Form No. 3329–546 Z255 Z–Master with 62 SFS Side Discharge Mower Model No. 74234—Serial No.
Warning Installing the Seat Retaining Rod . . . . . . . . . . . . Installing the Motion Control Levers . . . . . . . . . Activating the Battery . . . . . . . . . . . . . . . . . . . . . Checking the Hydraulic Fluid . . . . . . . . . . . . . . . Greasing the Bearings . . . . . . . . . . . . . . . . . . . . . Checking the Side Discharge Chute . . . . . . . . . . Checking the Level of Mower Deck . . . . . . . . . . Checking the Engine Oil Level . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . .
Servicing the Fuse . . . . . . . . . . . . . . . . . . . . . . . . Servicing the Battery . . . . . . . . . . . . . . . . . . . . . . Leveling the Mower . . . . . . . . . . . . . . . . . . . . . . . Cleaning Under the Deck . . . . . . . . . . . . . . . . . . . Inspecting Belts . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Deck Belt . . . . . . . . . . . . . . . . . . . Replacing the PTO Drive Belt . . . . . . . . . . . . . . . Replacing the Grass Deflector . . . . . . . . . . . . . . .
• Become familiar with the safe operation of the equipment, operator controls, and safety signs. • Do not change the engine governor setting or overspeed the engine. • All operators and mechanics should be trained. The owner is responsible for training the users. • Stop on level ground, lower implements, disengage drives, engage parking brake, shut off engine before leaving the operator’s position for any reason including emptying the catchers or unclogging the chute.
• Keep hands and feet away from moving parts. If possible, do not make adjustments with the engine running. • Be aware that loss of traction may occur going downhill. Weight transfer to the front wheels may cause drive wheels to slip and cause loss of braking and steering. • Charge batteries in an open well ventilated area, away from spark and flames. Unplug charger before connecting or disconnecting from battery. Wear protective clothing and use insulated tools.
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 106-6570 11 7. Maximum fill line 8. Minimum fill line 9.
106-6571 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 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 a bolt (5/16 x 1 inch) bolt and locknut 5/16 inch (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 Warning Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns. Charging battery produces gasses that can explode and cause serious injury. • 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.
Checking the Side Discharge Chute 2 1 Remove plastic tie holding side discharge chute up and lower into place. Checking the Level of Mower Deck Check the level of the deck before the machine is first put in use. Refer to Mower Leveling and Compression Spring Adjustment in the Maintenance section on page 45. 3 m–6478 Checking the Engine Oil Level Figure 8 Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking Oil Level, page 31. 1.
Controls Switching Fuel Tanks Become familiar with all the controls (Fig. 10) before you start the engine and operate the machine. 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. 12). 3 2 1 6 8 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.
Releasing the Parking Brake 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. 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 will rest against the brake stop. 2 1 1 2 2 1 m–4201 m–2719 Figure 14 Figure 15 1. PTO-On 2. PTO-Off 3 1. Choke–On 2.
The Safety Interlock System 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. Caution If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. Caution • Do not tamper with the interlock switches.
the engine is running, center either motion control and move (forward or reverse); the engine should stop. Repeat for other motion control. 2 3 5. Sitting on the seat, disengage the parking brake, move PTO switch to off and move the motion control levers to neutral lock position. Try starting the engine; the engine should not crank. 1 4 Driving Forward or Backward m–2715 Figure 19 The throttle control regulates the engine speed as measured in rpm (revolutions per minute).
1. Raise the height-of-cut lever to the transport position (also the 5 inch (127 mm) cutting height position) (Fig. 20). 1 2. To adjust, remove hairpin cotter and clevis pin from height-of-cut bracket (Fig. 20). 3. Select hole in height-of-cut bracket corresponding to the height-of-cut desired and, insert clevis pin (Fig. 20). m–5028 4. Secure clevis pin with hairpin cotter (Fig. 20). Figure 21 5. Move lever to selected height. 1.
Pushing 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. 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). 1 4 Important Do not rotate by-pass valves more than 1 turn. This prevents valves from coming out of the body and causing fluid to run out. 3 2 5 3. Disengage parking brake before pushing.
Using the Side Discharge Loading Machines The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. 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 (Fig. 25). The lower rear section of the tractor frame extends back between the rear wheels and serves as a stop for tipping backward.
1 4 4 3 2 2 5 1 3 m–5599 Figure 26 1 1. Z Stand 2. Latch 3. Bracket 4. Bracket Pin 5. Bottom of slot m–6841 Figure 25 1. Trailer 2. Full width ramp 3. Not greater than 15 degrees 4. Full width ramp—side view 1 3 2 m–5600 Using the Z Stand Figure 27 1. Z Stand (Positioned in slot) 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. 3. Raise latch.
Mow at Correct Intervals 9. Remove chocks or blocks. Normally, mow every four days. But remember, grass grows at different rates at different times. So to maintain the same cutting height, which is a good practice, mow more often in early spring. As the grass growth rate slows in mid summer, mow less frequently. If you cannot mow for an extended period, first mow at a high cutting height; then mow again two days later at a lower height setting. Driving off the Z Stand 1.
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 31 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. 32). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges. 3.
