Toro 74202 Operator's Manual

FORM NO. 3322–726 Rev A

Z–Master

250

Series



Z253

with 52” SFS Side

Discharge Mower

Model No. 74202–994001 & UP

Operator’s Manual

IMPORTANT: Read this manual carefully. It contains information about your

safety and the safety of others. Also become familiar with the controls and their proper use before you operate the product.

Introduction

Thank you for purchasing a Toro product. All of us at Toro want you to be completely satisfied

with your new product, so feel free to contact your local Authorized Service Dealer for help with service, genuine replacement parts, or other information you may require.

Whenever you contact your Authorized Service Dealer or the factory, always know the model and serial numbers of your product. These numbers will help the Service Dealer or Service Representative provide exact information about your specific product. You will find the model and serial number plate located in a unique place on the product as shown below

The warning system in this manual identifies potential hazards and has special safety messages that help you and others avoid personal injury, even death. DANGER, WARNING and CAUTION are signal words used to identify the level of hazard. However, regardless of the hazard, be extremely careful.

DANGER signals an extreme hazard that will cause serious injury or death if the recommended precautions are not followed.

WARNING signals a hazard that may cause serious injury or death if the recommended precautions are not followed.

CAUTION signals a hazard that may cause minor or moderate injury if the recommended precautions are not followed.

Two other words are also used to highlight information. “Important” calls attention to special mechanical information and “Note” emphasizes general information worthy of special attention.

1. Model

For your convenience, write the product model and serial numbers in the space below.

Model No:

Serial No.

Read this manual carefully to learn how to operate and maintain your product correctly. Reading this manual will help you and others avoid personal injury and damage to the product. Although we design, produce and market safe, state-of-the-art products, you are responsible for using the product properly and safely. You are also responsible for training persons, who you allow to use the product, about safe operation.

and Serial Number Plate

The left and right side of the machine is determined from the normal operator’s position.

The engine exhaust from this product

contains chemicals known to the State of

California to cause cancer, birth defects,

or other reproductive harm.

IMPORTANT: This engine is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate this engine on any forest–covered, brush–covered or grass–covered land. Other states or federal areas may have similar laws.

The Toro Company – 1999

Contents

Page

Safety 3.

Gasoline and Oil 13

Assembly 15

Operation 21

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safe Operating Practices 3 Slope Chart 7 Safety and Instruction Decals 9

Recommended Gasoline13. . . . . . . . . . . . . .

Stabilizer/Conditioner 14 Filling the Fuel Tank 14 Check Engine Oil Level 14

Loose Parts 15 Install Drive Wheels 16 Tire Pressure 16 Install Seat Retaining Rod 16 Install Motion Control Levers 17 Check Side Dischar Check the Leveling of Mower Deck 17 Activate the Battery 18 Install Battery 19 Hydraulic System 20

Think Safety First 21 Controls 21 Parking Brake 21 Starting and Stopping

the Engine 22 Operating the Power Take Off (PTO) 23 The Safety Interlock System 24 Driving Forward or Backward 25 Stopping the Machine 25 Instruments 26 Fuel Tanks 26

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . .

. . . . . . . . . .

ge Chute17. . . . . . . . . . .

. . . . .

. . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . . . . . . . .

Page

Adjusting Height-of-Cut 27 Adjusting Anti-Scalp Rollers 27 Positioning the Seat 28 Pushing the Machine by Hand 29 Tips for Mowing Grass 30

Maintenance 31

Service Interval Chart 31

Cutting Blades32. . . . . . . . . . . . . . . . . . . . . .

Air Cleaner 35 Engine Oil 37 Spark Plug 39 Greasing and Lubrication 40

Cleaning the Cooling Systems41. . . . . . . . . .

Tire Pressure 41 Fuel Filter 41 Fuel Tank 42 Hydraulic System 43 Adjusting Motion Controls Replacing the Pump Drive Belt 48 Adjustment Parking Brake 48 Fuse 49 Battery 50 Mower Leveling 51

Greasing the Bearings52. . . . . . . . . . . . . . . .

