back up the slope or if you feel uneasy on
it, do not mow it.
DO
• 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
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 of 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 operate machine on hillsides or slopes
exceeding 15°.
• Mow up and down slopes greater than 5°, not
across.
• Mow downhill only on slopes above 10°, never
mow uphill. 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
or while on the slope.
• Follow the manufacturer’s recommendations for
wheel weight or counterweights to improve
stability.
• Use extra care with grass catchers or other
attachments. These can change the stability of
the machine.
• 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.
3
Safety
Children
Tragic accidents can occur if the operator is not alert
to the presence of children. Children are often
attracted to the machine and the mowing activity.
Never assume that children will remain where you
last saw them. The following requirements must be
followed to prevent injury to children.
1. Keep children out of the mowing area and under
the watchful care of another responsible adult.
2. Be alert and turn the machine off if children
enter the area.
3. Before and while backing, look behind and down
for small children.
4. Never carry children. They may fall off and be
seriously injured or interfere with safe machine
operation.
5. Never allow children to operate the machine.
6. Use extra care when approaching blind corners,
shrubs, trees, the end of a fence or other objects
that may obscure vision.
4. Keep nuts and bolts tight, especially the blade
attachment bolts. Keep equipment in good
condition.
5. Never tamper with safety devices. Check safety
systems for proper operation before each use.
6. Keep the machine free of grass, leaves, or other
debris build-up. Clean up oil or fuel spillage.
Allow the machine to cool before storing.
7. Stop and inspect the equipment if you strike an
object. Repair, if necessary, before restarting.
8. Grass catcher components are subject to wear,
damage and deterioration, which could expose
moving parts or allow objects to be thrown.
Frequently check components and replace with
manufacturer’s recommended parts, when
necessary.
9. Mower blades are sharp and can cut. Wrap the
blade(s) or wear gloves, and use extra caution
when servicing them.
10. Use only genuine replacement parts to ensure
that original standards are maintained.
Service
1. Stop the engine and disconnect spark plug
wire(s) before performing any service, repairs,
maintenance or adjustments.
2. Use extra care when handling gasoline and other
fuels. They are flammable and vapors are
explosive.
A. Use only an approved container.
B. Never remove the gas cap or add fuel when
the engine is running. Allow the engine to
cool before refueling. Do not smoke.
C. Never refuel the machine indoors.
D. Never store the machine or fuel container
inside where there is an open flame, such as
near a water heater or furnace.
3. Never run a machine inside a closed area.
11. Check brake operation frequently. Adjust and
service as required.
12. 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.
13. Battery gases can explode. Keep cigarettes,
sparks and flames away from battery.
14. Hydraulic fluid escaping under pressure can
penetrate the skin and cause injury. Use
cardboard or paper to find hydraulic leaks.
15. Never modify ROPS (roll over protection)
frames or structures because they are specifically
designed, sized, located and tested for injury
reduction. If a rollover occurs, a modified ROPS
will not provide adequate protection.
4
Slope Chart
Read all safety instructions on pages 2–4.
Safety
5
6
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.
TOP OF CONSOLE UNDER SEAT
Safety
(Part No. E513747)
ON RIGHT SIDE OF HEIGHT OF
CUT PLATE
(Part No E633345)
ON TOP OV HYDRAULIC
RESERVOIR
(Part No. E513890)
ON LEFT SIDE OF
HEIGHT–OF–CUT PLA TE
(Part No E633706)
ON TOP OF CONSOLE LEFT
AND RIGHT SIDES
(Part No. E633354)
ON RUBBER FLAP
BEHIND SEA T
(Part No. E303517)
ON HYDRAULIC RESERVOIR
MOUNTING BRACKET
(Part No. E513929)
E
ON CONSOLE AND RUBBER
FLAP BEHIND SEA T
(Part No. E633462)
BELOW CENTER OF CONSOLE
(Part No. E633346)
E
7
Safety
UNDER FOOTREST
(Part No. E633766)
ON TOP OF RIGHT
ENGINE BAFFLE
(Part No. E633771)
ON RUBBER FLAP
BEHIND SEA T
(Part No. E513748)
E
ONHYDRAULIC T ANK
(Part No. 65–2690)
ON CONTROL PANEL
(Part No. E633738)
8
Gasoline and Oil
Recommended Gasoline
Use UNLEADED Regular Gasoline suitable for
automotive use (85 pump octane minimum). Leaded
regular gasoline may be used if unleaded regular is
not available.
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.
POTENTIAL HAZARD
• In certain conditions gasoline is extremely
flammable and highly explosive.
WHAT CAN HAPPEN
• A fire or explosion from gasoline can burn
you, others, and cause property damage.
HOW TO AVOID THE HAZARD
• Use a funnel and fill the fuel tank outdoors,
in an open area, when the engine is cold.
Wipe up any gasoline that spills.
• Do not fill the fuel tank completely full.
Add gasoline to the fuel tank until the level
is 1/4” to 1/2” (6 mm to 13 mm) below the
bottom of the filler neck. This empty space
in the tank allows gasoline to expand.
• Never smoke when handling gasoline, and
stay away from an open flame or where
gasoline fumes may be ignited by a spark.
• Store gasoline in an approved container
and keep it out of the reach of children.
Never buy more than a 30-day supply of
gasoline.
Stabilizer/Conditioner
Add the correct amount of gas stabilizer/conditioner
to the gas. Using a stabilizer/conditioner in the
machine:
• Keeps gasoline fresh during storage
• Cleans the engine while it runs
• Eliminates gum-like buildup in the fuel system,
which causes hard starting
IMPORTANT: Never use fuel additives
containing methanol or ethanol.
Filling the Fuel Tank
1. Shut the engine off and set the parking brake.
2. Clean around each fuel tank cap and remove the
cap. Add unleaded regular gasoline to both fuel
tanks, until the level is 1/4 to 1/2 inch (6 mm to
13 mm) below the bottom of the filler neck. This
space in the tank allows gasoline to expand. Do
not fill the fuel tanks completely full.
3. Install fuel tank caps securely. Wipe up any
gasoline that may have spilled.
4. Fuel gauge is located in right side tank.
Check Engine Oil Level
Before you start the engine and use the machine,
check the oil level in the engine crankcase; refer to
Checking Oil Level, page 27.
9
Assembly
Loose Parts
Note: Use the chart below to verify all parts have been shipped.
