Form No. 3328–242 Z257 Z–Master with 52 in. SFS Side Discharge Mower Model No. 74230—Serial No.
Warning Checking the Side Discharge Chute . . . . . . . . . . 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 . . . . . . . . . . . .
Waste Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . Mercury Tilt Switch . . . . . . . . . . . . . . . . . . . . . . . Disposing the Mercury Tilt Switch . . . . . . . . . . . Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Storage . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Toro Total Coverage Guarantee . . . . . . . . . . . . .
• All operators and mechanics should be trained. The owner is responsible for training the users. • Never operate with the PTO shield, or other guards not securely in place. Be sure all interlocks are attached, adjusted properly, and functioning property. • Never let children or untrained people operate or service the equipment. Local regulations may restrict the age of the operator. • Never operate with the discharge deflector raised, removed or altered, unless using a grass catcher.
• Carefully release pressure from components with stored energy. • Keep hands, feet, hair and loose clothing away from attachment discharge area, underside of mower and any moving parts while engine is running. • Disconnect battery or remove spark plug wire before making any repairs. Disconnect the negative terminal first and the positive last. Reconnect positive first and negative last. • Stop the engine before removing the grass catcher or unclogging the chute.
• Be certain that the seat belt can be released quickly if the machine is driven or rolls into ponds or water. • Check carefully for overhead clearances (i.e. branches, doorways, electrical wires) before driving under any objects and do not contact them. DO NOT • Do not mow slopes exceeding 15 degrees. • Avoid turning on slopes. If you must turn, turn slowly and gradually downhill, if possible. • Do not mow near drop-offs, ditches, or embankments.
Slope Chart 7
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 100-4311 12 7. Maximum fill line 8. Minimum fill line 9.
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 3 2 Think Safety First 1 6 8 7 Carefully read all the safety instructions and decals in the safety section. Knowing this information could help you, your family, pets or bystanders avoid injury. 4 The use of protective equipment for eyes, ears, feet, and head is recommended. 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. 5 9 Wear hearing protection when operating this machine.
Releasing the Parking Brake To use the right side fuel tank rotate the fuel shut off valve 1/4 turn to the right from the off location. This uses fuel from the right side tank only. When the right hand fuel tank is empty, move the fuel shut off valve 1/4 turn to the left from the off position. 1. Push forward and down on the parking brake lever to release the parking brake (Fig. 13). The parking brake is disengaged and the lever rests against the brake stop.
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. Close fuel shut off valve, on front panel before transporting or storing machine. 7. After the engine starts, move the choke to off (Fig. 15).
Disengaging the PTO the engine is running, release the parking brake, engage the PTO and rise slightly from the seat; the engine should stop. 1. To disengage push the PTO switch to the off position (Fig. 18). 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.
Adjusting the Height-of-Cut 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 1. Raise the height-of-cut lever to the transport position (also the 5 inch (127 mm) cutting height position) (Fig. 20). 4 m–2715 2. To adjust, remove hairpin cotter and clevis pin from height-of-cut bracket (Fig. 20). Figure 19 1. Motion control lever-neutral lock position 2. Center un-lock position 3.
3. Select hole so gage wheel is positioned to the nearest corresponding height-of-cut desired (Fig. 21). Pushing the Machine by Hand 4. Reinstall the flange nut and spring disk. Torque to 40–45 ft–lb (54.2–61.0 N m) (Fig. 21). Important Always push the machine by hand. Never tow the machine because hydraulic damage may occur. 5. Repeat adjustment on other gage wheels. To Push the Machine 1. Disengage the power take off (PTO) and turn the ignition key to off.
Transporting Machines Avoid sudden acceleration when driving up a ramp and sudden deceleration when backing down a ramp. Both maneuvers can cause the unit to tip backward. Use a heavy–duty trailer or truck to transport the machine. Ensure that the trailer or truck has all necessary lighting and marking as required by law. Please carefully read all the safety instructions in the safety section. Knowing this information could help you, your family, pets or bystanders avoid injury.
