Form No. 3328–249 Z255 Z–Master with 62 SFS Side Discharge Mower Model No. 74234—Serial No.
Warning Checking the Tire Pressure . . . . . . . . . . . . . . . . . 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 . .
Adjusting the Parking Brake . . . . . . . . . . . . . . . . Servicing the Fuse . . . . . . . . . . . . . . . . . . . . . . . . Servicing the Battery . . . . . . . . . . . . . . . . . . . . . . Leveling the Mower . . . . . . . . . . . . . . . . . . . . . . . Cleaning Under the Deck . . . . . . . . . . . . . . . . . . . Inspecting Belts . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Deck Belt . . . . . . . . . . . . . . . . . . . Replacing the PTO Drive Belt . . . . . . . . . . . . . . .
• 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. • Do not change the engine governor setting or overspeed the engine. • The owner/user can prevent and is responsible for accidents or injuries occurring to himself or herself, other people or property.
• 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 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 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 Remove plastic tie holding side discharge chute up and lower into place. Figure 8 Checking the Level of Mower Deck 1. Warning—wear hearing protection. Check the level of the deck before the machine is first put in use. Controls Become familiar with all the controls (Fig. 9) before you start the engine and operate the machine. Refer to Mower Leveling and Compression Spring Adjustment in the Maintenance section on page 44.
Warning 1 Parking brake may not hold machine parked on a slope and could cause personal injury or property damage. m–3077 Do not park on slopes unless wheels are chocked or blocked Figure 10 1. Hour meter Releasing the Parking Brake Switching Fuel Tanks 1. Push forward and down on the parking brake lever to release the parking brake (Fig. 12). The parking brake is disengaged and the lever will rest against the brake stop. The unit has two fuel tanks, located on the left and right sides.
6. Turn ignition key to start. When engines starts, release 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. Close fuel shut off valve, on front panel before transporting or storing machine.
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. 19). 1 4 2. To adjust, remove hairpin cotter and clevis pin from height-of-cut bracket (Fig. 19). 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. 22). 2. Slide the seat to the desired position and release lever to lock in position. m–5028 Figure 20 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.
Transporting Machines 1 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. Knowing this information could help you, your family, pets or bystanders avoid injury. To transport the machine: • Lock brake and block wheels. • Securely fasten the machine to the trailer or truck with straps, chains, cable, or ropes.
Warning 4 Loading a unit onto a trailer or truck increases the possibility of backward tip–over and could cause serious injury or death. • Use extreme caution when operating a unit on a ramp. • Use only a single, full width ramp; DO NOT use individual ramps for each side of the unit. • If individual ramps must be used, use enough ramps to create an unbroken ramp surface wider than the unit. • Do not exceed a 15 degree angle between ramp and ground or between ramp and trailer or truck.
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 29 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. 30). 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 32 1. Sail Area of Blade 2. Blade 3. Spring Disk 4. Blade Bolt 5. Cone Towards Bolt Head m–5804 Figure 33 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. 33). 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 35 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 37 1. Oil drain valve 2. Drain hose m–5803 7. Slowly pour approximately 80% of the specified oil into the filler cap (Fig. 36). Refer to Servicing the Engine Oil, page 30. Figure 36 1. Oil dipstick 2. Metal end 3. Filler cap 8. Check the oil level; refer to Checking the Oil Level, page 30. 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 38 1. Oil filter 2. Gasket 2 3. Adapter m–5801 Figure 39 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. 38). 2. Spark plug Checking the Spark Plug 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.
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. 43). 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 46 1. Engine shroud 2. Engine screen M–5035 Servicing the Spark Arrester Figure 44 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. 48). 3 4. Check the distance from bottom of slot in nut to inside edge of hole. Two threads or less should be showing (Fig. 48). 2 1 5. If more than two threads are showing remove nut and install washer between hub and nut (Fig. 48). 6. Torque the slotted nut to 125 ft.–lb. (169 N m) (Fig. 48). M–4640 Figure 49 7. Tighten nut until the next set of slots line up with the hole in the shaft (Fig. 48). 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. 50). 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 53 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. 54). 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. 58). 2 3. If adjustment is necessary, loosen the jam nut below the spring and tighten the nut directly below the yoke (Fig. 58). 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 59 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 27 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 M–4312 1 Figure 65 M–4373 Top View 1. Deck Belt 2. Idler Arm Figure 66 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 46. 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 67).
1 1 2 2 3 Figure 70 m–3746 1. Belt guide 2. PTO Drive belt Figure 68 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 67). 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.