DESCRIPTION QTY. USE
Retaining rod
Bolt 5/16–18 x 1” (26 mm)
Locknut 5/16”
Control lever–right
Control lever–left
Bolt 3/8–1 x 1” (26 mm)
Spring washer 3/8”
Strut–right
Strut–left
Bolt 5/8–11 x 5” (127 mm)
Lock washer 5/8”
Nut 5/8–11
Bolt 7/16–14 x 1-1/2” (38 mm)
Flange nut 7/16–14
Chain assembly
Strut rod
Bolt 5/16–18 x 3/4” (19 mm)
Flange locknut 5/16–18
1
1
1
1
1
4
4
1
1
2
2
2
4
8
4
2
2
2
Install seat rod
Install motion control levers
Install mower mounts to traction unit
Install mower to traction unit
Spring–PTO
Key
Operator’s Manual
Engine Operator’s Manual
Parts Catalog
Registration card
10
1
2
1
Read before operating machine
1
1
Fill out and return to Toro
1
Assembly
Install Seat Retaining Rod
5. Tilt seat up. Remove 5/16” locknut from bolt
attaching seat retaining rod to seat frame
(Fig. 1).
6. Remove retaining rod from seat and insert the
”L” shaped end of the rod into the hole directly
above the left–side hydraulic pump mounting
hardware (the ”L” must be positioned to the
right) (Fig. 1).
7. Place the seat retaining rod to the outside of the
mounting tab of the seat frame and secure with
5/16–18 x 1” (26 mm) bolt and 5/16” locknut
(Fig. 1).
8. Tighten until snug, then loosen so the rod pivots
freely.
2
Tire Pressure
Check the air pressure in the front and rear tires
(Fig. 2).
Pressure: 13 psi (90 kPa)
1
m–1872
Figure 2
1. Valve stem
1
1. L end of retaining rod
2. Locknut 5/16”
3
m–3750
Figure 1
3. Bolt 5/16–18 x 1” (26 mm)
11
Assembly
Install Motion Control Levers
9. Remove the (4) 3/8–16 x 1” (26 mm) bolts and
(4) 3/8 spring washers which attach the motion
control levers to the control arm shafts for
shipping (Fig. 3).
10. Place the levers (with the mounting plate
towards the rear) on the outside of the control
arm shaft and secure with (4) 3/8–16 x 1”
(26 mm) bolts and (4) 3/8 spring washers
(Fig. 3).
11. Position the lever so the bolts are in the center of
the slots on the lever mounting plate and tighten
until snug.
12. Align the front\rear position of the levers, with
each other, in the neutral position. Loosen
hardware and adjustment by sliding/tilting the
lever(s) forward or backward until properly
aligned(Fig. 3).
13. If the ends of the levers hit against each other,
while in the drive position (Fig 4) (levers rotated
in as far as possible).
14. Make adjustments by moving the levers
outwards to the neutral lock position and
carefully bend them outward. Move them back
to the drive position and check for clearance,
repeat if necessary.
Figure 4
2
3
1. Mounting plate
2. Bolt 3/8–18 x 1” (26 mm)
1
m–3751
Figure 3
3. Spring washer 3/8”
12
Assembly
Activate the Battery
Bulk electrolyte with 1.260 specific gravity must be
purchased from a local battery supply outlet.
1. Remove the battery from the machine.
IMPORTANT: Be careful not to damage the
long vent tube when removing the battery
box.
POTENTIAL HAZARD
• Battery electrolyte contains sulfuric acid
which is a deadly poison and it causes
severe burns.
WHAT CAN HAPPEN
• If you carelessly drink electrolyte you could
die or if it gets onto your skin you will be
burned.
HOW TO AVOID THE HAZARD
• Do not drink electrolyte and avoid contact
with skin, eyes or clothing. Wear safety
glasses to shield your eyes and rubber
gloves to protect your hands.
• Fill the battery where clean water is always
available for flushing the skin.
• Follow all instructions and comply with all
safety messages on the electrolyte container.
2. Remove filler caps from the battery. Slowly pour
electrolyte into each cell until the electrolyte
level is up to the lower part of the tube (Fig. 5).
1
2
3
m–1262
Figure 5
1. Filler caps
2. Electrolyte
3. Lower part of the tube
3. Leave the covers off and connect a 3 to 4 amp
battery charger to the battery posts (Fig. 6).
Charge the battery at a rate of 4 amperes or less
for 4 hours (12 volts).
4
2
3
1
1. Positive post
2. Negative post
m–1254
Figure 6
3. Charger red (+) wire
4. Charger black (–) wire
13
Assembly
Install Battery
POTENTIAL HAZARD
• Charging battery produces gasses.
WHAT CAN HAPPEN
• Battery gasses can explode.
HOW TO AVOID THE HAZARD
• Keep cigarettes, sparks and flames away
from battery.
4. When the battery is fully charged, disconnect the
charger from the electrical outlet then from the
negative and positive battery posts (Fig. 6).
5. Slowly pour electrolyte into each cell until the
level is once again up to the “UPPER” line on
the battery case (Fig. 5) and install covers.
6. Position battery in tray with terminal posts
toward the engine (Fig. 7).
7. Slide the red terminal boot onto the positive
(red) battery cable.
8. Install the positive (red) battery cable to positive
(+) battery terminal then negative battery cable
and ground wire to the negative (–) battery
terminal.
9. Secure cables with (2) 1/4 x 3/4” (19 mm) bolts
1/4” washers and 1/4” locknuts (Fig. 7).
10. Secure battery with J-bolts, hold down clamp
and (2) 1/4” washers and (2) 1/4” wing nuts
(Fig. 7).
9 5
11
7
4
2
6
10
1
1. Battery
2. Terminal boot
3. Positive battery cable
4. Negative battery cable
5. Ground wire
6. Bolt 1/4–20 x 3/4” (19 mm)
7
3
8
m–3752
Figure 7
7. Washer 1/4”
8. Locknut 1/4”
9. Battery clamp
10. J-bolts
11. Wing nut 1/4”
14
Assembly
When installing the mower the following assembly
operations must also be completed.
Install Mower Mounts
1. Attach left and right struts, with greases fitting
up. Secure inside of rear frame member with
5/8–11 x 5” (127 mm) bolts, 5/8” lock washers
and 5/8–11 nuts (Fig. 8).
4
3
2
1. Strut
2. Bolt 5/8–1 1 x 5” (127 mm)
1
Figure 8
3. Lock washer 5/8”
4. Nut 5/8 11
m-3685
Install Power Take Off (PTO)
Spring
4. Install the PTO clutch spring. Hook one end
around frame bolt, between washer and spacer
(Fig 10). Stretch spring and hook other end to
the PTO idler arm.
5. Install and adjust PTO Drive belt, refer to
Replacing the PTO Drive Belt.
2 3
1
4
Figure 10
1. Spring
2. Washer
3. Spacer
4. PTO idler arm
m–3689
2. Remove one 7/16–14 flange nut from bolt in
each chain assembly (Fig. 9).
