Form No. 3329–537 Z257 Z–Master with 52 in. SFS Side Discharge Mower Model No. 74230—Serial No.
Warning Checking the Level of Mower Deck . . . . . . . . . . Checking the Engine Oil Level . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Think Safety First . . . . . . . . . . . . . . . . . . . . . . . . Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating the Parking Brake . . . . . . . . . . . . . . . . Starting and Stopping the Engine . . . . . . . . . . . . Operating the Power Take Off (PTO) . . . . . . . . .
Mercury Tilt Switch . . . . . . . . . . . . . . . . . . . . . . . Disposing the Mercury Tilt Switch . . . . . . . . . . . Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Storage . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Toro Total Coverage Guarantee . . . . . . . . . . . . . Page 47 47 48 49 50 52 Warning, and Caution are signal words used to identify the level of hazard.
• Never operate without the PTO shield, or other guards securely in place. Be sure all interlocks are functioning properly. Training • Read the Operator’s Manual and other training material. If the operator(s) or mechanic(s) can not read English it is the owner’s responsibility to explain this material to them. • Never operate with the discharge deflector raised, removed or altered, unless using a grass catcher.
• Watch for ditches, holes, rocks, dips, and rises that change the operating angle, as rough terrain could overturn the machine. • Use care when checking blades. Wrap the blade(s) or wear gloves, and use caution when servicing them. Only replace blades. Never straighten or weld them. • Avoid sudden starts when mowing uphill because the mower may tip backwards. • Keep hands and feet away from moving parts. If possible, do not make adjustments with the engine running.
Slope Chart 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.
1-633818 93-1122 43-8480 93-7818 1. Warning—read the Operator’s Manual for instructions on torquing the blade bolt/nut to 115–149 N⋅m (85–110 ft.-lb). 66-1340 98-3798 67-5360 98-4387 1. Warning—wear hearing protection.
98-5954 103-0368 104-4163 1. Explosion hazard 2. No fire, open flames, or smoking. 3. Caustic liquid/chemical burn hazard 99-4632 1. Engine—stop 2. Engine—run 4. Wear eye protection 5. Read the Operator’s Manual. 6. Keep bystanders a safe distance from the battery. 3.
104-4164 1. Contains lead; do not discard. 2. Recycle 3. Wear eye protection; explosive gases can cause blindness and other injuries 4. No sparks, flame, or smoking 5. Sulfuric acid can cause blindness or severe burns. 6. Flush eyes immediately with water and get medical help fast. 103-2433 106-6571 11 7. Maximum fill line 8. Minimum fill line 9.
106-6570 12
Gasoline and Oil Warning Gasoline is harmful or fatal if swallowed. Long–term exposure to vapors can cause serious injury and illness. 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. • Avoid prolonged breathing of vapors. • Keep face away from nozzle and gas tank or conditioner opening. • Keep gas away from eyes and skin.
Setup Loose Parts Note: Use the chart below to verify all parts have been shipped. DESCRIPTION QTY.
3. Place the seat retaining rod to the outside of the mounting tab of the seat frame and secure with one bolt (5/16 x 1 inch) and locknut (5/16 inch) (Fig. 3). 4. Tighten until snug, then loosen so the rod pivots freely. 2 1 1 4 2 5 6 3 m–5596 Figure 4 1. Mounting plate 2. Bolt, 3/8 x 1 inch 3. Spring washer, 3/8 inch 4. Top hole 5. Middle hole 6. Bottom hole 3 5.
Danger Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns. 2 • Do not drink electrolyte and avoid contact with skin, eyes or clothing. Wear safety glasses to shield your eyes and robber 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. 3 1 m–5004 Figure 6 1. Filler caps 2. Upper line 3. Lower line 1.
1 Important Tighten the valve cover screws to 70 in–lb (5 N m) torque. 5. Remove plastic plugs from air intake elbow on engine and air cleaner hose (Fig. 7). 6. Install hose to air intake elbow on engine and air cleaner. Tighten hose clamps to secure the hose connections (Fig. 7). 7. With the air intake cap pointing upward, tighten the tensioning bolt until the clamp ends are a 1/2 inch (13 mm) apart (Fig. 7). 9 M–5035 Figure 8 7 1.
Operation The use of protective equipment for eyes, ears, feet, and head is recommended. Note: Determine the left and right sides of the machine from the normal operating position. Caution This machine produces sound levels in excess of 85 dBA at the operator’s ear and can cause hearing loss through extended periods of exposure. Think Safety First Please read all safety instructions and symbols in the safety section. Knowing this information could help you or bystanders avoid injury.
