Toro Z325 Z Master Traction Unit, without Mower or Bagger Riding Product Operator's Manual

FORM NO. 3319–419
Z–325
OUT FRONT Z
Traction Unit
Model No. 74182 – 790001 & Up
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.
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
1. Model and Serial Number Plate
For your convenience, write the product model and
serial numbers in the space below.
Model 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.
Serial No.
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Operating Practices . . . . . . . . . . . . . .
Slope Chart . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals . . . . . . . . . . .
Gasoline and Oil . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Gasoline . . . . . . . . . . . . . . .
Stabilizer/Conditioner . . . . . . . . . . . . . . . .
Filling the Fuel Tank . . . . . . . . . . . . . . . . .
Check Engine Oil Level . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts . . . . . . . . . . . . . . . . . . . . . . . . .
Install Drive Wheels . . . . . . . . . . . . . . . . . .
Install Castor Wheel . . . . . . . . . . . . . . . . . .
Install Seat . . . . . . . . . . . . . . . . . . . . . . . . .
Activate the Battery . . . . . . . . . . . . . . . . . .
Install Battery . . . . . . . . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Think Safety First . . . . . . . . . . . . . . . . . . .
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake . . . . . . . . . . . . . . . . . . . . . . .
Starting and Stopping Engine . . . . . . . . . .
Operating Power Take Off (PTO) . . . . . . .
The Safety Interlock System . . . . . . . . . . .
Instruments . . . . . . . . . . . . . . . . . . . . . . . . .
Driving Forward or Backward . . . . . . . . . .
Page
2
2
5
6
7
7
7
7
7
8
8
9
9
10
11
12
13
13
13
13
14
16
16
17
18
Page
Stopping the Machine . . . . . . . . . . . . . . . . 18
Positioning the Seat . . . . . . . . . . . . . . . . . . 19
Pushing the Machine by Hand . . . . . . . . . . 19
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Service Interval Chart . . . . . . . . . . . . . . . . 20
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . 21
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . 22
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . 24
Greasing and Lubrication . . . . . . . . . . . . . . 25
Cleaning the Cooling Systems . . . . . . . . . . 26
Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . 27
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Hydraulic System . . . . . . . . . . . . . . . . . . . . 29
Adjusting Motion Controls . . . . . . . . . . . . 31
Replacing Power Take Off (PTO) Belts . . . 31
Replacing the Traction Belt . . . . . . . . . . . . 32
Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . 35
Hydraulic Diagram . . . . . . . . . . . . . . . . . . . 36
Cleaning and Storage . . . . . . . . . . . . . . . . . 37
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 38
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.
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.
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:
2
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.
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.
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. Wear seat belt when operating a machine with
ROPS (roll over protection).
•
Keep all movement on slopes slow and gradual.
Do not make sudden changes in speed or
direction.
•
Avoid starting or stopping on a slope. If tires
lose traction, disengage the blades and proceed
slowly straight down the slope.
•
When operating machine on slopes, banks or
near drop offs, always have ROPS (roll over
protection) installed.
•
When operating a machine with ROPS (roll over
protection) always use seat belt.
•
Be certain that the seat belt can be released
quickly if the machine is driven or rolls into
ponds of water.
•
Check carefully for overhead clearances (i.e.
branches, doorways, electrical wires) before
driving under any objects and do not contact
them.
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 NOT
DO
•
Mow up and down slopes greater than 5°, not
across.
•
Mow downhill only on slopes less than 10°,
Mow uphill only on slopes less than 15°
•
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. Choose a low gear so that you
will not have to stop or shift 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.
•
Do not operate machine on hillsides or slopes
exceeding 15°.
•
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.
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.
C.
Never remove the gas cap or add fuel when
the engine is running. Allow the engine to
cool before refueling. Do not smoke.
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.
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.
11. Check brake operation frequently. Adjust and
service as required.
Service
B.
4.
Never run a machine inside a closed area.
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.
Safety
Slope Chart
Read all safety instructions on pages 2–4.
5
Safety
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.
ON INSTRUMENT PANEL
(Part No. 98–0753)
BELOW FRONT OF SEAT
(Part No. 98–1313)
6
UNDER SEAT PAN ON RIGHT
FRAME AND REAR OF SEAT PAN
(Part No. 77–3100)
ON FRONT FRAME MEMBER
(Part No. 77–3100)
ON REAR FRAME MEMBER
AND CLUTCH GUARD
(Part No. 93–9198)
ON UTILITY BOX LATCH
(Part No. 98–1306)
Gasoline and Oil
Recommended Gasoline
Stabilizer/Conditioner
Use UNLEADED Regular Gasoline suitable for
automotive use (85 pump octane minimum). Leaded
regular gasoline may be used if unleaded regular is
not available.