3. Place bolt of chain into traction unit lift arm slot
and secure with previously removed 7/16–14
flange nut (Fig. 9). Tighten flange nut securely.
2
3
3
Figure 9
1. Lift chain assembly
2. Flange nut 7/16–14
1
3. Lift arm
m–3686
15
Operation
Think Safety First
Please carefully read all the safety instructions on
pages 2–8. Knowing this information could help you,
your family, pets or bystanders avoid injury.
Controls
Become familiar with all the controls (Fig. 1) before
you start the engine and operate the machine.
2
3
8
7
1
10
Parking Brake
Always set the parking brake when you stop the
machine or leave it unattended.
Setting the Parking Brake
1. Move the motion control levers (Fig. 1) out to
the neutral lock position.
2. Pull back and up on the parking brake lever to
set the parking brake (Fig. 2). The parking brake
lever should stay firmly in the “ENGAGED”
position.
Releasing the Parking Brake
1. Push forward and down on the parking brake
lever release the parking brake (Fig. 2). The
parking brake is “DISENGAGED” and the lever
rests against the front of the opening.
4
1. Ignition switch
2. Motion control lever
3. Parking brake lever
4. Throttle
5. Choke
6
Figure 1
5
9
6. Power take off (PTO)
7. Height-of-Cut lever
8. Fuel cap
9. Fuel shut off lever
10. Hourmeter
1
2
m–3656
Figure 2
1. Parking brake-ON 2. Parking brake-OFF
16
Operation
Starting and Stopping
the Engine
Starting
1. Sit down on the seat and move the motion
controls to neutral locked position.
2. Set the parking brake; refer to Setting the
Parking Brake, page 16.
3. Move the PTO (power take off) to “OFF”
(Fig. 3).
4. Move the choke control to “ON” position before
starting a cold engine.
Note: A warm or hot engine may require
choking. After engine starts, move
choke control to “RUN” position.
5. Move the throttle control to the “FAST” position
before starting a cold engine.
Figure 3
1. PTO-On
2. PTO-Off
2
m–3729
1
2
1
m–2719
Figure 4
1. Choke–On
2. Choke–Off
1
2
1
2
3
6. Turn ignition key “START” to energize starter.
When engines starts, release key.
IMPORTANT: Do not engage starter for
more than 10 seconds at a time. If engine fails
to start allow 30 second cool-down period
between attempts. Failure to follow these
instructions can burn out starter motor.
7. After the engine starts, move the choke to “OFF”
(Fig. 4). If the engine stalls or hesitates, move
the choke back to “ON” for a few seconds. Then
move the throttle lever to desired setting. Repeat
this as required.
1. Fast
2. Slow
Figure 5
m–2720
Figure 6
1. Off
2. Run
3. Start
17
Operation
Stopping
1. Move the throttle lever to “SLOW” (Fig. 5).
2. Turn the ignition key to “OFF” (Fig. 6).
Note: If the engine has been working hard or
is hot, let it idle for a minute before
turning the ignition key “OFF.” This
helps cool the engine before it is
stopped. In an emergency, the engine
may be stopped by turning the ignition
key to “OFF.”
3. Pull wire off spark plug(s) to prevent possibility
of accidental starting before transporting or
storing machine.
4. Close fuel shut off valve, on front panel before
transporting or storing machine.
IMPORTANT: Make sure fuel shut off valve
is closed before transporting or storing
machine, as fuel leakage may occur.
Operating the Power Take Off
(PTO)
The power take off (PTO) switch engages and
disengages power to the electric clutch.
Engaging the PTO
1. Release pressure on the traction control levers
and place in neutral, refer to traction unit
Operator’s Manual.
2. Release the parking brake, refer to traction unit
Operator’s Manual.
3. Pull out on the power take off (PTO) switch to
engage (Fig. 7).
2
1
m–3739
Figure 7
1. PTO – Off 2. PTO – On
Disengaging the PTO
1. To disengage push the PTO switch to the “OFF”
position (Fig. 7).
18
The Safety Interlock System
Understanding the Safety Interlock
System
The safety interlock system is designed to prevent the
engine from starting unless:
• You are sitting on the seat
• The parking brake is on “ENGAGED”
• The power take off (PTO) is disengaged “OFF”
• The motion control levers are in neutral
The safety interlock system also is designed to stop
the engine when the traction controls are moved with
the parking brake on “ENGAGED” or if you rise
from the seat when the PTO is “ON” engaged.
Operation
Testing the Safety Interlock System
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.
1. Sitting on the seat, “ENGAGE” parking brake
and move PTO “ON”. Try starting the engine;
the engine should not crank.
2. Sitting on the seat, “ENGAGE” parking brake
and move PTO “OFF”. Move either motion
control lever (forward or reverse). Try starting
the engine; the engine should not crank.
3. Sitting on the seat, “ENGAGE” parking brake,
move PTO “OFF” and lock the motion control
levers in neutral. Now start the engine. While the
engine is running, release the parking brake,
engage the PTO and rise slightly from the seat;
the engine should stop.
4. Sitting on the seat, “ENGAGE” parking brake,
PTO “OFF” and lock the motion control levers
in neutral. Now start the engine. While the
engine is running, center the motion controls and
move (forward or reverse); the engine should
stop.
19
Operation
Driving Forward or Backward
The throttle control regulates the engine speed as
measured in rpm (revolutions per minute). Place the
throttle control in the “FAST” position for best
performance. Always operate in the full throttle
position
Forward
1. Release the parking brake; refer to Setting the
Parking Brake, page 16.
2. Move levers to the center, un-locked position.
3. To go forward, slowly push the motion control
levers forward (Fig. 8).
Note: Engine will kill if traction control
levers are moved with parking brake
engaged.
To go straight, apply equal pressure to both motion
control levers (Fig. 8).
Backward
1. Move levers to the center, un-locked position.
2. To go backward, slowly pull the motion control
levers rearward (Fig. 8).
To go straight, apply equal pressure to both motion
control levers (Fig. 8).
To turn, release pressure on the motion control lever
toward the direction you want to turn (Fig. 8).
To stops push the motion control levers to neutral.
Stopping the Machine
To stop the machine, move the traction control levers
to neutral and separate to lock, disengage the power
take off (PTO), and turn the ignition key to “OFF” to
stop the engine. Also set the parking brake when you
leave the machine; refer to Setting the Parking Brake,
page 16. Remember to remove the key from the
ignition switch.
To turn, release pressure on the motion control lever
toward the direction you want to turn (Fig. 8).
The farther you move the traction control levers in
either direction, the faster the machine will move in
that direction.
To stop pull the motion control levers to neutral.
