Form No. 3328–246 Z257 Z–Master with 72 SFS Side Discharge Mower Model No. 74232– 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 . . . . . . . . . . . .
Replacing the Grass Deflector . . . . . . . . . . . . . . . Waste Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . Mercury Tilt Switch . . . . . . . . . . . . . . . . . . . . . . . Disposing the Mercury Tilt Switch . . . . . . . . . . . Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Storage . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Toro Total Coverage Guarantee . . . . . . . . . . .
• The owner/user can prevent and is responsible for accidents or injuries occurring to himself or herself, other people or property. • Do not change the engine governor setting or overspeed the engine. • Stop on level ground, lower implements, disengage drives, engage parking brake (if provided), shut off engine before leaving the operator’s position for any reason including emptying the catchers or unclogging the chute.
• 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. • 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. • Watch for traffic when operating near or crossing roadways.
• 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. 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.
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 54-9220 98-3798 98-4387 66-1340 1. Warning—wear hearing protection.
103-0368 93-7818 1. Warning—read the Operator’s Manual for instructions on torquing the blade bolt/nut to 115–149 N⋅m (85–110 -lb.). 104-4163 1. Explosion hazard 2. No fire, open flames, or smoking. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 5. Read the Operator’s Manual. 6. Keep bystanders a safe distance from the battery. 99-4632 1. Engine—stop 2. Engine—run 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 Note: Determine the left and right sides of the machine from the normal operating position. Loose Parts Note: Use the chart below to verify all parts have been shipped. DESCRIPTION QTY.
2. Remove retaining rod from seat and insert the L shaped end of the rod into the hole directly above the left–side hydraulic pump (Fig. 3). 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 in.) (Fig. 3). 2 1 4 4. Tighten until snug, then loosen so the rod pivots freely. 5 1 2 6 3 m–5596 Figure 4 1. Mounting plate 2. Bolt, 3/8 x 1 inch 3. Spring washer, 3/8 inch 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–5036 Figure 8 7 2 1.
Operation 3 2 Note: Determine the left and right sides of the machine from the normal operating position. 1 6 8 7 4 Think Safety First 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. The use of protective equipment for eyes, ears, feet, and head is recommended.
Releasing the Parking Brake Close fuel shut off valve, on front panel before transporting or storing machine. 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. 1 1 Figure 12 1. Shut off valve 2 Operating the Parking Brake Always set the parking brake when you stop the machine or leave it unattended. Setting the Parking Brake 3 1. Move the motion control levers (Fig.
7. After the engine starts, move the choke to off (Fig. 15). 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. Important Make sure that the fuel shut off valve is closed before transporting or storing the machine, as fuel leakage may occur. Set the parking brake before transporting. Make sure to remove the key as the fuel pump may run and cause the battery to lose charge.
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. 20). 1 4 2. To adjust, remove hairpin cotter and clevis pin from height-of-cut bracket (Fig. 20). m–2715 3.
Positioning the Seat The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable. 1 1. To adjust, move the lever sideways to unlock seat (Fig. 23). 2. Slide the seat to the desired position and release lever to lock in position. m–5028 Figure 21 1. Lift Assist Lever Adjusting the Anti-Scalp Rollers Whenever you change the height-of-cut it is recommended to adjust the height of the anti-scalp rollers. 1.
Loading Machines 1 Use extreme caution when loading units on trailers or trucks. One full width ramp that is wide enough to extend beyond the rear tires is recommended instead of individual ramps for each side of the unit. The lower rear section of the tractor frame extends back between the rear wheels and serves as a stop for tipping backward. Having a full width ramp provides a surface for the frame members to contact if the unit starts to tip backward.
3. Raise latch. Swing stand foot out front and slide stand toward machine, into the bottom of slot (Fig. 25 and 26). Warning Unit could fall onto someone and cause serious injury or death. 4. Set foot of stand on the ground and rest latch on pivot tab (Fig. 26). • 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.
Tips for Mowing Grass Long Grass Fast Throttle Setting If the grass is ever allowed to grow slightly longer than normal, or if it contains a high degree of moisture, raise the cutting height higher than usual and cut the grass at this setting. Then cut the grass again using the lower, normal setting. For best mowing and maximum air circulation, operate the engine at fast.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position.