Add the correct amount of gas stabilizer/conditioner
to the gas. Using a stabilizer/conditioner in the
machine:
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.
•
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.
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.
Filling the Fuel Tank
1.
Shut the engine off and set the parking brake.
2.
Clean around the fuel tank cap and remove the
cap. Add unleaded regular gasoline until the
level is to the bottom of the filler neck. Do not
fill the neck completely full, this space in the
tank allows gasoline to expand.
3.
Install fuel tank cap securely. Wipe up any
gasoline that may have spilled.
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.
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 23.
7
Assembly
Loose Parts
Note:
Use the chart below to verify all parts have been shipped.
DESCRIPTION
8
QTY.
USE
Wheel–drive
2
Lug nut 1/2–13
8
Wheel assembly–castor
1
Axle
1
Locknut 1/2–13
1
Washer 1/2” (13 mm)
2
Spacer
1
Nut 1/2–13
1
Jam nut 1/2–13
1
Seat
1
Washer 5/16” (8 mm)
4
Lock washer 5/16” (8 mm)
4
Bolt 5/16–18 x 3/4” (19 mm)
4
Battery
1
Battery clamp
1
Battery support rod
2
Wing nut 1/4–20
4
Terminal boot
1
Bolt 1/4–20 x 3/4” (19 mm)
2
Washer 1/4”
2
Pivot pin assembly
2
Hairpin cotter
2
Key
2
Safety Booklet
1
Operator’s Manual
1
Engine Operator’s Manual
1
Parts Catalog
1
For ordering parts
Registration card
1
Fill out and return to Toro
Install drive wheels
Install castor wheel
Install seat
Install battery
Install mower attachment
Read before operating machine
Assembly
Install Drive Wheels
Install Castor Wheel
1.
Jack up front of unit and remove lug nuts from
studs (Fig. 1).
1.
Remove nuts, washers, spacer and axle shaft
from fork (Fig. 2).
2.
Install drive wheels onto studs and secure with
previously removed 1/2–13 lug nuts (Fig. 1).
2.
Jack up rear of unit and install rear wheel into
castor fork (Fig. 2).
3.
Torque lug nuts to 75 ft–lb (101 Nm).
3.
Place wheel between fork and slide axle through
bearings (Fig. 2).
4.
Secure axle with
5.
Torque nuts to 75 ft–lb (55 N⋅m).
6.
Grease castor wheel bearings (Fig. 2).
m–3226
Figure 1
1. Stud
2. Wheel
3. Lug nut 1/2–13
m–3227
Figure 2
1. Wheel assembly
2. Axle
3. Washer 1/2” (13 mm)
4. Spacer
5. Nut 1/2–13
6. Jam nut 1/2–13
Check the air pressure in the front and rear tires: refer
to Tire Pressure in Maintenance section.
9
Assembly
Install Seat
1.
Tip seat pan up and position seat over slots
(Fig. 3).
2.
Secure with 5/16” lock washer, 5/16” washer and
5/16–18 x 3/4” (19 mm) bolt, through from the
bottom (Fig. 3).
3.
Connect seat switch lead to wire harness
terminal (Fig. 3).
4.
Slide to comfortable operating position and
tighten bolts.
m–3221
Figure 3
1. Seat switch lead
2. Washer 5/16” (8 mm)
3. Lock washer 5/16” (8 mm)
10
4. Bolt 5/16–18 x 3/4”
(19mm)
5. Harness terminal
Assembly
Activate the Battery
1
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.
2
3
m–1262
1. Filler caps
2. Electrolyte
WHAT CAN HAPPEN
3.
• 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.
Figure 4
POTENTIAL HAZARD
• Battery electrolyte contains sulfuric acid
which is a deadly poison and it causes
severe burns.
3. Lower part of the tube
Leave the covers off and connect a 3 to 4 amp
battery charger to the battery posts (Fig. 5).
Charge the battery at a rate of 4 amperes or less
for 4 hours (12 volts).
4
2
3
1
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. 4).
m–1254
Figure 5
1. Positive post
2. Negative post
3. Charger red (+) wire
4. Charger black (–) wire
11
Assembly
Install Battery
1.
Fill battery with electrolyte and charge, refer to
BATTERY, page 34.
WHAT CAN HAPPEN
• Battery gasses can explode.
2.
Position battery in tray with terminal posts
toward the engine (Fig. 6).
HOW TO AVOID THE HAZARD
3.