3
4
Figure 8
1. Motion control
lever-neutral lock position
2. Center un-lock position
2
1
m–2715
3. Forward
4. Backward
POTENTIAL HAZARD
• Someone could move or attempt to operate
the tractor while it is unattended.
WHAT CAN HAPPEN
• Children or bystanders may be injured if
they use the tractor.
HOW TO AVOID THE HAZARD
• Always remove the ignition key and set the
parking brake when leaving the machine,
even if just for a few minutes.
20
Operation
Instruments
Hour Meter
The hour meter records the number of hours the
engine has operated. It operates when the engine is
running. Use these times for scheduling regular
maintenance.
1
m–3077
Figure 9
1. Hour meter
Fuel Tanks
The unit has two fuel tanks, located on the left and
right sides. Each tank connects to the fuel shut off
valve in the control panel from there a common fuel
line leads to the engine (Fig. 10).
To use the right side fuel tank rotate the fuel shut off
valve 1/4 turn to the right from the off location. This
uses fuel from the right side tank only. When the right
hand fuel tank is empty, move the fuel shut off valve
1/4 turn to the left from the off position.
Close fuel shut off valve, on front panel before
transporting or storing machine.
Figure 10
1. Shut off valve
21
Operation
Adjusting Height-of-Cut
The height-of-cut is adjusted from 1-1/2” to 5”
(38 to 127 mm) in 1/2” (13 mm) increments by
relocating clevis pin in different hole locations.
1. Raise the height-of-cut lever to the transport
position (also the 5” (127 mm) cutting height
position) (Fig. 11).
2. To adjust, remove hairpin cotter and clevis pin
from height-of-cut bracket (Fig. 11).
3. Select hole in height-of-cut bracket
corresponding to the height-of-cut desired. Lift
handle to transport position, insert clevis pin
(Fig. 11).
4. Secure clevis pin with hairpin cotter (Fig. 11).
Positioning the Seat
The seat can move forward and backward. Position
the seat where you have the best control of the
machine and are most comfortable.
1. To adjust, move the lever sideways to unlock
seat (Fig. 12).
2. Slide the seat to the desired position and release
lever to lock in position.
m–3655
1
1
1200
1. Height of cut lever
2. Clevis Pin
Figure 11
3. Hairpin Cotter
2
3
m-3654
Figure 12
1. Adjustment knob
22
Pushing the Machine by Hand
IMPORTANT: Always push the machine by
hand. Never tow the machine because
hydraulic damage may occur.
To Push the Machine
1. Disengage the power take off (PTO) and turn the
ignition key to “OFF” to stop the engine.
2. Rotate the by-pass valves counterclockwise 1
turn to push. This allows hydraulic fluid to
by-pass the pump enabling the wheels to turn
(Fig. 13).
IMPORTANT: Rotate by-pass valve a
maximum of 2 turns so the valve does not
come out of the body causing fluid to run out.
Operation
To Operate the Machine
1. Turn the by-pass valves in to operate (Fig. 13).
Note: The machine will not drive unless
by-pass valves are turned in.
E
Figure 13
1. By-pass valve
1
23
Maintenance
Service Interval Chart
Each
Service Operation
Hydraulic fluid–check level Initial X X
Oil—check level X X
Oil—change* Initial X X
Oil Filter–change (200 hours or every
other oil change)
Hydraulic filter–change Initial X X
Safety System—check X X
Chassis—grease* X X
Linkage bushings—oil* X X
Foam Air Cleaner—service* X X
Paper Air Cleaner—replace* X X
Spark Plug(s)—check X X
Belts—check for wear/cracks X X
Gasoline—drain X
Cooling systems–clean X X X
Hydraulic lines–check X X
Battery–check electrolyte X X
Battery–charge, Disconnect cables X
Fuel Filter—replace X X
Tires—check pressure X X
Chipped Surfaces—paint X
* More often in dusty, dirty conditions
Use8Hours25Hours50Hours
100
Hours
200
Hours
X X
Storage
Service
24
POTENTIAL HAZARD
• If you leave the key in the ignition switch, someone could start the engine.
WHAT CAN HAPPEN
• Accidental starting of the engine could seriously injure you or other bystanders.
HOW TO AVOID THE HAZARD
• Remove the key from the ignition switch and pull the wire(s) off the spark plug(s)
before you do any maintenance. Also push the wire(s) aside so it does not
accidentally contact the spark plug(s).
Maintenance
Air Cleaner
Foam Element: Clean and re-oil after every 25
operating hours.
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.
Removing the Foam and Paper Elements
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.
2. 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).
1
3. Carefully slide the foam element off the paper
element (Fig. 14).
4. Unscrew the cover nut and remove the cover and
paper element (Fig. 14).
Cleaning the Foam and Paper Elements
1. Foam Element
A. Wash the foam element in liquid soap and
warm water. When the element is clean,
rinse it thoroughly.
B. Dry the element by squeezing it in a clean
cloth (do not wring).
C. Put one or two ounces of oil on the element
(Fig. 15). Squeeze the element to distribute
the oil.
IMPORTANT: Replace the foam element if it
is torn or worn.
2
3
5
1. Knob
2. Air cleaner cover
3. Cover nut
4. Cover
Figure 14
5. Foam element
6. Paper element
7. Rubber seal
8. Air cleaner base
2
4
6
87
m–3214
1. Foam element 2. Oil
1
m–1213
Figure 15
2. Paper Element
25
Maintenance
A. Lightly tap the element on a flat surface to
remove dust and dirt (Fig. 16).
B. Inspect the element for tears, an oily film,
and damage to the rubber seal.
IMPORTANT: Never clean the paper element
with pressurized air or liquids, such as
solvent, gas, or kerosene. Replace the paper
element if it is damaged, defective, or cannot
be cleaned thoroughly.
1
2
Engine Oil
Change oil:
• After the first 5 operating hours.
• After every 100 operating hours.
Note: Change oil more frequently when
operating conditions are extremely
dusty or sandy.
Oil Type: Detergent oil (API service SG or SH)
Crankcase Capacity: w/filter, 2.1 qt. (2 l)
Viscosity: See table below
USE THESE SAE VISCOSITY OILS
10W–30, 10W–40
m–1213
Figure 16
1. Paper element 2. Rubber seal
Installing the Foam and Paper Elements
1. Installing the Foam and Paper Elements
IMPORTANT: To prevent engine damage,
always operate the engine with the complete
foam and paper air cleaner assembly
installed.
1. Carefully slide the foam element onto the paper
air cleaner element (Fig. 14).
2. Place the air cleaner assembly onto the air
cleaner base (Fig. 14).
3. Install the air cleaner cover and secure with
cover nut (Fig. 14).