3 1 5 4 2 2 3 1 3 4 4 M–4226 5 Figure 34 1. Sail Area of Blade 2. Blade 3. Spring Disk 4. Blade Bolt 5. Cone Towards Bolt Head m–5804 Figure 35 1. Knob 2. Air cleaner cover 3. Air cleaner nut 4. Paper element 5. Foam element Servicing the Air Cleaner Foam Element: Clean after every 25 operating hours. 3. Carefully slide the foam element off the paper element (Fig. 35). Paper Element: Clean after every 100 operating hours.
USE THESE SAE VISCOSITY OILS Important Never clean the paper element with pressurized air or liquids. Replace the paper element if it is damaged, or cannot be cleaned thoroughly. 2 1 m–4292 m–5805 Checking the Engine Oil Level Figure 37 1. Paper element Note: Check oil when engine is cold. 2. Rubber seal 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. Installing the Foam and Paper Elements 2.
2 1 1 2 m–5800 3 Figure 39 1. Oil drain valve 2. Drain hose m–5803 7. Slowly pour approximately 80% of the specified oil into the filler cap (Fig. 38). Refer to Servicing the Engine Oil, page 31. Figure 38 1. Oil dipstick 2. Metal end 3. Filler cap 8. Check the oil level; refer to Checking the Oil Level, page 31. 9. Slowly add additional oil to bring it to the full mark. Changing the Engine Oil Note: A hose was included in loose parts. Use this hose to direct the engine oil into the drain pan.
3 1 1 2 m–1256 Figure 40 1. Oil filter 2. Gasket 2 3. Adapter m–5801 Figure 41 1. Spark plug wire 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. 40). 2. Spark plug Checking the Spark Plug 1. Look at the center of the spark plug(s) (Fig. 42). If you see light brown or gray on the insulator, the engine is operating properly.
Servicing the Fuel Filter Servicing the Fuel Tank Replace the fuel filter after every 200 operating hours or yearly, whichever occurs first. Draining The Fuel Tank Danger Replacing the Fuel Filter In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property. Never install a dirty filter if it is removed from the fuel line. 1. Disengage the power take off (PTO) and turn the ignition key to off.
Greasing and Lubrication Lubricate the machine when shown on the Check Service Reference Aid decal (Fig. 45). Grease more frequently when operating conditions are extremely dusty or sandy. Grease Type: General-purpose grease. How to Grease 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. 2. Clean the grease fittings with a rag. Make sure to scrape any paint off the front of the fitting(s). 3.
1 2 m–5806 Figure 48 1. Engine shroud 2. Engine screen M–5035 Servicing the Spark Arrester Figure 46 Inspect the spark arrester every 50 hours for damage, such as holes in the screen, and for buildup on the screen. If it is damaged, replace it with a new spark arrester. If it is dirty, remove it and clean the screen with a wire brush and/or soak it in solvent.
3. Torque slotted nut to 125 ft.–lb. (169 N m) (Fig. 50). 3 4. Check the distance from bottom of slot in nut to inside edge of hole. Two threads or less should be showing (Fig. 50). 2 1 5. If more than two threads are showing remove nut and install washer between hub and nut (Fig. 50). 6. Torque the slotted nut to 125 ft.–lb. (169 N m) (Fig. 50). M–4640 Figure 51 7. Tighten nut until the next set of slots line up with the hole in the shaft (Fig. 50). 1. Spring Washers 2. Lock Nut 8.
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 the first 8 operating hours. Note: The fluid level should be to the top of the hot level of the baffle, when the fluid is warm (Fig. 52). 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. • After every 200 operating hours. 7. Install cap on filler neck.
Warning 1 3 Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • 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. • Use cardboard or paper to find hydraulic leaks.
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 55 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. 56). 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. 60). 2 3. If adjustment is necessary, loosen the jam nut below the spring and tighten the nut directly below the yoke (Fig. 60). 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 Danger Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns. 1 • 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. m–3653 Figure 61 1. Main-30 amp 2.
9 5 4 11 Warning 2 Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. 7 6 7 • 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. 3 8 10 1 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to off.
Charging the Battery Leveling the Mower 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 Charging the battery produces gasses that can explode. 2. Check tire pressure of all four tires. If needed, adjust to 13 psi (90 kPa) Never smoke near the battery and keep sparks and flames away from battery. 3. Set anti–scalp rollers to top holes or remove them completely for this adjustment. 4.
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 25. 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 M–4312 1 Figure 67 M–4373 Top View 1. Deck Belt 2. Idler Arm Figure 68 3. Idler nuts 4. Idler adjusting nut 1. 2. 3. 4. 6. Reinstall the PTO drive belt. Refer to Replacing the PTO Drive Belt, page 47. Clutch Clutch retaining strap clutch Terminal PTO belt 5. Machine Frame 6. 1/4 inch 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 69).
1 1 2 2 3 Figure 72 m–3746 1. Belt guide 2. PTO Drive belt Figure 70 1. Fixed Idler 3. 1/8–1/4 inch (3–7 mm) 2. Adjustment slot Replacing the Grass Deflector 8. Check belt tension again. The center bolt of spring loaded idler must be between the two alignment holes in left support plate (Fig 69). Adjust, if necessary, and tighten all hardware securely. Warning 9.
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. If the switch is damaged or broken open use extreme caution in handling. Call your local waste management authority or Toro Customer Service for instructions. 8 6 4 2 3 5 1 Caution The mercury contained in the tilt switch is poisonous and exposure to mercury can cause severe illness. 7 • Never attempt to open or repair the tilt switch.
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.