Slide the red terminal boot onto the red battery
cable.
4.
Install the positive (red) battery cable to positive
(+) battery terminal then negative battery cable
to the negative (–) battery terminal. Secure
cables with (2) 1/4 x 3/4” (19 mm) bolts 1/4”
washers, 1/4” lock washers and 1/4” locknuts.
POTENTIAL HAZARD
• Charging battery produces gasses.
• 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. 5).
5.
Slowly pour electrolyte into each cell until the
level is once again up to the “UPPER” line on
the battery case (Fig. 4) and install covers.
IMPORTANT: Route cables so they do not
contact metal edges or frame members.
5.
Secure battery with (2) support rods, a battery
clamp and (2) 1/4” wing nuts. Position support
rods in mounting holes (Fig. 6). Tighten wing
nuts so battery is held securely in position and
will not slide. DO NOT OVERTIGHTEN.
4
3
9
9
8
2
7
5
1
6
m–3224
Figure 6
1.
2.
3.
4.
5.
12
Battery tray
Terminal boot
Positive battery cable
Negative battery cable
Bolt 1/4–20 x 3/4” (19 mm)
6.
7.
8.
9.
Washer 1/4”
Battery support rod
Battery clamp
Wing nut 1/4”
Operation
Think Safety First
Parking Brake
Please carefully read all the safety instructions on
pages 2–8. Knowing this information could help you,
your family, pets or bystanders avoid injury.
Always set the parking brake when you stop the
machine or leave it unattended.
Setting the Parking Brake
Controls
1.
Move the motion control levers to the neutral
(Fig. 1).
Become familiar with all the controls (Fig. 1) before
you start the engine and operate the machine.
2.
Pull up on the parking brake lever to set the
parking brake (Fig. 2). The parking brake lever
should stay firmly in the “SET” position.
1
2
Releasing the Parking Brake
3
1.
4
8
Push in on the button and lower parking brake
lever to “OFF” (Fig. 2).
5
1
9
2
6
7
10
m–3179
3
Figure 1
1.
2.
3.
4.
5.
Motion control lever
Parking brake
Ignition switch
Throttle
Power take off (PTO)
6.
7.
8.
9.
10.
Hourmeter
Choke
Drink holder
Fuel cap
Hydro reservoir cap
m–3287
Figure 2
1. Parking brake–SET
2. Button
3. Parking brake-OFF
13
Operation
Starting and Stopping Engine
2
1
Starting
1.
Sit down on the seat and set the parking brake;
refer to Setting the Parking Brake, page 13.
2.
Move the motion control levers to neutral.
3.
Move the PTO (power take off) to “OFF”
(Fig. 3).
4.
Move the throttle control midway between
“SLOW” and “FAST” positions before starting a
cold engine.
5.
Move the choke control to “ON” position before
starting a cold engine.
Note:
6.
A warm or hot engine may require
choking. After engine starts, move
choke control to “OFF” position.
If starter does not crank, move the
motion control levers slightly to locate
neutral.
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.
14
1
m–2721
Figure 3
m–2719
Figure 4
1. PTO-Off
2. PTO-On
1. Choke–On
2. Choke–Off
1
1
2
2
3
Turn ignition key “START” to energize starter.
When engines starts, release key.
Note:
7.
2
After the engine starts, gradually 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.
m–
Figure 5
1. Fast
2. Slow
m–2718
Figure 6
1. Off
2. Run
3. Start
Operation
Stopping
1.
Move the throttle lever to “SLOW” (Fig. 5).
2.
Set the parking brake.
3.
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.”
4.
Pull wire off spark plug(s) to prevent possibility
of accidental starting before transporting or
storing machine.
5.
Close fuel shut off valve, under fuel tank before
transporting or storing machine.
IMPORTANT: Make sure fuel shut off valve
is closed before transporting or storing
machine, as fuel leakage may occur.
15
Operation
Operating Power Take Off
(PTO)
The Safety Interlock System
Understanding the Safety Interlock
System
The power take off (PTO) switch engages and
disengages power to the attachment clutch.
The safety interlock system is designed to prevent the
engine from starting unless:
Engaging the Power Take Off (PTO)
•
The parking brake is “SET”
1.
Move motion control levers to neutral to stop the
machine.
•
The power take off (PTO) is disengaged “OFF”
2.
Raise the cover and move the power take off
(PTO) switch to the “ON” position to engage
(Fig. 7).
•
The motion control levers are in neutral
1
3
2
The safety interlock system also is designed to stop
the engine when the motion control levers are moved
out of neutral with the parking brake on “SET” or if
you rise from the seat when the power take off (PTO)
is “ON” position or the motion control levers are not
in neutral.