2. Remove bracket pin (Fig. 24). Warning 4 Parking brake may not hold machine parked on Z Stand and could cause personal injury or property damage. Do not park on Z Stand unless wheels are chocked or blocked. 2 5 1 8. Perform maintenance. 3 m–5599 9. Remove chocks or blocks. Figure 24 1. Z Stand 2. Latch 3. Bracket Driving off the Z Stand 4. Bracket Pin 5. Bottom of slot 1. Raise latch to unlocked position (Fig. 26). 2. Start engine and place at half throttle. Disengage parking brake. 3.
Tips for Mowing Grass Cutting Speed Fast Throttle Setting To improve cut quality, use a slower ground speed in certain conditions. For best mowing and maximum air circulation, operate the engine at fast. Air is required to thoroughly cut grass clippings, so do not set the height-of-cut so low as to totally surround the mower by uncut grass. Always try to have one side of the mower free from uncut grass, which allows air to be drawn into the mower.
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. 30). 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 Servicing the Primary Filter Primary Filter: Check and/or replace after every 200 operating hours or more often in dusty conditions. Check and/or replace it after 200 operating hours. If the primary filter is dirty, bent, or damaged then replace the filter. Safety Filter: Replace after every 600 operating hours. Do not clean the primary filter. Note: Check the filters more frequently if operating conditions are extremely dusty or sandy.
Servicing the Engine Oil 2 1 3 Change oil: • After the first 8 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, 67 oz. (2.0 l) m–4811 Figure 34 Viscosity: See table below 1. Oil dipstick 2. Filler tube USE THESE SAE VISCOSITY OILS 10W–30, 10W–40 0 –30 5C –20 20 –10 3. Metal end Changing the Oil 1.
7. Slowly add additional oil to bring it to the full mark. Removing the Spark Plug(s) Changing the Oil Filter 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. Replace the oil filter every 200 hours or every other oil change. 2. Pull the wire(s) off the spark plug(s) (Fig. 37). Now clean around the spark plug(s) to prevent dirt from falling into the engine and potentially causing damage.
2 3 1 0.030 inch (0.76 mm) 1 2 m–3215 m–3217 Figure 38 1. Center electrode insulator 2. Side electrode Figure 39 3. Air gap (not to scale) 1. Filter 2. Hose clamp Installing the Spark Plug(s) Servicing the Fuel Tank 1. Install the spark plug(s). Make sure the air gap is set correctly. Draining The Fuel Tank 2. Tighten the spark plug(s) to 20 ft-lb (27 N m). Danger 3. Push the wire(s) onto the spark plug(s) (Fig. 37).
5. Remove grease zerk in hole. Reinstall hex plug and cap. 5. Install the fuel line onto the fuel filter. Slide the hose clamp close to the fuel filter to secure the fuel line (Fig. 40). Where to Add Grease Lubricate the grease fittings as shown on the Check Service Reference Aid decal (Fig. 41). 3 1 4 m–3717 2 Figure 40 1. Fuel shut-off valve 2. Fuel filter 3. Hose clamp 4. Fuel line Greasing and Lubrication Lubricate the machine when shown on the Check Service Reference Aid decal (Fig. 41).
3 1 2 m–5766 Figure 44 1. Panel 2. Engine shroud 3. Screws M–5035 Checking the Tire Pressure Figure 42 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. 45). Check the tires when they are cold to get the most accurate pressure reading.
6. Torque the slotted nut to 125 ft–lb (170 N m) (Fig. 46). 3 2 7. Tighten nut until the next set of slots line up with the hole in the shaft (Fig. 46). 1 8. Replace cotter pin. 1 4 M–4640 3 Figure 47 2 1. Spring Washers 2. Lock Nut Servicing the Hydraulic System m–4638 Figure 46 1. Slotted Nut 2. Two threads or less showing 3. Dust Cap 3. Hole in threaded rod 4. Washer (if needed) Checking the Hydraulic Fluid Check the hydraulic fluid level before engine is first started.
