Promaster 250Z, 260Z, 272Z 09254300A 8/04 Printed in USA Repair Service Manual

Download Promaster 250Z, 260Z, 272Z 09254300A 8/04 Printed in USA Service Manual

992018, 020, 023, 027, 029, 030 992032, 033, 034, 035

The purpose of this manual is to provide complete instructions for service, maintenance, disassembly, repair, and installation of the mechanical components for the Promaster 250Z, 260Z, and 272Z. Dealer trained service personnel should use this manual as a supplement to and reminder of the training sessions conducted by the company. Read all information for servicing a part or system before repair work is started to avoid needless disassembly.



This Manual Covers:

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
The Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Service and Replacement Parts . . . . . . . . . . . . . 5
Product Registration . . . . . . . . . . . . . . . . . . . . . . 5
Unauthorized Replacement Parts. . . . . . . . . . . . 5
Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Technical Service Communications . . . . . . . . . . 5
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety Alert Symbol . . . . . . . . . . . . . . . . . . . . . . 6
Signal Words. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Notations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Practices and Laws. . . . . . . . . . . . . . . . . . . . . . .6
Required Operator Training . . . . . . . . . . . . . . . .6
Safety Decals And Locations . . . . . . . . . . . . . . . 6
Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Controls and Features. . . . . . . . . . . . . . . . . . . . 14
General Maintenance & Adjustments. . . . . . . . 15
Maintenance Schedule . . . . . . . . . . . . . . . . . . .15
Service and Adjustments . . . . . . . . . . . . . . . . .16
Service Positions . . . . . . . . . . . . . . . . . . . . . . .16
Moving Unit Manually . . . . . . . . . . . . . . . . . . . .16
Transporting Unit . . . . . . . . . . . . . . . . . . . . . . .17
Starting and Shutting Off the Engine. . . . . . . . .17
Cleaning and Storage . . . . . . . . . . . . . . . . . . . .17
Filling Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . .18
Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
General Lubrication . . . . . . . . . . . . . . . . . . . . .18
Servicing the Battery. . . . . . . . . . . . . . . . . . . . .18
Basic Engine Maintenance . . . . . . . . . . . . . . . .19
Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Mower Blades . . . . . . . . . . . . . . . . . . . . . . . . . .21
Adjusting Control Levers. . . . . . . . . . . . . . . . . .22
Adjusting the Parking Brake . . . . . . . . . . . . . . .22
Adjusting Unit To Track Straight . . . . . . . . . . . .22
Leveling the Mower Deck . . . . . . . . . . . . . . . . .23
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Engine Troubleshooting . . . . . . . . . . . . . . . . . .24
Removing the Engine . . . . . . . . . . . . . . . . . . . .25
Installing the Engine . . . . . . . . . . . . . . . . . . . . .25
Electric Clutch. . . . . . . . . . . . . . . . . . . . . . . . . .25
Drive Train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Checking the Hydraulic Fluid Level. . . . . . . . . .26
Changing Hydraulic Fluid and Filter . . . . . . . . .26
Hydraulic Drive Flow Test . . . . . . . . . . . . . . . . .26
Replacing the Hydraulic Pump . . . . . . . . . . . . .27
Replace Wheel Motor . . . . . . . . . . . . . . . . . . . .27
Hydraulic Deck Lift Pressure Test . . . . . . . . . . .28
Replace Lift Valve . . . . . . . . . . . . . . . . . . . . . . .28
Hydraulic Diagram . . . . . . . . . . . . . . . . . . . . . .29
Mower Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Anti-Scalp Rollers . . . . . . . . . . . . . . . . . . . . . . .31
Front Suspension. . . . . . . . . . . . . . . . . . . . . . . . 32
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Electrical Measurements. . . . . . . . . . . . . . . . . .33
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Solenoid and Relays. . . . . . . . . . . . . . . . . . . . .36
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Diodes and Rectifiers . . . . . . . . . . . . . . . . . . . .36
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . .38
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . .42

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