Using the Hour Meter Warning 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. Parking brake may not hold machine parked on a slope and could cause personal injury or property damage. 1 Do not park on slopes unless wheels are chocked or blocked Releasing the Parking Brake m–3077 Figure 12 1. Push forward and down on the parking brake lever to release the parking brake (Fig. 14).
6. Turn ignition key to start to energize starter. When the engines starts, release the key. 5. Pull wire off spark plug(s) to prevent possibility of someone accidentally starting the machine before transporting or storing machine. 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. 6.
The Safety Interlock System the engine is running, release the parking brake, engage the PTO and rise slightly from the seat; the engine should stop. Caution 4. Sitting on the seat, engage the parking brake, move PTO switch to off and move the motion control levers to neutral lock position. Now start the engine. While the engine is running, center either motion control and move (forward or reverse); the engine should stop. Repeat for other motion control.
Adjusting the Height-of-Cut To stop pull the motion control levers to neutral. The height-of-cut is adjusted from 1-1/2 to 5 inch (38 to 127 mm) in 1/4 inch (6 mm) increments by relocating clevis pin in different hole locations. 2 3 1. Raise the height-of-cut lever to the transport position (also the 5 inch (127 mm) cutting height position) (Fig. 21). 1 4 2. To adjust, remove hairpin cotter and clevis pin from height-of-cut bracket (Fig. 21). m–2715 3.
Pushing the Machine by Hand 5. Repeat adjustment on other gage wheels. 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. Move levers to neutral locked position and apply parking brake. 1 4 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. 24).
Using a Rollover Protection System (ROPS) slope, position the trailer or truck so it is on the down side of the slope and the ramp extends up the slope. This will minimize the ramp angle. The trailer or truck should be as level as possible. A ROPS is available and its use is recommended for areas where there are slopes, drop–offs or water. Contact an Authorized Service Dealer for information on obtaining ROPS for your machine.
Using the Z Stand The Z Stand is used for raising the front end of the machine. This allows for cleaning of the deck and removal of the blades. 1 3 2 Warning m–5600 Unit could fall onto someone and cause serious injury or death. Figure 27 1. Z Stand (Positioned in slot) • Use extreme caution when operating unit on Z Stand. • Use only for cleaning deck and removing blades. • Do not keep unit on Z Stand for extended periods of time.
Cutting Speed 4 To improve cut quality, use a slower ground speed in certain conditions. 3 2 Avoid Cutting Too Low 1 If the cutting width of the mower is wider than the mower you previously used, raise the cutting height to ensure that uneven turf is not cut too short. m–5601 Long Grass Figure 28 1. Z Stand 2. Latch 3. Locked position 4.
Maintenance Recommended Maintenance Schedule Maintenance Service Interval After first 5 hours Each Use Maintenance Procedure • Hydraulic fluid—check level • Engine Oil—change • Hydraulic filter—change • • • • Oil—check level Safety System—check Mower Housing—clean Engine Cooling System—clean1 Every 5 Hours • Cutting Blades—check • Blade Spindle Bearings—grease Every 25 Hours • • • • • Every 50 Hours • Belts—check for wear/cracks • Tires—check pressure Every 100 Hours • • • • Paper Air Cleaner—re
Servicing the Cutting Blades Maintain sharp blades throughout the cutting season because sharp blades cut cleanly without tearing or shredding the grass blades. Tearing and shredding turns grass brown at the edges, which slows growth and increases the chance of disease. 2 1 Check the cutter blades daily for sharpness, and for any wear or damage. File down any nicks and sharpen the blades as necessary. If a blade is damaged or worn, replace it immediately with a genuine TORO replacement blade.
dimension exceeds 1/8 inch (3 mm), the blade is bent and must be replaced. Refer to Removing the Blades, and Installing the Blades on page 29. 1. Use a file to sharpen the cutting edge at both ends of the blade (Fig. 32). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges. Warning 1 A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders.
Servicing the Air Cleaner Do not clean the primary filter. Primary Filter: Check and/or replace after every 200 operating hours or more often in dusty conditions. Servicing the Safety Filter Safety Filter: Replace after every 600 operating hours. Replace it after 600 operating hours. Note: Check the filters more frequently if operating conditions are extremely dusty or sandy. Important Never attempt to clean the safety filter.
Checking the Oil Level Note: Check oil when engine is cold. 1. Disengage the power take off (PTO) and turn the ignition key to off. Move levers to neutral locked position and apply parking brake. Remove the key. 1 2. Clean around the oil dipstick (Fig. 36) so dirt cannot fall into the filler hole and damage the engine. 3. Pull the oil dipstick and wipe the metal end clean (Fig. 36). m–5624 Figure 37 4. Slide the oil dipstick fully into the filler tube.
