Form No. 3327–497 Z255 Z–Master with 72 SFS Side Discharge Mower Model No. 74235—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 . .
Servicing the Battery . . . . . . . . . . . . . . . . . . . . . . Leveling the Mower . . . . . . . . . . . . . . . . . . . . . . . Cleaning Under the Deck . . . . . . . . . . . . . . . . . . . Inspecting the Belts . . . . . . . . . . . . . . . . . . . . . . . Replacing the Deck Belt . . . . . . . . . . . . . . . . . . . Replacing the PTO Drive Belt . . . . . . . . . . . . . . . Replacing the Grass Deflector . . . . . . . . . . . . . . . Mercury Tilt Switch . . . . . . . . . . . . . . . . . . . . . . .
• 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 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 ft.-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. USE Rear Wheels 2 Installing wheels to traction unit Retaining rod 1 Bolt, 5/16 x 1 in. 1 Locknut, 5/16 in. 1 Control lever—right 1 Control lever—left 1 Bolt, 3/8 x 1 in. 4 Spring washer, 3/8 in.
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 in.) bolt 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 in. 3. Spring washer, 3/8 in. 4. Top hole 5. Middle hole 6. Bottom hole 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 1 2 Remove plastic tie holding side discharge chute up and lower into place. Figure 8 Checking the Level of Mower Deck 1. Caution Check the level of the deck before the machine is first put in use. 2. Wear hearing protection Controls Refer to Leveling the Mower in the Maintenance section on page 43. Become familiar with all the controls (Fig. 9) before you start the engine and operate the machine.
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.
4. Turn the ignition key to off (Fig. 16). 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.
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. 17). 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.
1. Raise the height-of-cut lever to the transport position (also the 5 in. (127 mm) cutting height position) (Fig. 19). 2 3 2. To adjust, remove hairpin cotter and clevis pin from height-of-cut bracket (Fig. 19). 1 3. Select hole in height-of-cut bracket corresponding to the height-of-cut desired and, insert clevis pin (Fig. 19). 4 m–2715 4. Secure clevis pin with hairpin cotter (Fig. 19). Figure 18 1. Motion control lever-neutral lock position 2. Center un-lock position 5.
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. 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. After adjusting height-of-cut remove flange nut and spring disk while holding stud with wrench (Fig. 21). 1 m–3655 Note: Do not remove the wheel nut and washer (Fig. 21). Figure 22 3.
Transporting Machines 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. 1 To transport the machine: m–5779 • Lock brake and block wheels. Figure 23 • Securely fasten the machine to the trailer or truck with straps, chains, cable, or ropes. 1.
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. 4 Warning Loading a unit onto a trailer or truck increases the possibility of backward tip–over and could cause serious injury or death. 2 5 1 • 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.
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.
1 3 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 2 1 m–4292 m–5805 Figure 35 1. Paper element Checking the Engine Oil Level 2. Rubber seal Note: Check oil when engine is cold. Installing the Foam and Paper Elements 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. Important To prevent engine damage, always operate the engine with the complete foam and paper air cleaner assembly installed. 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, on page 30, into the filler cap (Fig. 36). Now check the oil level; refer to Checking Oil Level, page 30. Slowly add additional oil to bring it to the full mark. Figure 36 1. Oil dipstick 2. Metal end 3. Filler cap Change the Engine Oil Filter Changing the Engine Oil Replace the oil filter every 200 hours or every other oil change. Note: A hose was included in loose parts.
3 1 1 2 2 m–1256 m–5801 Figure 38 1. Oil filter 2. Gasket Figure 39 3. Adapter 1. Spark plug wire 2. Spark plug 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.
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 Servicing the Spark Arrester M–5036 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.
will keep the pin at the end of the slot and allow the adjustment bolt to move the lever to the appropriate position). Warning Engine must be running so motion control adjustment can be performed. Contact with moving parts or hot surfaces may cause personal injury. 6. Tighten nut and jam nut. 7. Repeat on opposite side of unit. 4 1 Keep hands, feet, face, clothing and other body parts away from rotating parts, muffler and other hot surfaces. 2.
Replacing the Pump Drive Belt 4 5 Check pump drive belt for wear after every 50 hours of operation. 6 1. Pull spring loaded idler down and remove traction belt from the engine and hydro pump pulleys (Fig. 54). Remove belt between pulleys. 1 2. Install new belt around engine and hydro pump pulleys (Fig. 54). 2 3. Pull spring loaded idler down and align below traction belt. Release pressure on spring loaded idler (Fig. 54). m–3788 3 Figure 55 1. Brake lever 2. Spring 2.75 in. (70 mm) 3.
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. • 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.
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. 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 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 front of machine by using the Z–Stand. Refer to Z–Stand operation on page 24. Danger 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.
Note: Idler belt has to be installed between spacer and PTO belt idler pulley. 4 1 7. Install clutch retaining strap and plug clutch terminal into main wire harness (Fig. 63). 4 5 2 3 M–4312 2 m–3748 Figure 62 3 1 Top View 1. Deck belt 2. Idler arm 3. Idler nuts 4. Idler adjusting nut M–4373 Figure 63 1. Clutch 2. Clutch retaining strap 3. Clutch terminal 6. Reinstall the PTO drive belt. Refer to Replacing the PTO Drive Belt, page 45. 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 re-leveled. See Leveling the Mower on page 43. 2 3 1 1 1 m–3744 2 Figure 65 1. Center bolt, spring loaded idler 2. Alignment hole m–3740 Figure 67 1. Push arm 2. 15″ (381 mm) nominal 9. If adjustment is required, loosen the fixed idler on right support plate and move up or down in adjustment slot (Fig. 66).
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 One-Year 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 any Toro Product used for commercial, institutional, or rental purposes if defective in materials or workmanship.