5W–20, 5W–30
–20 0 20
°
F
–30°–20 –10
C
40 60
32
01020
80 100
30 40
26
Maintenance
Checking Oil Level
1. Park the machine on a level surface, disengage
the power take off (PTO) and turn the ignition
key to “OFF” to stop the engine. Remove the
key.
2. Clean around the oil dipstick (Fig. 17) so dirt
cannot fall into the filler hole and damage the
engine.
3. Unscrew the oil dipstick and wipe the metal end
clean (Fig. 17).
4. Slide the oil dipstick fully into the filler tube, do
not thread onto tube (Fig. 17). Pull the dipstick
out and look at the metal end. If oil level is low,
slowly pour only enough oil into the filler tube
to raise the level to the “FULL” mark.
IMPORTANT: Do not overfill the crankcase
with oil because the engine may be damaged.
1
2
3
Changing/Draining Oil
1. Start the engine and let it run five minutes. This
warms the oil so it drains better.
2. Park the machine so that the drain side is slightly
lower than the opposite side to assure the oil
drains completely. Then disengage the power
take off (PTO), set the parking brake, and turn
the ignition key to “OFF” to stop the engine.
Remove the key.
3. Place a pan below the oil drain. Remove the oil
drain cap (Fig. 18).
4. When oil has drained completely, install the
drain cap.
Note: Dispose of the used oil at a certified
recycling center.
m–3217 m–3219
Figure 17
1. Oil dipstick
2. Filler tube
3. Metal end
1
Figure 18
1. Oil drain cap
m–3658
5. Slowly pour approximately 80% of the specified
amount of oil specified, page 26, into the filler
tube (Fig. 17). Now check the oil level; refer to
Checking Oil Level, page 27. Slowly add
additional oil to bring to “FULL” mark on
dipstick.
27
Maintenance
Change Oil Filter
Replace the oil filter every 200 hours or every other
oil change.
Note: Change oil filter more frequently when
operating conditions are extremely
dusty or sandy.
1. Drain the oil from the engine; refer to
Changing/Draining Oil, page 27.
2. Remove the old filter and wipe the filter adapter
(Fig. 19) gasket surface.
3. Pour new oil of the proper type in through the
center hole. Stop pouring when the oil reaches
the bottom of the threads. Allow a minute or two
for the oil to be absorbed by filter material.
4. Apply a thin coat of new oil to the rubber gasket
on the replacement filter (Fig. 19).
Spark Plug
Check the spark plug(s) after every 200 operating
hours. Make sure the air gap between the center and
side electrodes is correct before installing the spark
plug. Use a spark plug wrench for removing and
installing the spark plug(s) and a gapping tool/feeler
gauge to check and adjust the air gap. Install a new
spark plug(s) if necessary.
Type: Champion RC12YC (or equivalent) Air Gap:
0.030 in. (0.76 mm)
Removing the Spark Plug(s)
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.
2. Pull the wire(s) off the spark plug(s) (Fig. 20).
Now clean around the spark plug(s) to prevent
dirt from falling into the engine and potentially
causing damage.
3
1
Figure 19
1. Oil filter
2. Gasket
2
3. Adapter
m–1256
5. Install the replacement oil filter to the filter
adapter. Turn the oil filter clockwise until the
rubber gasket contacts the filter adapter, then
tighten the filter an additional 1/2 turn (Fig. 19).
6. Fill the crankcase with the proper type of new
oil; refer to Changing/Draining Oil, page 27.
3. Remove the spark plug(s) and metal washer.
1
2
m–3218
Figure 20
1. Spark plug wire 2. Spark plug
28
Maintenance
Checking the Spark Plug
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.
IMPORTANT: Never clean the spark plug(s).
Always replace the spark plug(s) when it has:
a black coating, worn electrodes, an oily film,
or cracks.
2. Check the gap between the center and side
electrodes (Fig. 21). Bend the side electrode
(Fig. 21) if the gap is not correct.
2
1
3
0.030 in.
(0.76 mm)
Greasing and Lubrication
Lubricate the machine when shown on the CHECK
SERVICE REFERENCE AID decal (Fig. 22). Grease
more frequently when operating conditions are
extremely dusty or sandy.
Grease Type: General-purpose grease.
How to Grease
1. Disengage the power take off (PTO) and turn the
ignition key to “OFF” to stop the engine.
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. Wipe up any excess grease.
m–3215
Figure 21
1. Center electrode insulator
2. Side electrode
3. Air gap (not to scale)
Installing the Spark Plug(s)
1. Install the spark plug(s). Make sure the air gap is
set correctly.
2. Tighten the spark plug(s) to 20 ft-lb (27 N.m).
3. Push the wire(s) onto the spark plug(s) (Fig. 20).
Where to Add Grease
Lubricate the grease fittings as shown on the CHECK
SERVICE REFERENCE AID decal (Fig. 22).
Figure 22
29
Maintenance
ÓÓ
ÓÓ
ÓÓ
ÓÓ
Cleaning the Cooling Systems
Before each use, check and clean cooling screen.
Remove any build–up of grass, dirt or other debris
from the oil cooler screen and engine air intake.
Every 100 hours clean oil cooler, engine cylinder and
cylinder head cooling fins. Also clean around
carburetor, governor levers and linkage. This will
help insure adequate cooling to hydraulic pumps,
motors and engine and will reduce the possibility of
overheating and mechanical damage.
2
Figure 23
1. Engine screen 2. Oil cooler
m–3801
Fuel Filter
Replace the fuel filter after every 200 operating hours
or yearly, whichever occurs first.
Replacing the Fuel Filter
Never install a dirty filter if it is removed from the
fuel line.
1. Disengage the power take off (PTO), set the
parking brake, and turn the ignition key to
1
“OFF” to stop the engine. Remove the key.
2. Close fuel shut–off valve on console.
3. Squeeze the ends of the hose clamps together
and slide them away from the filter (Fig. 25).
4. Remove the filter from the fuel lines.
5. Install a new filter and move the hose clamps
close to the filter (Fig. 26).
Tire Pressure
Maintain the air pressure in the front and rear tires as
specified. Uneven tire pressure can cause uneven cut.
Check the pressure at the valve stem after every 50
operating hours or monthly, whichever occurs first
(Fig. 24). Check the tires when they are cold to get
the most accurate pressure reading.
Pressure: 13 psi (90 kPa) drive wheels and castor
wheels.
1
m–1872
Figure 24
1. Valve stem
6. Open fuel shut-off valve on console.
1
2
m–3217
Figure 25
1. Filter 2. Hose clamp
30
Maintenance
Fuel Tank
Draining The Fuel Tank
POTENTIAL HAZARD
• In certain conditions gasoline is extremely
flammable and highly explosive.
WHAT CAN HAPPEN
• A fire or explosion from gasoline can burn
you, others, and cause property damage.