Belt Inspection52. . . . . . . . . . . . . . . . . . . . . .

Replacing the Deck Belt53. . . . . . . . . . . . . .

Replacing the PTO Drive Belt 53 Replacing the Grass Deflector 55 Wiring Diagram 56

Cleaning and Storage 57 Troubleshooting 58 Warranty 62

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . .

. . . . . . . . .

. . . . . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . . . . . . . . .

                  

Contents

                          

Safety

This machine meets or exceeds CPSC blade safety requirements for rotary mowers and the B71.4 1990 specifications of the American National Standards Institute, in effect at time of production.

Note: The addition of certain attachments

that do not meet American National Standards Institute certification will cause noncertification of this machine.

Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means CAUTION, WARNING, or DANGER—“personal safety instruction.” Failure to comply with the instruction may result in personal injury or death.

Safe

This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death.

Operating Practices

POTENTIAL HAZARD

• Engine exhaust contains carbon monoxide,

which is an odorless, deadly poison.

WHAT CAN HAPPEN

• Carbon monoxide can kill you and is also

known to the State of California to cause birth defects.

HOW TO AV

OID THE HAZARD

• Do not run engine indoors or in an enclosed

area.

This product is designed for cutting and recycling grass or, when equipped with a grass bagger, for catching cut grass. Any use for purposes other than these could prove dangerous to user and bystanders.

Note: This engine is not equipped with a

spark arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate this engine on any forest–covered, brush–covered or grass–covered land. Other states or federal areas may have similar laws.

Safety

General Operation

1. Read, understand, and follow all instructions in

the operator’s manual and on the machine before starting.

2. Allow only responsible adults who are familiar

with the instructions to operate the machine.

3. Clear the area of objects such as rocks, toys,

wire, etc., which could be picked up and thrown by the blade.

4. Be sure the area is clear of other people before

mowing. Stop the machine if anyone enters the area.

5. Never carry passengers.

6. Do not mow in reverse unless absolutely

necessary. Always look down and behind before and while backing.

7. Be aware of the mower discharge direction and

do not point it at anyone. Do not operate the mower without either the entire grass catcher or the guard in place.

12. Stop the engine before removing the grass

catcher or unclogging the chute.

13. Mow only in daylight or good artificial light.

14. Do not operate the machine while under the

influence of alcohol or drugs.

15. Watch for traffic when operating near or crossing

roadways.

16. Use extra care when loading or unloading the

machine onto a trailer or truck.

17. Do not touch equipment or attachment parts

which may be hot from operation. Allow to cool before attempting to maintain, adjust or service.

18. Before operating a machine with ROPS (roll

over protection) be certain the seat belts are attached.

8. Slow down before turning. Sharp turns on any

terrain may cause loss of control.

9. Never leave a running machine unattended.

Always turn off blades, set parking brake, stop engine, and remove key before dismounting.

10. Turn off blades when not mowing.

11. Keep hands, feet, hair and loose clothing away

from attachment discharge area, underside of mower and any moving parts while engine is running.

Safety

Slope Operation

Slopes and ramps are a major factor related to loss-of-control and tip-over accidents, which can result in severe injury or death. All slopes and ramps require extra caution. If you cannot back up the slope or if you feel uneasy on it, do not mow it.

• Mow up and down slopes greater than 5°, not

across.

• Mow downhill only on slopes above 10°, never

mow uphill. If a steep slope must be ascended, back up the hill, and drive forward down the hill, keeping the machine in gear.

• Remove obstacles such as rocks, tree limbs, etc.

from the mowing area. Watch for holes, ruts or bumps, as uneven terrain could overturn the machine. T

• Use slow speed so that you will not have to stop

while on the slope.

• Follow the manufacturer’s recommendations for

wheel weights or counterweights to improve stability.

• Use extra care with grass catchers or other

attachments. These can change the stability of the machine.

• Keep all movement on slopes slow and gradual.

Do not make sudden changes in speed or direction.

all grass can hide obstacles.

• 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 operate machine on hillsides or slopes

exceeding 15

• 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. Reduced traction

could cause sliding.

• Do not try to stabilize the machine by putting

your foot on the ground.