Testing the Safety Interlock System
m–2721
Figure 7
1. Cover
2. ON-Engaged
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.
“SET” the parking brake and move power take
off (PTO) to “ON”. Try starting the engine; the
engine should not crank.
2.
“SET” the parking brake and move power take
off (PTO) to “OFF”. Move one then the other
motion control lever forward or reverse. Try
starting the engine; the engine should not crank.
3.
“SET” the parking brake, move power take off
(PTO) to “OFF” and hold the motion control
levers in neutral. Now start the engine. While the
engine is running engage the power take off
(PTO) and rise slightly from the seat; the engine
should stop.
4.
“SET” the parking brake, move power take off
(PTO) to “OFF” and hold the motion control
levers in neutral. Now start the engine. While the
engine is running, move the motion control
levers forward or reverse; the engine should
stop.
3. OFF-Disengaged
Disengaging the Power Take Off (PTO)
1.
Move motion control levers to neutral to stop the
machine.
2.
Lower the cover of the power take off (PTO)
switch. This moves the switch to the “OFF”
position to disengage (Fig. 7).
16
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–2717
Figure 8
1. Hour meter
17
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
1.
Release the parking brake; refer to Setting the
Parking Brake, page 13.
2.
To go forward, slowly push the motion control
levers forward (Fig. 9).
Engine will kill if motion control
levers are moved with parking brake
engaged.
To go straight, apply equal pressure to both motion
control levers (Fig. 9).
To turn, decrease pressure on the motion control lever
toward the direction you want to turn (Fig. 9).
The farther you move the motion control levers in
either direction, the faster the machine will move in
that direction.
To slow or stop move the motion control levers to
neutral.
5
4
5
1.
Release the parking brake; refer to Setting the
Parking Brake, page 13.
2.
To go backward, slowly pull the motion control
levers rearward (Fig. 9).
To go straight, apply equal pressure to both motion
control levers (Fig. 9).
Forward
Note:
Backward
2
2
1
1
3
3
5
To turn, decrease pressure on the motion control lever
toward the direction you want to turn (Fig. 9).
To slow or stop move the motion control levers to
neutral.
Stopping the Machine
To stop the machine, move the motion control levers
to neutral, 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 13.
Remember to remove the key from the ignition
switch.
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.
4
5
HOW TO AVOID THE HAZARD
• Always remove the ignition key and set the
m–3288
Figure 9
1. Motion control
lever-neutral position
2. Forward
18
3. Backward
4. Slow
5. Fast
parking brake when leaving the machine,
even if just for a few minutes.
Operation
Positioning the Seat
Pushing the Machine by Hand
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, tip seat forward and loosen the seat
mounting bolts (Fig. 10).
2.
Slide the seat to the desired position in the
adjusting slots and tighten the mounting bolts.
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 pump by-pass valves counterclockwise 2
turns to push. This allows hydraulic fluid to
by-pass the pump enabling the wheels to turn
(Fig. 11).
1
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.
2
m–3280
Figure 10
1. Adjustment slot
2. Mounting bolt
3.
Release the parking brake.
To Operate the Machine
1.
Turn the by-pass valves in to operate (Fig. 11).
Note:
The machine will not drive unless
by-pass valves are turned in.
1
m–3305
Figure 11
1. By-pass valve
19
Maintenance
Service Interval Chart
Service Operation
Each
Use
8
Hours
Hydraulic fluid–check level
Initial
X
Oil—check level
25
Hours
50
Hours
100
Hours
X
Initial
X
Oil Filter–change (200 hours or every
other oil change)
Hydraulic filter–change
Initial
X
X
X
X
X
X
Chassis—grease*
X
X
X
PTO Gearbox–check level (change
every 500 hours or six months)
X
Foam Air Cleaner—service*
X
X
X
Paper Air Cleaner—replace*
X
Spark Plug(s)—check
X
X
Belts—check for wear/cracks
X
X
X
Hydraulic lines–check
Battery–check electrolyte
X
X
X
X
X
X
Battery–charge, Disconnect cables
X
Fuel Filter—replace
Tires—check pressure
X
X
Chipped Surfaces—paint
* More often in dusty, dirty conditions
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).
20
X
X
Gasoline—drain
Cooling systems–clean
Storage
Service
X
X
Oil—change*
Safety System—check
200
Hours
X
X
X
Maintenance
Air Cleaner
3.
Carefully slide the foam element off the paper
element (Fig. 12).
Foam Element: Clean and re-oil after every 25
operating hours.