HOW TO AVOID THE HAZARD
• Drain gasoline from the fuel tank when the
engine is cold. Do this outdoors in an open
area. Wipe up any gasoline that spills.
• Never drain gasoline near an open flame or
where gasoline fumes may be ignited by a
spark.
• Never smoke a cigarette, cigar or pipe.
4. Pull the fuel line off fuel filter (Fig. 26). Open
fuel shut-off valve and allow gasoline to drain
into a gas can or drain pan.
Note: Now is the best time to install a new
fuel filter because the fuel tank is
empty.
5. Install the fuel line onto the fuel filter. Slide the
hose clamp close to the fuel filter to secure the
fuel line (Fig. 26).
3
1
4
2
m–3717
1. Park the machine on a level surface, to assure
fuel tank drains completely. Then disengage the
power take off (PTO), set the parking brake, and
turn the ignition key to “OFF” to stop the
engine. Remove the key.
2. Close fuel shut–off valve (Fig. 26).
3. Loosen the hose clamp at the fuel filter and slide
it up the fuel line away from the fuel filter
(Fig. 26).
1. Fuel shut-off valve
2. Fuel filter
Figure 26
3. Hose clamp
4. Fuel line
31
Maintenance
Hydraulic System
Checking the Hydraulic Fluid
Check the hydraulic fluid level before engine is first
started and after every 25 operating hours.
Fluid Type: Mobil 1 15W–50 synthetic motor oil.
IMPORTANT: Use only oil specified. Other
fluids could cause system damage.
Tank Capacity: 2.1 qt. (2.0 l)
1. Position machine on a level surface and stop the
engine and set the parking brake.
2. Clean area around filler neck of hydraulic tank
(Fig. 27).
3. Remove cap from filler neck and look inside to
check fluid level. Fluid level should be above the
baffle inside the tank (Fig. 27).
4. If level is low, add fluid to raise level to above
the baffle (Fig. 27).
POTENTIAL HAZARD
• Hydraulic fluid escaping under pressure
can penetrate skin and cause injury.
WHAT CAN HAPPEN
• Fluid accidentally injected into the skin
must be surgically removed within a few
hours by a doctor familiar with this form of
injury or gangrene may result.
HOW TO AVOID THE HAZARD
• Keep body and hands away from pin hole
leaks or nozzles that eject high pressure
hydraulic fluid.
• Use cardboard or paper to find hydraulic
leaks.
Replacing the Hydraulic Filter
Change the hydraulic filter:
• After the first 8 operating hours.
5. Install cap on filler neck.
1
3
Figure 27
1. Cap
2. Baffle
3. Fluid level-Full
2
m–3657
• After every 200 operating hours.
1. Position machine on a level surface, stop the
engine, and remove key from ignition switch.
IMPORTANT: Do not substitute automotive
oil filter or severe hydraulic system damage
may result.
2. Remove hydro cap and temporarily cover
opening with a plastic bag and rubber band to
prevent all hydro fluid from draining out.
32
Maintenance
3. Place drain pan under filter, remove the old filter
and wipe the filter adapter gasket surface clean
(Fig. 28).
1
m–3291
Figure 28
1. Hydraulic filter
4. Apply a thin coat hydro fluid to the rubber
gasket on the replacement filter (Fig. 29).
5. Install replacement hydraulic filter onto the filter
adapter. Do not tighten.
6. Remove plastic bag from tank opening and allow
filter to fill with hydro fluid.
7. When fluid overflows filter turn the oil filter
clockwise until the rubber gasket contacts the
filter adapter, then tighten the filter an additional
1/2 turn (Fig. 29).
10. Check fluid level in hydraulic tank and add to
raise level to cover bottom of screen. DO NOT
OVER FILL.
1. Hydraulic filter
2. Gasket
1
Figure 29
3. Adapter
3
2
m–1256
Bleeding Hydraulic System
The traction system is self bleeding, however, it may
be necessary to bleed the system if fluid is changed or
after work is performed on the system.
1. Raise front of the machine so wheels are off the
ground and support with jack stands.
2. Start the engine and run at idle speed. Engage
traction on one side and spin the wheel by hand.
8. Clean up any spilled fluid.
9. Start engine and let run for about two minutes to
purge air from the system. Stop the engine and
check for leaks. If one or both wheels will not
drive, refer Bleeding Hydraulic System, page 33.
3. When the wheel begins to spin on its own, keep
it engaged until wheel drives smoothly.
(minimum 2 minute)
4. Check hydraulic fluid level as it drops and add
as required to maintain proper level.
5. Repeat procedure on opposite wheel.
33
Maintenance
Check Hydraulic Lines
After every 100 operating hours, check hydraulic
lines and hoses for leaks, loose fittings, kinked lines,
loose mounting supports, wear, weather and chemical
deterioration. Make necessary repairs before
operating.
POTENTIAL HAZARD
• Hydraulic fluid escaping under pressure
can penetrate skin and cause injury.
WHAT CAN HAPPEN
• Fluid accidentally injected into the skin
must be surgically removed within a few
hours by a doctor familiar with this form of
injury or gangrene may result.
HOW TO AVOID THE HAZARD
• Keep body and hands away from pin hole
leaks or nozzles that eject high pressure
hydraulic fluid.
• Use cardboard or paper to find hydraulic
leaks.
Adjusting Motion Controls
If motion control levers do not align, or move easily
into the console notch, adjustment is required. Adjust
each lever, spring and rod separately.
1. Stop engine, remove ignition key and tilt seat
forward.
2. Begin with either the left or right motion control
lever. Move lever to the neutral position and pull
lever back until the clevis pin (on arm below
pivot shaft) contacts the end of the slot (just
beginning to put pressure on spring) (Fig. 30).
3. Check where lever is relative to notch in console
(should be centered allowing lever to pivot
outward to the neutral lock position) (Fig. 30).
4. If adjustment is needed, loosen the nut against
the yoke and while applying slight rearward
pressure on the motion control lever, turn the
head of the adjustment bolt in the appropriate
direction until lever is centered (keeping
rearward pressure on the lever will keep the pin
at the end of the slot and allow the adjustment
bolt to move the lever to the appropriate
position). Tighten lock nut.
5. Repeat on opposite side of unit.
1
2
3
Figure 30
1. Neutral lock position
2. Clevis pin in slot
3. Nut
4
3
4. Bolt
5. Pump rod
6. Double nuts
1
6
5
m–3800
34
Maintenance
6. This adjustment must be made with drive wheels
turning. First raise the frame and block up so
drive wheels can rotate freely.
7. Start engine, open throttle 1/2 way and release
parking brake. Refer to Starting and Stopping
the Engine, page 17.