Checking the Spark Plug 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. 38). 1. Look at the center of the spark plug(s) (Fig. 40). 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. 6.
5. Install the fuel line onto the fuel filter. Slide the hose clamp close to the fuel filter to secure the fuel line (Fig. 42). 4. Remove the filter from the fuel lines. 5. Install a new filter and move the hose clamps close to the filter (Fig. 42). 6. Wipe up any spilled fuel. 7. Open fuel shut-off valve on console. 3 1 1 4 2 m–3717 2 Figure 42 1. Fuel shut-off valve 2. Fuel filter m–3217 3. Hose clamp 4. Fuel line Figure 41 1. Filter 2.
5. Remove grease zerk in hole. Reinstall hex plug and cap. 3. Grease the fittings on the push arms(Fig. 44). Where to Add Grease Lubricate the grease fittings as shown on the Check Service Reference Aid decal (Fig. 43). M–5035 Figure 44 Cleaning the Cooling Systems Cleaning the Engine Screen and the Oil Cooler Figure 43 Before each use, check and clean engine screen and oil cooler. Remove any build–up of grass, dirt or other debris from the oil cooler screen and engine air intake (Fig. 45).
6. Torque the slotted nut to 125 ft–lb (170 N m) (Fig. 48). 3 1 7. Tighten nut until the next set of slots line up with the hole in the shaft (Fig. 48). 8. Replace cotter pin. 2 1 4 m–5766 3 Figure 46 1. Panel 2. Engine shroud 2 3. Screws Checking the Tire Pressure m–4638 Figure 48 Maintain the air pressure in the front and rear tires as specified. Uneven tire pressure can cause uneven cut.
Servicing the Hydraulic System 1 2 Checking the Hydraulic Fluid 4 Check the hydraulic fluid level before engine is first started. 3 Check the hydraulic fluid level after first 8 operating hours. Check the hydraulic fluid level after every 25 operating hours. m–5615 Figure 50 Fluid Type: Mobil 1 15W-50 synthetic motor oil or equivalent synthetic oil. 1. Cap 2. Baffle 3. Cold fluid level—full 4. Hot fluid level—full Important Use oil specified or equivalent. Other fluids could cause system damage.
Bleeding the Hydraulic System 2. Remove hydro cap and temporarily cover opening with a plastic bag and rubber band to prevent all hydro fluid from draining out. 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. 3. Place drain pan under filter, remove the old filter and wipe the filter adapter gasket surface clean (Fig. 51). 1.
1. Stop the engine, remove ignition key and tilt seat forward. 2 9 1 6 7 2. Begin with either the left or right motion control lever. 3 3. Move lever to the neutral position but not locked (Fig. 54). 4. Pull lever back until the clevis pin (on arm below pivot shaft) contacts the end of the slot (just beginning to put pressure on the spring) (Fig. 54). 5. Check where the control lever is relative to notch in console (Fig. 53).
1. Raise the frame and block up the machine so drive wheels can rotate freely. Setting the Left–hand Hydraulic Pump Neutral 2. Disconnect electrical connector from the seat safety switch. Temporarily install a jumper wire across terminals in the wiring harness connector. 1. Loosen the locknuts at the ball joints on pump control rod (Fig. 54). 3. Slide seat forward, disconnect prop rod and tilt seat fully forward. 2. Start the engine, open throttle 1/2 way and release parking brake.
3. Tip the seat up to access the tracking knob. Adjusting the Parking Brake Note: Determine the left and right sides of the machine from the normal operating position. Check parking brake for proper adjustment. 1. Disengage brake lever (lever down). 4. To make the machine go right, turn the knob towards the rightside of the machine. Refer to figure 56. 2. Measure the length of the spring. Measurement should be 2-3/4 inch (70 mm) between washers (Fig. 58). 5.
2. To replace fuses pull out on the fuse to remove it (Fig. 59). 2 1 2 3 1 m–5004 Figure 60 m–3653 1. Filler caps 2. Upper line Figure 59 1. Main-20 amp 3. Lower line 2. Alternator-20 amp Danger Servicing the Battery Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns. Warning • Do not drink electrolyte and avoid contact with skin, eyes or clothing. Wear safety glasses to shield your eyes and robber gloves to protect your hands.
6. Secure battery with J-bolts, hold down clamp and 2 washers (1/4 inch), and 2 wing nuts (1/4 inch) (Fig. 61). 9 5 Warning Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. 4 11 2 • Always Disconnect the negative (black) battery cable before disconnecting the positive (red) cable. • Always Reconnect the positive (red) battery cable before reconnecting the negative (black) cable.