4.
Unscrew the cover nut and remove the cover and
paper element (Fig. 12).
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.
2.
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.
Disengage the power take off (PTO), set the
parking brake, and turn the ignition key to
“OFF” to stop the engine. Remove the key.
Dry the element by squeezing it in a clean
cloth (do not wring).
C.
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. 12).
Put one or two ounces of oil on the element
(Fig. 13). Squeeze the element to distribute
the oil.
IMPORTANT: Replace the foam element if it
is torn or worn.
2
1
2
1
3
4
5
m–1213
6
7
Figure 13
1. Foam element
8
2. Oil
m–3214
Figure 12
1.
2.
3.
4.
Knob
Air cleaner cover
Cover nut
Cover
5.
6.
7.
8.
Foam element
Paper element
Rubber seal
Air cleaner base
21
Maintenance
2.
Paper Element
Engine Oil
A. Lightly tap the element on a flat surface to
remove dust and dirt (Fig. 14).
Change oil:
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.
•
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
1
10W–30
2
5W–20, 5W–30
m–1213
Figure 14
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. 12).
2.
Place the air cleaner assembly onto the air
cleaner base (Fig. 12).
3.
Install the air cleaner cover and secure with
cover nut (Fig. 12).
22
–20
°F
0
–30
°C
–20
20
–10
32 40
0
80
60
10
20
100
30
40
Maintenance
Checking Oil Level
Changing/Draining Oil
1.
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. 16).
4.
When oil has drained completely, install the
drain cap.
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. 15) so dirt
cannot fall into the filler hole and damage the
engine.
3.
Unscrew the oil dipstick and wipe the metal end
clean (Fig. 15).
4.
Slide the oil dipstick fully into the filler tube, do
not thread onto tube (Fig. 15). 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.
Note:
Dispose of the used oil at a certified
recycling center.
IMPORTANT: Do not overfill the crankcase
with oil because the engine may be damaged.
1
3
2
1
m–3217
Figure 16
m–3219
Figure 15
1. Oil dipstick
2. Filler tube
m–3216
1. Oil drain cap
3. Metal end
5.
Slowly pour approximately 80% of the specified
amount of oil specified, page 22, into the filler
tube (Fig. 15). Now check the oil level; refer to
Checking Oil Level, page 23. Slowly add
additional oil to bring to “FULL” mark on
dipstick.
23
Maintenance
Change Oil Filter
Spark Plug
Replace the oil filter every 200 hours or every other
oil change.
Note:
1.
Change oil filter more frequently when
operating conditions are extremely
dusty or sandy.
Drain the oil from the engine; refer to
Changing/Draining Oil, page 23.
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)
2.
Remove the old filter and wipe the filter adapter
(Fig. 17) 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.
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.
Apply a thin coat of new oil to the rubber gasket
on the replacement filter (Fig. 17).
2.
Pull the wire(s) off the spark plug(s) (Fig. 18).
Now clean around the spark plug(s) to prevent
dirt from falling into the engine and potentially
causing damage.
3.
Remove the spark plug(s) and metal washer.
4.
3
1
2
Removing the Spark Plug(s)
m–1256
1
Figure 17
1. Oil filter
2. Gasket
3. Adapter
2
m–3218
5.
6.
24
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. 17).
Fill the crankcase with the proper type of new
oil; refer to Changing/Draining Oil, page 23.
Figure 18
1. Spark plug wire
2. Spark plug
Maintenance
Checking the Spark Plug
1.
Greasing and Lubrication
Look at the center of the spark plug(s) (Fig. 19).
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.
Grease the castor wheel bearings and motion control
lever pivots every 8 operating hours. 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.
Check the gap between the center and side
electrodes (Fig. 19). Bend the side electrode
(Fig. 19) if the gap is not correct.
2
3
1
0.030 in.
(0.76 mm)
Where to Add Grease
m–3215
Figure 19
1. Center electrode insulator
2. Side electrode
3. Air gap (not to scale)
1.
Lubricate the castor wheel bearings and motion
control lever pivots until grease begins to ooze
out of the bearings (Fig. 20).
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. 18).
m–3289
m–3222
Figure 20
25
Maintenance
Lubricate Power Take Off (PTO) Gearbox
Check the oil level in the PTO gearbox every 50
operating hours. Change the oil every 500 hours or
six months, whichever occurs first.
Oil Type: SAE EP-80\90 wt. gear oil
Capacity: 16 oz. (377 ml)
1.
Clean area around top and side plugs of the PTO
gearbox. Remove side plug of the gearbox and
check the level of lubrication in the gearbox.