• Do not use a grass catcher on steep slopes.

Heavy grass bags could cause loss of control or overturn the machine.

°.

Children

Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the machine and the mowing activity. Never assume that children will remain where you last saw them. The following requirements must be followed to prevent injury to children.

• Avoid starting or stopping on a slope. If tires

lose traction, disengage the blades and proceed slowly straight down the slope.

• When operating machine on slopes, banks or

near drop offs, always have ROPS (roll over protection) installed.

• When operating a machine with ROPS (roll over

protection) always use seat belt.

• Be certain that the seat belt can be released

quickly if the machine is driven or rolls into ponds or water.

1. Keep children out of the mowing area and under

the watchful care of another responsible adult.

2. Be alert and turn the machine off if children

enter the area.

3. Before and while backing, look behind and down

for small children.

4. Never carry children. They may fall off and be

seriously injured or interfere with safe machine operation.

Safety

5. Never allow children to operate the machine.

6. Use extra care when approaching blind corners,

shrubs, trees, the end of a fence or other objects that may obscure vision.

Service

1. Stop the engine and disconnect spark plug

wire(s) before performing any service, repairs, maintenance or adjustments.

2. Use extra care when handling gasoline and other

fuels. They are flammable and vapors are explosive.

A. Use only an approved container. B. Never remove the gas cap or add fuel when

the engine is running. Allow the engine to

cool before refueling. Do not smoke. C. Never refuel the machine indoors. D. Never store the machine or fuel container

inside where there is an open flame, such as

near a water heater or furnace.

9. Mower blades are sharp and can cut. Wrap the

blade(s) or wear gloves, and use extra caution when servicing them.

10. Use only genuine replacement parts to ensure

that original standards are maintained.

11. Check brake operation frequently. Adjust and

service as required.

12. Battery acid is poisonous and can cause burns.

Avoid contact with skin, eyes and clothing. Protect your face, eyes and clothing when working with a battery.

13. Battery gases can explode. Keep cigarettes,

sparks and flames away from battery.

14. Hydraulic fluid escaping under pressure can

penetrate the skin and cause injury. Use cardboard or paper to find hydraulic leaks.

15. Never modify ROPS (roll over protection)

frames or structures because they are specifically designed, sized, located and tested for injury reduction. If a rollover occurs, a modified ROPS will not provide adequate protection.

3. Never run a machine inside a closed area.

4. Keep nuts and bolts tight, especially the blade

attachment bolts. Keep equipment in good condition.

5. Never tamper with safety devices. Check safety

systems for proper operation before each use.

6. Keep the machine free of grass, leaves, or other

debris build-up. Clean up oil or fuel spillage. Allow the machine to cool before storing.

7. Stop and inspect the equipment if you strike an

object. Repair, if necessary, before restarting.

8. Grass catcher components are subject to wear,

damage and deterioration, which could expose moving parts or allow objects to be thrown. Frequently check components and replace with manufacturer’s recommended parts, when necessary.

Safety

Slope

Read all safety instructions on pages 4–6.

Chart

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.

ON RIGHT SIDE OF HEIGHT OF

CUT PLA

(Part No E633345)

OP OF CONSOLE UNDER SEA

(Part No. E513747)

ON LEFT SIDE OF

HEIGHT–OF–CUT PLA

(Part No E633706)

ON T

OP OF CONSOLE LEFT

AND RIGHT SIDES

(Part No. E633354)

BELOW CENTER OF CONSOLE

(Part No. E633346)

Safety

UNDER FOOTREST

(Part No. E633766)

ON T

OP OF RIGHT

ENGINE BAFFLE

(Part No. E633771)

ON RUBBER FLAP BEHIND SEA

(Part No. E513748)

ON RUBBER FLAP

BEHIND SEA

(Part No. E303517)

ON CONSOLE AND RUBBER

FLAP BEHIND SEA

(Part No. E633462)

ON CONTROL P

(Part No. 99–461

ANEL

ON LEFT SIDE GAS T

(Part No. 99–4632)

ANK

ON T

OP OF HYDRAULIC

RESERVOIR

(Part No. E513890)