Leveling the Mower 5. Wait five to ten minutes after filling the battery cells. Add distilled water, if necessary, until the electrolyte level is up to the upper line (Fig. 60) on the battery case. 1. Position mower on a flat surface. Stop the engine, set the parking brake, remove the key and disconnect the spark plug wire(s) from the spark plug(s). 6. Reinstall battery vent caps. 2. Check tire pressure of all four tires. If needed, adjust to 13 psi (90 kPa) Charging the Battery 3.
Warning Unit could fall onto someone and cause serious injury or death. 1 3 4 2 • Use extreme caution when operating unit on Z Stand. • Use only for cleaning deck and removing blades. • Do not keep unit on Z Stand for extended periods of time. • Always shut engine off and set parking brake before performing any maintenance to deck. 2 m–3747 Figure 64 1. 19–17/32 inch (496 mm) outside swivels 2. Top chain bolt 3. Front swivel 4.
4 1 6 6 4 5 7 m–4451 2 3 2 3 1 M–4312 M–4373 Figure 65 Figure 66 Top View 1. Deck Belt 2. Idler Arm 1. 2. 3. 4. 3. Idler nuts 4. Idler adjusting nut 6. Reinstall the PTO drive belt. Refer to Replacing the PTO Drive Belt, page 45. Clutch Clutch retaining strap clutch Terminal PTO belt 5. Machine Frame 6. 1/4’ Belt Twist 7. 1/8 inch Belt Twist 6. Check belt tension. The center bolt of spring loaded idler must be between the two alignment holes in left support plate (Fig 67).
7. If adjustment is required, loosen the fixed idler on right support plate and move up or down in adjustment slot. To relieve belt tension lift up on spring loaded idler. 11. Rotate the belt guide, on rear of the mower, so it is 1/8–1/4 inch (3–7 mm) away from the vertical side of the PTO belt (Fig. 70). 1 1 2 2 3 M–4374 Figure 70 1. Belt guide 2. PTO Drive belt m–3746 3. 1/8–1/4 inch (3–7 mm) Figure 68 1. Fixed Idler 2. Adjustment slot Replacing the Grass Deflector 8. Check belt tension again.
that these sealed devices contain mercury and should not be placed in the garbage until the mercury is removed and reused, recycled or otherwise managed to insure that it does not become part of solid waste or waters. Management and disposal practices must be within relevant federal, state or local laws. 8 6 4 2 3 5 1 Return the switch to your Toro dealer if it is faulty and is being replaced or if the unit containing the switch is no longer operating and is being scrapped.
BK BK BN GND PTO CLUTCH VIO (NEUTRAL) SW5 W VIO Y SHOWN WITH LEVER IN NEUTRAL POSITION SHOWN WITH LEVER IN NEUTRAL POSITION Y SHOWN IN OFF POSITION GY SW4 (NEUTRAL) SHOWN WITH PARK BRAKE DISENGAGED SW3 (BRAKE) BN SW2 (PTO) OR BK P1–B T K2 (START RELAY) P2–C Y SW6 (SEAT SW) SHOWN WITH OPERATOR IN SEAT SW7 (TILT SW) SWITCH OPENS WHEN TILTED PAST 60 DEGREES FROM VERTICAL P1–A DELAY MODULE 100–6186 P1–C PK B KEY SW S I TERMINAL VIEW FROM BACK OF SWITCH A Y X NO CONNECTION B
Cleaning and Storage A. Add a petroleum based stabilizer/conditioner to fuel in the tank. Follow mixing instructions from stabilizer manufacture. Do not use an alcohol based stabilizer (ethanol or methanol). 1. Disengage the power take off (PTO), set the parking brake and turn the ignition key to off. Remove spark plug wire. Remove the key. Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline and used at all times. 2.
Troubleshooting Problem Starter does not crank Engine g will not start,, starts hard,, or f il to fails t keep k running. i Engine g loses power. Engine g overheats. 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.
Problem Machine does not drive. Abnormal vibration. Uneven cutting g height. g Blades do not rotate. Possible Causes Corrective Action 1. Traction belt is worn, loose or broken. 1. Contact Authorized Service Dealer. 2. Traction belt is off pulley. 2. Contact Authorized Service Dealer. 3. Hydro fluid level low. 3. Add hydro fluid to reservoir. 1. Cutting blade(s) is/are bent or unbalanced. 1. Install new cutting blade(s). 2. Blade mounting bolt is loose. 2. Tighten blade mounting bolt. 3.
The Toro Total Coverage Guarantee LCE A Limited Warranty Conditions and Products Covered Owner Responsibilities The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair the listed Toro Products if defective in materials or workmanship. The following time periods apply from the date of purchase: You must maintain your Toro Product by following the maintenance procedures described in the operator’s manual.