2.
If level is low, remove top plug and add until
level is up to side plug in gearbox. (Fig. 21).
3.
To change oil, park the machine so the gearbox
is level, 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.
4.
Place a pan below the oil drain. Remove the
bottom plug (Fig. 16).
5.
When oil has drained completely, install the
bottom plug.
6.
Fill oil as in steps 1 and 2.
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.
1.
To remove cooling screen remove lower bolts
and loosen top bolts. Slide screen down and
rearward to expose oil cooler (Fig. 22). Save all
mounting hardware.
2.
Blow out fins of oil cooler and area between fins
and screen with compressed air. If area between
screen and fins is tightly packed, remove oil
cooler.
3.
Clean off engine air intake (Fig. 22).
4.
Install screen from rear and raise over oil cooler.
Secure with previously removed hardware
(Fig. 22).
3
Note:
Dispose of the used oil at a certified
recycling center.
1
3
3
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2
2
1
2
m–3296
4
Figure 22
4
Figure 21
1. Gearbox
2. Side plug
26
3. Top plug
4. Bottom plug
1. Oil cooler screen
2. Lower bolts
3. Top bolts
4. Engine air intake
Maintenance
Tire Pressure
Fuel Filter
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. 23). Check the tires when they are cold to get
the most accurate pressure reading.
Replace the fuel filter after every 200 operating hours
or yearly, whichever occurs first.
Pressure: 20 psi (83 kPa) drive wheels and 6 psi
(41 kPa) castor wheel.
1
m–1872
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
“OFF” to stop the engine. Remove the key.
2.
Close fuel shut–off valve at fuel tank (Fig. 25).
3.
Squeeze the ends of the hose clamps together
and slide them away from the filter (Fig. 24).
4.
Remove the filter from the fuel lines.
5.
Install a new filter and move the hose clamps
close to the filter.
6.
Open fuel shut-off valve at fuel tank (Fig. 25).
Figure 23
1. Valve stem
1
2
m–3217
Figure 24
1. Filter
2. Hose clamp
27
Maintenance
Fuel Tank
4.
Draining The Fuel Tank
Pull the fuel line off fuel shut-off valve (Fig. 25).
Open fuel shut-off valve and allow gasoline to
drain into a gas can or drain pan.
Note:
POTENTIAL HAZARD
• In certain conditions gasoline is extremely
flammable and highly explosive.
5.
Install the fuel line onto the fuel shut-off valve.
Slide the hose clamp close to the fuel shut-off
valve to secure the fuel line (Fig. 25).
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.
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 at fuel tank (Fig. 25).
3.
Loosen the hose clamp and slide it up the fuel
line away from the fuel shut-off valve (Fig. 25).
28
Now is the best time to install a new
fuel filter because the fuel tank is
empty.
4
3
2
1
Figure 25
1. Fuel shut-off valve
2. Hose clamp
3. Fuel line
4. Fuel cap
m–3293
Maintenance
Replacing the Hydraulic Filter
Hydraulic System
Change the hydraulic filter:
Checking the Hydraulic Fluid
Check the hydraulic fluid level before engine is first
started and after every 8 operating hours.
Fluid Type: Mobil Fluid 424 (ISO 46) or equivalent
anti–wear hydraulic fluid.
•
After the first 8 operating hours.
•
After every 200 operating hours.
1.
Position machine on a level surface, stop the
engine, and remove key from ignition switch.
IMPORTANT: Use only hydraulic oils
specified. Other fluids could cause system
damage.
IMPORTANT: Do not substitute automotive
oil filter or severe hydraulic system damage
may result.
Tank Capacity: 6 qt. (5.7 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. 26).
3.
Remove cap from filler neck and look inside to
check fluid level. Fluid level should be above the
bottom of the screen (Fig. 26).
4.
If level is low, add fluid to raise level to above
the bottom of the screen (Fig. 26).
5.
Install cap on filler neck.
2.
Remove hydro cap and temporarily cover
opening with a plastic bag and rubber band to
prevent all hydro fluid from draining out.
3.
Place drain pan under filter, remove the old filter
and wipe the filter adapter gasket surface clean
(Fig. 27).
1
1
m–3291
Figure 27
1. Hydraulic filter
2
3
m–3292
Figure 26
1. Hydraulic reservoir cap
2. Screen
3. Fluid level-Full
29
Maintenance
Bleeding Hydraulic System
4.
Apply a thin coat hydro fluid to the rubber
gasket on the replacement filter (Fig. 28).
5.
Install replacement hydraulic filter onto the filter
adapter. Do not tighten.