Replacing the Hydraulic Filter 5. Run the machine at low idle for 15 minutes to allow any air to purge out of the system and warm fluid. Refer to Starting and Stopping the Engine on page 19. Change the hydraulic filter: • After the first 8 operating hours. 6. Recheck the fluid level while the fluid is warm. If required, add fluid to the reservoir until it reaches the hot level of the baffle. • After every 200 operating hours. 1. Disengage the power take off (PTO) and turn the ignition key to off.
11. Recheck level while fluid is warm. Add fluid to raise level to top of the baffle, if required. Do not overfill. 1 Warning Hydraulic fluid escaping under pressure can penetrate skin and cause injury. 3 • If hydraulic fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result if this is not done. • Keep body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid.
Setting the Hydraulic Pump Neutral 2 3 Note: Adjust handle neutral first. That has to be correct before the following adjustment can be made. Danger 1 Mechanical or hydraulic jacks may fail to support machine and cause a serious injury. m–6282 Figure 51 1. Neutral locked position 2. Control lever • Use jack stand when supporting machine. • Do not use hydraulic jacks. 3. Neutral potion Warning 6. If adjustment is needed, loosen the nut and jam nut against the yoke (Fig. 52). 7.
2 1 Warning 4 Electrical system will not perform proper safety shut off with jumper wire installed. • Remove jumper wire from wire harness connector and plug connector into seat switch when adjustment is completed. • Never operate this unit with jumper installed and seat switch bypassed. 7. After both pump neutrals are set, shut off the machine. 8. Remove jumper wire from wire harness connector and plug connector into seat switch. 9. Reinstall prop rod and lower the seat into position.
2. Measure the length of the spring. Measurement should be 2-3/4 inch (70 mm) between washers (Fig. 56). 2 3. If adjustment is necessary, loosen the jam nut below the spring and tighten the nut directly below the yoke (Fig. 56). Turn the nut until the correct measurement is obtained. Tighten the two nuts together and repeat on opposite side of unit. 3 4 4. Turn nuts clockwise to shorten spring length and turn counter–clockwise to lengthen the spring. 1 5. Engage parking brake, lever up. 6.
2 1 2 1 3 m–3653 m–5004 Figure 57 1. Main-20 amp Figure 58 2. Alternator-20 amp 1. Filler caps 2. Upper line 3. Lower line Servicing the Battery Danger Warning Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns. Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.
5. Slide the red terminal boot onto the positive (red) battery post. Warning 6. Secure battery with J-bolts, hold down clamp and 2 washers (1/4 inch), and 2 wing nuts (1/4 inch) (Fig. 59). 9 5 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 7 • Always Disconnect the negative (black) battery cable before disconnecting the positive (red) cable.
6. Reinstall battery vent caps. Leveling the Mower Charging the Battery 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). Warning 2. Check tire pressure of all four tires. If needed, adjust to 13 psi (90 kPa) Charging the battery produces gasses that can explode. 3. Set anti–scalp rollers to top holes or remove them completely for this adjustment.
2. Raise the deck to the transport position. Note: When properly adjusted, the front blade tip will be slightly lower than the rear blade tip. See Checking for Bent Blades on page 28 to measure. 3. Raise the front of the machine by using the Z Stand; refer to Using the Z Stand, page 24. Warning 1 Unit could fall onto someone and cause serious injury or death. 3 4 2 • Use extreme caution when operating unit on Z Stand. • Use only for cleaning deck and removing blades.
4 1 6 6 4 5 7 m–4451 2 3 2 3 1 M–4312 M–4373 Figure 63 Figure 64 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 46. 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 65).
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. 68). 1 1 2 2 3 M–4374 Figure 68 1. Belt guide 2. PTO Drive belt m–3746 3. 1/8–1/4 inch (3–7 mm) Figure 66 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.