8. The reverse indicator spring must be correct
before the following adjustment can be made
(see step 1).
9. Slide seat forward, remove prop rod and tilt seat
fully forward.
10. Remove electrical connector from the seat safety
switch.
terminals in the connector of wiring harness.
11. Loosen locknut at ball joint on pump control rod
(Fig. 30).
Note: The front nut of each rod has left–hand
Temporarily install a jumper wire across
threads.
Replacing the Pump Drive Belt
Check pump drive belt for wear after every 50 hours
of operation.
1. Pull spring loaded idler down and remove
traction belt from the engine and hydro pump
pulleys (Fig. 31). Remove belt between pulleys.
2. Install new belt around engine and hydro pump
pulleys (Fig. 31).
3. Pull spring loaded idler down and align below
traction belt. Release pressure on spring loaded
idler (Fig. 31).
12. Adjust pump rod length by rotating double nuts
on rod, in the appropriate direction, until wheel
is still or slightly creeps in reverse (Fig. 30).
13. Move motion control lever forward and reverse,
then back to neutral. Wheel must stop turning or
slightly creep in reverse.
Note: Motion control lever must be in neutral
while making any adjustments.
14. Open throttle to fast. Make sure wheel remains
stopped or slightly creeps in reverse, re-adjust if
necessary.
15. Repeat on opposite side of unit. Tighten locknuts
against ball joints.
16. Shut off unit. Remove jumper wire from wire
harness connector and plug connector into seat
switch.
17. Reinstall prop rod and lower seat.
Figure 31
35
Maintenance
Adjustment Parking Brake
Check parking brake for adjusted properly.
1. Disengage brake lever (lever down).
2. Measure the length of the spring. Measurement
should be 2.9” (74 mm) between washers
(Fig. 32).
3. If adjustment is necessary, loosen the jam nut
below the spring and tighten the nut directly
below the yoke (Fig. 32). Turn the nut until the
correct measurement is obtained. Tighten the
two nuts together and repeat on
unit.
4. Turn nuts clockwise to shorten spring length and
turn counter–clockwise to lengthen the spring.
5. Engage parking brake, lever up.
6. Measure the distance between the trunnion roller
and the collar on brake rod . Measurement
should be 3/16”–1/4” (5–7 mm) (Fig. 32).
opposite side of
Fuse
Service Interval/Specification
The electrical system is protected by fuses. It requires
no maintenance, however, if a fuse blows check
component/circuit for malfunction or short.
Fuse: Main F1–20 amp, blade-type
Alternator F2–20 amp, blade-type
1. Raise the seat to gain access to fuse holder (Fig.
33).
2. To replace fuses pull out on the fuse to remove it
(Fig. 33).
2
1
7. If adjustment is necessary, loosen the jam nut
directly below the yoke. Turn the bottom rod
until the correct measurement is obtained
(Fig. 32). Tighten jam nut at yoke
4
1
1. Brake lever
2. Spring 2.9” (74 mm)
3. Adjusting nuts
2
3
Figure 32
4. Collar on brake rod
5. 3/16”–1/4’ (5–7 mm)
6. Jam nut and yoke
5
6
m–3788
m–3653
Figure 33
1. Main-30 amp 2. Alternator-25 amp
36
Maintenance
Battery
Check the electrolyte level in the battery every 25
hours. Always keep the battery clean and fully
charged. Use a paper towel to clean the battery case.
If the battery terminals are corroded, clean them with
a solution of four parts water and one part baking
soda. Apply a light coating of grease to the battery
terminals to prevent corrosion.
Voltage: 12 v
Checking Electrolyte Level
1. Open covers to see into the cells. The electrolyte
must be up to the lower part of the tube
(Fig. 34). Do not allow the electrolyte to get
below the plates. (Fig. 34).
2. If the electrolyte is low, add the required amount
of distilled water; refer to Adding Water to the
Battery, page 37.
IMPORTANT: Do not overfill the battery
because electrolyte (sulfuric acid) can cause
severe corrosion and damage to the chassis.
4. Press the filler caps onto the battery.
Charging the Battery
IMPORTANT: Always keep the battery fully
charged (1.260 specific gravity). This is
especially important to prevent battery
damage when the temperature is below 32°F
(0°C).
1. Check the electrolyte level; refer to Checking
Electrolyte Level, page 37.
2. 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.
1
2
1. Filler caps
2. Lower part of tube
Figure 34
3. Plates
3
1262
Adding Water to the Battery
The best time to add distilled water to the battery is
just before you operate the machine. This lets the
water mix thoroughly with the electrolyte solution.
1. Clean the top of the battery with a paper towel.
2. Lift off the filler caps (Fig. 34).
3. Slowly pour distilled water into each battery cell
until the level is up to the lower part of the tube
(Fig. 34).
POTENTIAL HAZARD
• Charging the battery produces gasses.
WHAT CAN HAPPEN
• Battery gasses can explode.
HOW TO AVOID THE HAZARD
• Keep cigarettes, sparks and flames away
from battery.
37
Maintenance
Wiring Diagram
38
Maintenance
Cleaning and Storage
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.
2. Remove grass clippings, dirt, and grime from the
external parts of the entire machine, especially
the engine. Clean dirt and chaff from the outside
of the engine’s cylinder head fins and blower
housing.
IMPORTANT: You can wash the machine
with mild detergent and water. Do not
pressure wash the machine. Avoid excessive
use of water, especially near the control panel,
engine, hydraulic pumps and motors.
3. Service the air cleaner; refer to Air Cleaner,
page 25.
4. Grease and oil the machine; refer to Greasing
and Lubrication, page 29.
5. Change the crankcase oil; refer to Engine Oil,
page 26.
10. For long-term storage (more than 90 days) add
stabilizer/conditioner additive to fuel in the tank
(1 oz. per gallon).
A. Run engine to distribute conditioned fuel
through the fuel system (5 minutes).
B. Stop engine, allow to cool and drain the
fuel tank; refer to Fuel Tank, page 31.
C. Restart engine and run until it stops.
Repeat, on “CHOKE” until engine will not
restart.
D. Dispose of fuel properly. Recycle as per
local codes.
Note: Do not store stabilizer/conditioned
gasoline over 90 days.
11. Check and tighten all bolts, nuts, and screws.
Repair or replace any part that is damaged or
defective.
12. Paint all scratched or bare metal surfaces. Paint
is available from your Authorized Service
Dealer.
6. Change the hydraulic fluid; refer to Hydraulic
System, page 32.
7. Remove the spark plug(s) and check its
condition; refer to Spark Plug, page 28. With the
spark plug(s) removed from the engine, pour two
tablespoons of engine oil into the spark plug
hole. Now use the starter to crank the engine and
distribute the oil inside the cylinder. Install the
spark plug(s). Do not install the wire on the
spark plug(s).
