FORM NO. 3319–786 Z–Master 250 Series Z–255 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.
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 . . . . . . . . .
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.
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.
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.
Safety Slope Chart Read all safety instructions on pages 2–4.
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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. TOP OF CONSOLE UNDER SEAT (Part No. E513747) ON RIGHT SIDE OF HEIGHT OF CUT PLATE (Part No E633345) ON LEFT SIDE OF HEIGHT–OF–CUT PLATE (Part No E633706) ON TOP OV HYDRAULIC RESERVOIR (Part No. E513890) ON HYDRAULIC RESERVOIR MOUNTING BRACKET (Part No.
Safety UNDER FOOTREST (Part No. E633766) ON RUBBER FLAP BEHIND SEAT (Part No. E513748) E ONHYDRAULIC TANK (Part No. 65–2690) ON TOP OF RIGHT ENGINE BAFFLE (Part No. E633771) ON CONTROL PANEL (Part No.
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.
Assembly Loose Parts Note: Use the chart below to verify all parts have been shipped. DESCRIPTION QTY.
Assembly Install Seat Retaining Rod Tire Pressure 5. Tilt seat up. Remove 5/16” locknut from bolt attaching seat retaining rod to seat frame (Fig. 1). Check the air pressure in the front and rear tires (Fig. 2). 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). Pressure: 13 psi (90 kPa) 7.
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). 13.
Assembly Activate the Battery 2. Bulk electrolyte with 1.260 specific gravity must be purchased from a local battery supply outlet. 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 1. Remove the battery from the machine. IMPORTANT: Be careful not to damage the long vent tube when removing the battery box.
Assembly Install Battery 6. Position battery in tray with terminal posts toward the engine (Fig. 7). WHAT CAN HAPPEN 7. Slide the red terminal boot onto the positive (red) battery cable. HOW TO AVOID THE HAZARD 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).
Assembly When installing the mower the following assembly operations must also be completed. Install Power Take Off (PTO) Spring Install Mower Mounts 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. 1. Attach left and right struts, with greases fitting up.
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 (Fig. 1) out to the neutral lock position. Become familiar with all the controls (Fig. 1) before you start the engine and operate the machine. 2.
Operation Starting and Stopping the Engine 2 1 Starting 2 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: 5. 6. m–3729 Figure 3 m–2719 Figure 4 1. PTO-On 2. PTO-Off A warm or hot engine may require choking.
Operation Stopping 1. Move the throttle lever to “SLOW” (Fig. 5). 2. Turn the ignition key to “OFF” (Fig. 6). Note: 3. 4. 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.” Pull wire off spark plug(s) to prevent possibility of accidental starting before transporting or storing machine.
Operation 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 “
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).
Operation Instruments Fuel Tanks 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 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.
Operation Adjusting Height-of-Cut Positioning the Seat 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. The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable. 1. Raise the height-of-cut lever to the transport position (also the 5” (127 mm) cutting height position) (Fig. 11). 1.
Operation 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).
Maintenance Service Interval Chart Service Operation Each Use Hydraulic fluid–check level Initial Oil—check level 8 Hours 25 Hours 50 Hours 100 Hours X X Initial X Oil Filter–change (200 hours or every other oil change) Hydraulic filter–change Storage Service X X Oil—change* Safety System—check 200 Hours Initial X X X X X X X Chassis—grease* X X Linkage bushings—oil* X X Foam Air Cleaner—service* X X Paper Air Cleaner—replace* X Spark Plug(s)—check X X Belts—check for w
Maintenance Air Cleaner 3. Carefully slide the foam element off the paper element (Fig. 14). Foam Element: Clean and re-oil after every 25 operating hours. 4. Unscrew the cover nut and remove the cover and paper element (Fig. 14). 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. Cleaning the Foam and Paper Elements 1. A. Wash the foam element in liquid soap and warm water.
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. Engine Oil Change oil: • After the first 5 operating hours. • After every 100 operating hours.
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. 18). 4.
Maintenance Spark Plug Change Oil Filter 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 27. 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.
Maintenance Greasing and Lubrication 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. Lubricate the machine when shown on the CHECK SERVICE REFERENCE AID decal (Fig. 22).
Maintenance Cleaning the Cooling Systems Fuel Filter 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.
Maintenance Fuel Tank 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. Draining The Fuel Tank Note: POTENTIAL HAZARD • In certain conditions gasoline is extremely flammable and highly explosive. 5. Now is the best time to install a new fuel filter because the fuel tank is empty. Install the fuel line onto the fuel filter. Slide the hose clamp close to the fuel filter to secure the fuel line (Fig. 26).
Maintenance Hydraulic System Checking the Hydraulic Fluid POTENTIAL HAZARD • Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Check the hydraulic fluid level before engine is first started and after every 25 operating hours. 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. Fluid Type: Mobil 1 15W–50 synthetic motor oil.
Maintenance 3. Place drain pan under filter, remove the old filter and wipe the filter adapter gasket surface clean (Fig. 28). 10. Check fluid level in hydraulic tank and add to raise level to cover bottom of screen. DO NOT OVER FILL. 1 3 2 1 m–3291 m–1256 Figure 28 1. Hydraulic filter 4. Apply a thin coat hydro fluid to the rubber gasket on the replacement filter (Fig. 29). Figure 29 1. Hydraulic filter 2. Gasket 3. Adapter Bleeding Hydraulic System 5.
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. 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.
Maintenance 6. 7. 8. 9. This adjustment must be made with drive wheels turning. First raise the frame and block up so drive wheels can rotate freely. Start engine, open throttle 1/2 way and release parking brake. Refer to Starting and Stopping the Engine, page 17. Replacing the Pump Drive Belt Check pump drive belt for wear after every 50 hours of operation. 1. The reverse indicator spring must be correct before the following adjustment can be made (see step 1).
Maintenance Adjustment Parking Brake Fuse Check parking brake for adjusted properly. Service Interval/Specification 1. Disengage brake lever (lever down). 2. Measure the length of the spring. Measurement should be 2.9” (74 mm) between washers (Fig. 32). The electrical system is protected by fuses. It requires no maintenance, however, if a fuse blows check component/circuit for malfunction or short. 3.
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. IMPORTANT: Do not overfill the battery because electrolyte (sulfuric acid) can cause severe corrosion and damage to the chassis. 4.
Maintenance Wiring Diagram 38
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.
Troubleshooting PROBLEM Starter does not crank Engine will not start, starts hard, or f il to fails t keep k running. i Engine loses power. 40 POSSIBLE CAUSES CORRECTIVE ACTION 1. Blade control (PTO) is ENGAGED. 1. Move blade control (PTO) to DISENGAGED. 2. Parking brake is not on. 2. Set parking brake. 3. Operator is not seated. 3. Sit on the seat. 4. Battery is dead. 4. Charge the battery. 5. Electrical connections are corroded or loose. 5.
Troubleshooting PROBLEM Engine 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.
A OneĆYear Limited Warranty (A TwoĆYear Full Warranty for Residential Use) LCG 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.