Caution If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition and disconnect the wire from the spark plug(s) before you do any maintenance. Set the wire aside so that it does not accidentally contact the spark plug. Servicing the Cutting Blades Maintain sharp blades throughout the cutting season because sharp blades cut cleanly without tearing or shredding the grass blades.
Sharpening the Blades Warning MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE When sharpening blade, pieces of blade could be thrown and cause serious injury. m–2539 Wear proper eye protection when sharpening blade. Figure 30 2. Rotate the opposite ends of the blades forward. 1. Use a file to sharpen the cutting edge at both ends of the blade (Fig. 31). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges. 3.
3 3 5 4 4 1 2 1 3 4 5 M–4226 2 Figure 33 1. Sail Area of Blade 2. Blade 3. Spring Disk 1 4. Blade Bolt 5. Cone Towards Bolt Head m–4815 Figure 34 1. Latches 2. Air cleaner cover 3. Air filter body 4. Primary filter 5. Safety filter 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.
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) m–4811 Crankcase Capacity: w/filter, 67 oz. (2.0 l) Figure 35 Viscosity: See table below 1. Oil dipstick 2. Filler tube USE THESE SAE VISCOSITY OILS 1. Start the engine and let it run five minutes. This warms the oil so it drains better.
Changing the Engine Oil Filter Removing the Spark Plug(s) Replace the oil filter every 200 hours or every other oil change. 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. Note: Change oil filter more frequently when operating conditions are extremely dusty or sandy. 2. Pull the wire(s) off the spark plug(s) (Fig. 38).
2 3 1 0.030 inch (0.76 mm) 1 2 m–3215 m–3217 Figure 39 1. Center electrode insulator 2. Side electrode Figure 40 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. 38). In certain conditions, gasoline is extremely flammable and highly explosive.
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. 41). Where to Add Grease Lubricate the grease fittings as shown on the Check Service Reference Aid decal (Fig. 42). 3 1 4 m–3717 2 Figure 41 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. 42).
3 1 2 m–5766 Figure 45 1. Panel 2. Engine shroud 3. Screws M–5036 Figure 43 Checking the Tire Pressure 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. 46). Check the tires when they are cold to get the most accurate pressure reading.
6. Torque the slotted nut to 125ft–lb (169 N m) (Fig. 47). 3 7. Tighten nut until the next set of slots line up with the hole in the shaft (Fig. 47). 2 8. Replace cotter pin. 1 1 4 3 M–4640 2 Figure 48 1. Spring Washers 2. Lock Nut 3. Dust Cap m–4638 Figure 47 1. Slotted Nut 2. Two threads or less showing Servicing the Hydraulic System 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 52 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. 53). 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. 57). 2 3. If adjustment is necessary, loosen the jam nut below the spring and tighten the nut directly below the yoke (Fig. 57). 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 58 1. Main-20 amp Figure 59 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. 60). 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 (4) 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 Note: Idler belt has to be installed between spacer and PTO belt idler pulley. 7. Install clutch retaining strap and plug clutch terminal into main wire harness (Fig. 65). 4 5 2 3 M–4312 2 m–3748 Figure 64 3 1 Top View 1. Deck Belt 2. Idler Arm 3. Idler nuts 4. Idler adjusting nut M–4373 Figure 65 6. Install the PTO drive belt. Refer to Replacing the PTO Drive Belt, page 46. 1. Clutch 2. Clutch retaining strap 3. clutch Terminal 4. PTO belt 5.
Note: Increase belt tension by lengthening the push arms and decrease belt tension by shortening push arms. Important If the push arm lengths are changed, then the mower deck must be leveled. See Leveling the Mower on page 44. 2 1 3 4 m–3744 1 Figure 67 1. Center bolt, spring loaded idler 2 2. Alignment hole m–6273 Figure 69 1. Push arm 2. 15–5/16 inch (389 mm) nominal 9. If adjustment is required, loosen the fixed idler on right support plate and move up or down in adjustment slot (Fig. 68).
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.