8. Check the tire pressure; refer to Tire Pressure,
page 30.
9. Charge the battery; refer to Battery page 37.
13. Store the machine in a clean, dry garage or
storage area. Remove the key from the ignition
switch and keep it in a memorable place. Cover
the machine to protect it and keep it clean.
39
Troubleshooting
PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION
Starter does not crank
Engine will not start, starts hard, or
fails to keep running.
1. Blade control (PTO) is
ENGAGED.
2. Parking brake is not on. 2. Set parking brake.
3. Operator is not seated.
4. Battery is dead.
5. Electrical connections are
corroded or loose.
6. Fuse is blown. 6. Replace fuse.
7. Relay or switch is defective. 7. Contact Authorized Service
1. Fuel tank is empty. 1. Fill fuel tank with gasoline.
2. Choke is not ON. 2. Move choke lever to ON.
3. Air cleaner is dirty. 3. Clean or replace air cleaner
4. Spark plug wires is loose or
disconnected.
5. Spark plugs are pitted, fouled,
or gap is incorrect.
6. Dirt in fuel filter. 6. Replace fuel filter.
1. Move blade control (PTO) to
DISENGAGED.
3. Sit on the seat.
4. Charge the battery.
5. Check electrical connections
for good contact.
Dealer.
element.
4. Install wires on spark plug.
5. Install new, correctly gapped
spark plugs.
Engine loses power.
7. Dirt, water, or stale fuel is in
fuel system.
1. Engine load is excessive. 1. Reduce ground speed.
2. Air cleaner is dirty. 2. Clean air cleaner element.
3. Oil level in crankcase is low. 3. Add oil to crankcase.
4. Cooling fins and air passages
under engine blower housing
are plugged.
5. Spark plugs are pitted, fouled,
or gap is incorrect.
6. V ent in fuel cap is closed. 6. Open vent in fuel cap.
7. Dirt in fuel filter. 7. Replace fuel filter.
8. Dirt, water, or stale fuel is in
fuel system.
7. Contact Authorized Service
Dealer.
4. Remove obstruction from
cooling fins and air passages.
5. Install new, correctly gapped
spark plugs.
8. Contact Authorized Service
Dealer.
40
PROBLEM CORRECTIVE ACTIONPOSSIBLE CAUSES
Troubleshooting
Engine overheats.
Abnormal vibration.
Machine does not drive.
1. Engine load is excessive. 1. Reduce ground speed.
2. Oil level in crankcase is low. 2. Add oil to crankcase.
3. Cooling fins and air passages
under engine blower housing
are plugged.
1. Engine mounting bolts are
loose.
2. Loose engine pulley, idler
pulley, or blade pulley.
3. Engine pulley is damaged. 3. Contact Authorized Service
1. Traction belt is worn, loose or
broken.
2. Traction belt is off pulley. 2. Contact Authorized Service
3. Hydro fluid level low. 3. Add hydro fluid to reservoir.
3. Remove obstruction from
cooling fins and air passages.
1. Tighten engine mounting
bolts.
2. Tighten the appropriate
pulley.
Dealer.
1. Contact Authorized Service
Dealer.
Dealer.
41
LCG
A OneĆYear Limited Warranty
(A TwoĆYear Full Warranty for Residential Use)
What Is Covered By This Express Warranty?
The Toro Company promises to repair any TORO Product
used for commercial, institutional, or rental purposes if defective in materials or workmanship for a period of one year from
the date of purchase. The cost of parts and labor are included, but the customer pays the transportation cost. Transportation within a 15-mile radius of a TORO ProLine Service
Dealer is covered under this warranty for Riding Products,
Mid-size Mowers and Turf Maintenance Equipment.
What Products Are Covered By This Warranty?
The following products and their attachments are covered by
this warranty:
Z-Master Zero Radius Tractors
ProLine Mid-size Mowers
Groundsmaster Riding Mowers
ProLine Hand-held Gas Products
Backpack Blowers
Commercial WPM
Turf Maintenance Equipment
Debris Management Equipment
How About Residential Use?
TORO Products used for residential use are covered by a full
two-year warranty.
How Do You Get Warranty Service?
Should you feel your TORO Product contains a defect in materials or workmanship, contact the dealer who sold you the
product or any TORO ProLine Service Dealer. The Yellow
Pages of your telephone directory is a good reference
source; look under TORO Commercial Service Dealers. The
Service Dealer will either arrange service at his/her dealership or recommend another authorized Service Dealer who
may be more convenient. You may need proof of purchase
(copy of registration card, sales receipt, etc.) for warranty
validation.
If for any reason you are dissatisfied with a Service Dealer ’s
analysis of the defect in materials or workmanship or if you
need a referral to a TORO ProLine Service Dealer, please feel
free to contact us at the following address:
What Must You Do To Keep The Warranty In Effect?
You must maintain your TORO Product by following the maintenance procedures described in the operator’s manual. Such
routine maintenance, whether performed by a dealer or by
you, is at your expense.
What Does This Warranty Not Cover?
and
How Does Your State Law Relate To This Warranty?
There is no other express warranty except for special emission system coverage on some products and as described
above. This express warranty does not cover:
Cost of regular maintenance service or parts, such as
filters, fuel, lubricants, tune-up parts, blade sharpening,
brake and clutch adjustments.
Any product or part which has been altered or misused or
required replacement or repair due to normal wear, accidents, or lack of proper maintenance.
Repairs necessary due to improper fuel, contaminants in
the fuel system, or failure to properly prepare the fuel system prior to any period of non-use over three months.
Pickup and delivery charges for distances beyond a
15-mile radius from a TORO ProLine Service Dealer.
All repairs covered by this warranty must be performed by a
TORO Service Dealer using T o ro approved replacement parts.
The Toro Company is not liable for indirect or consequential damages in connection with the use of the TORO
Products covered by this warranty, including any cost or
expense of providing substitute equipment or service during reasonable periods of malfunction or non-use pending completion of repairs under this warranty. Some
states do not allow exclusions of incidental or consequential damages, so the above exclusion may not apply
to you.
This warranty gives you specific legal rights, and you may
also have other rights which vary from state to state.
Toro Customer Service Department
81 11 Lyndale Avenue South
Bloomington, MN 55420–1196
612–888–8801 or 800–348–2424
Customers who have purchased TORO products exported from the United States or Canada should contact their TORO DisĆ
tributor (Dealer) to obtain guarantee policies for your country, province, or state. If for any reason you are dissatisfied with
your Distributor's service or have difficulty obtaining guarantee information, contact the TORO importer. If all other remedies
fail, you may contact us at The Toro Company.
Rev 6/18/97
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