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.
6.
Remove plastic bag from tank opening and allow
filter to fill with hydro fluid.
1.
Raise front of the machine so wheels are off the
ground and support with jack stands.
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. 28).
2.
Start the engine and run at idle speed. Engage
traction on one side and spin the wheel by hand.
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.
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 30.
10. Check fluid level in hydraulic tank and add to
raise level to cover bottom of screen. DO NOT
OVER FILL.
1
3
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.
2
POTENTIAL HAZARD
• Hydraulic fluid escaping under pressure
can penetrate skin and cause injury.
m–1256
Figure 28
1. Hydraulic filter
2. Gasket
3. Adapter
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.
30
Maintenance
Adjusting Motion Controls
If motion control levers do not align, adjustment is
required. Adjust each rod separately.
1.
Loosen jam nuts on pump control rod (Fig. 29).
2.
Push and firmly hold motion control lever
against forward stop (Fig. 29).
3.
Rotate pump control rod until pump control
plate is in the full forward position (Fig. 29).
Motion control lever will lift off forward stop.
4.
Replacing Power Take Off
(PTO) Belts
Check power take off (PTO) belts for wear after every
50 hours of operation.
1.
Hold spring loaded idler against belts and pull
spring down to remove from lower bolt mount
(Fig. 30).
2.
Lower idler to relax tension on belts and remove
belts from gear box pulley (Fig. 30).
IMPORTANT: Hold motion control lever
firmly against forward stop to determine
when pump control reaches stop.
3.
Hold flats on clutch hub and remove clutch
mounting bolt and washer. Slide clutch off
crankshaft and lower through frame (Fig. 30).
Rotate control rod 1 turn, to lengthen rod, and
tighten jam nuts (Fig. 29).
4.
Remove belts over clutch (Fig. 31).
4
IMPORTANT: Motion control lever must
contact forward stop before pump contacts
internal stop or pump damage may occur.
5.
7
6
If motion control levers do not line up in neutral,
identify control rod of handle closer to the seat.
Rotate to lengthen this control rod a little.
Tighten jam nuts.
3
5
1
3
5
4
m–3295
2
1
Figure 30
5
m–3290
1.
2.
3.
4.
Idler
Spring
Gr box pulley
Clutch hub
5. Stop
6. Bolt
7. Washer
2
Figure 29
1. Motion control lever
2. Forward stop
3. Pump control plate
4. Control rod
5. Jam nut
31
Maintenance
5.
6.
7.
Install new belts over clutch. Align clutch hub
key with crankshaft keyway and notch with stop
bracket. Slide clutch onto crankshaft (Fig. 31).
Apply Loctite (blue) thread lock to threads and
install washer and bolt securing clutch.
Torque clutch mounting bolt to 50–60 ft–lb.
(68–81 Nm).
8.
Route belts around clutch and gearbox pulleys
and above spring loaded idler (Fig. 31).
9.
Hold spring loaded idler against belts and pull
spring down to install on lower bolt mount
(Fig. 30).
1
2
Replacing the Traction Belt
Check traction drive belt for wear after every 50
hours of operation.
1.
Remove PTO belts; refer to Replacing Power
Take Off (PTO) Belts.
2.
Push spring loaded idler down and remove
traction belt from the engine, fixed idler and
hydro pump pulleys (Fig. 32). Remove belt over
clutch.
3.
Install new belt over clutch and around engine,
fixed idler and hydro pump pulleys (Fig. 32).
4.
Push spring loaded idler down and align below
traction belt. Release pressure on spring loaded
idler (Fig. 32).
5.
Install PTO belts; refer to Replacing Power Take
Off (PTO) Belts.
4
3
m–3225
4
Figure 31
1. PTO belt
2. Clutch pulleys
3
2
3. Gearbox pulley
4. Spring loaded idler
1
5
Figure 32
1. Traction belt
2. Engine pulley
3. Fixed idler pulley
32
4. Hydro pump pulley
5. Spring loaded idler
m–3225
Maintenance
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 F1–30 amp, blade-type
Alternator F2–25 amp, blade-type
Safety Interlock and Clutch F3–15 amp,
blade-type
1.
Remove dash panel screws to gain access to fuse
holder (Fig. 33).
2.
To replace fuses pull out on the fuse to remove it
(Fig. 33).
4
3
2
1
m–3223
Figure 33
1. Main-30 amp
2. Alternator-25 amp
3. Safety interlock and
clutch-15 Amp
4. Screw
33
Maintenance
Battery
Check the electrolyte level in the battery every 8
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.
IMPORTANT: Do not overfill the battery
because electrolyte (sulfuric acid) can cause
severe corrosion and damage to the chassis.
4.
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).
Voltage: 12 v, 280 Cold Cranking Amps
Checking Electrolyte Level
1.
2.
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).
If the electrolyte is low, add the required amount
of distilled water; refer to Adding Water to the
Battery, page 34.
Press the filler caps onto the battery.
1.
Check the electrolyte level; refer to Checking
Electrolyte Level, page 34.
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
POTENTIAL HAZARD
• Charging the battery produces gasses.
3
1262
Figure 34
1. Filler caps
2. Lower part of tube
3. Plates
WHAT CAN HAPPEN
• Battery gasses can explode.
HOW TO AVOID THE HAZARD
• Keep cigarettes, sparks and flames away
from battery.
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).
34
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Maintenance
Wiring Diagram
35
36
Maintenance
Hydraulic Diagram
Maintenance
Cleaning and Storage
1.
2.
Disengage the power take off (PTO), set the
parking brake and turn the ignition key to “OFF”
to stop the engine. Remove the key.
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 21.
4.
Grease the machine; refer to Greasing and
Lubrication, page 25.
5.
Change the crankcase oil; refer to Engine Oil,
page 22.
6.
Change the hydraulic fluid; refer to Hydraulic
System, page 29.
7.
Remove the spark plug(s) and check its
condition; refer to Spark Plug, page 24. 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 27.
9.
Charge the battery; refer to Battery page 34.
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 28.
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.
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.
37
Troubleshooting
PROBLEM
Starter does not crank
Engine
g
will not start,, starts hard,, or
f il to keep
fails
k
running.
i
Engine
g
loses power.
38
POSSIBLE CAUSES
CORRECTIVE ACTION
1.
Power take off (PTO) is
ENGAGED.
1.
Move power take off (PTO) to
DISENGAGED.
2.
Parking brake is not on.
2.
Set parking brake.
3.
Motion control levers are not
in neutral.
neutral
3.
Move motion control levers
into neutral.
neutral
4.
Battery is dead.
4.
Charge the battery.
5.
Electrical connections are
corroded or loose.
5.
Check electrical connections
for good contact.
6.
Fuse is blown.
6.
Replace fuse.
7.
Relay or switch is defective.
7.
Contact Authorized Service
Dealer.
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
element.
4.
Spark plug wires is loose or
disconnected.
4.
Install wires on spark plug.
5.
Spark plugs are pitted, fouled,
or gap is incorrect.
5.
Install new, correctly gapped
spark plugs.
6.
Dirt in fuel filter.
6.
Replace fuel filter.
7.
Dirt, water, or stale fuel is in
fuel system.
7.
Contact Authorized Service
Dealer.
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.
4.
Remove obstruction from
cooling fins and air passages.
5.
Spark plugs are pitted, fouled,
or gap is incorrect.
5.
Install new, correctly gapped
spark plugs.
6.
Dirt in fuel filter.
6.
Replace fuel filter.
7.
Dirt, water, or stale fuel is in
fuel system.
7.
Contact Authorized Service
Dealer.
Troubleshooting
PROBLEM
Engine
g
overheats.
Abnormal vibration.
Machine does not drive.
POSSIBLE CAUSES
CORRECTIVE ACTION
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.
3.
Remove obstruction from
cooling fins and air passages.
1.
Engine mounting bolts are
loose.
1.
Tighten engine mounting
bolts.
2.
Loose engine pulley, idler
pulley, or blade pulley.
2.
Tighten the appropriate
pulley.
3.
Engine pulley is damaged.
3.
Contact Authorized Service
Dealer.
1.
Parking brake is on.
1.
Move parking brake to off.
2.
Traction belt is worn, loose or
broken.
2.
Contact Authorized Service
Dealer.
3.
Traction belt is off pulley.
3.
Contact Authorized Service
Dealer.
4.
Hydro fluid level low.
4.
Add hydro fluid to reservoir.
39
+# % ## %*
(!+# & ## %* !# $ % $
What Is Covered By This Express Warranty?
What Must You Do To Keep The Warranty In Effect?
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.
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 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?
What Does This Warranty Not Cover?
and
How Does Your State Law Relate To This Warranty?
There is no other express warranty except 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.
TORO Products used for residential use are covered by a full All repairs covered by this warranty must be performed by a
TORO Service Dealer using Toro approved replacement parts.
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.
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.
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:
Toro Customer Service Department
8111 Lyndale Avenue South
Bloomington, MN 55420–1196
612–888–8801 or 800–348–2424
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Rev 5/97