Safety

ON HYDRAULIC RESER

MOUNTING BRACKET

(Part No. E513929)

ON DECK SUPPORT FRAME

(Part No. E633818)

VOIR

Safety

ON RIGHT SIDE OF MOWER

(Part No. 66-1340)

ON LEFT SIDE OF MOWER

(Part No. 43-8480)

UNDER DEFLECTOR

(Part No. 66-6380)

ON DEFLECTOR

(Part No. 54-9220)

UNDER

FOOTREST AND (2)

UNDER PULLEY COVERS

(Part No. 98–5954)

(2) ON BELT COVERS

(Part No. 67-5360)

ON TOP CENTER OF MOWER

(Part No. 98-3799)

NEXT TO ANTIĆSCALP ROLLER

(Part No. 98-3798)

ON LEFT FRONT OF MOWER

(Part No. 93-7818)

115–149 NSm

85–110

SLbs

Gasoline and Oil

Recommended

Use UNLEADED Regular Gasoline suitable for automotive use (85 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available.

IMPORTANT: Never use methanol, gasoline containing methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged. Do not mix oil with gasoline.

POTENTIAL HAZARD

Gasoline

• In certain conditions gasoline is extremely

flammable and highly explosive.

WHAT CAN HAPPEN

• A fire or explosion from gasoline can burn

you, others, and cause property damage.

HOW TO AV

OID THE HAZARD

• Use a funnel and fill the fuel tank outdoors,

in an open area, when the engine is cold. Wipe up any gasoline that spills.

• Do not fill the fuel tank completely full.

Add gasoline to the fuel tank until the level is 1/4” to 1/2” (6 mm to 13 mm) below the bottom of the filler neck. This empty space in the tank allows gasoline to expand.

• Never smoke when handling gasoline, and

stay away from an open flame or where gasoline fumes may be ignited by a spark.

• Store gasoline in an approved container

and keep it out of the reach of children. Never buy more than a 30-day supply of gasoline.

POTENTIAL HAZARD

• In certain conditions gasoline is extremely

flammable and highly explosive.

WHAT CAN HAPPEN

• A fire or explosion from gasoline can burn

you, others, and cause property damage.

HOW TO AV

OID THE HAZARD

• Always place gasoline containers on the

ground away from your vehicle before filling.

• Do not fill gasoline containers inside a

vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge.

• When practical, r

equipment from the truck or trailer and refuel the equipment with its wheels on the ground.

emove gas–power

• If this is not possible, then refuel such

equipment on a truck or trailer from a portable container, rather than from a gasoline dispenser nozzle.

• If a gasoline dispenser nozzle must be used,

keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete.

Gasoline and Oil

Stabilizer/Conditioner

Add the correct amount of gas stabilizer/conditioner to the gas. Using a stabilizer/conditioner in the machine:

• Keeps gasoline fresh during storage

• Cleans the engine while it runs

• Eliminates gum-like buildup in the fuel system,

which causes hard starting

IMPORTANT: Never use fuel additives containing methanol or ethanol.

Filling

1. Shut the engine off and set the parking brake.

2. Clean around each fuel tank cap and remove the

3. Install fuel tank caps securely. Wipe up any

Check

Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking Oil Level, page 37.

the Fuel T

cap. Add unleaded regular gasoline to both fuel tanks, until the level is 1/4 to 1/2 inch (6 mm to 13 mm) below the bottom of the filler neck. This space in the tank allows gasoline to expand. Do not fill the fuel tanks completely full.

gasoline that may have spilled.

ank

Engine Oil Level

Assembly

Loose

Note: Use the chart below to verify all parts have been shipped.

DESCRIPTION QTY. USE

Rear Wheels Retaining rod

Bolt 5/16–18 x 1” (26 mm) Locknut 5/16”

Control lever–right Control lever–left Bolt 3/8–1 x 1” (26 mm) Spring washer 3/8”

Key Operator’ Engine Operator’s Manual Parts Catalog Registration card

Parts

s Manual

2 1

1 1

1 1 4 4

2 1 1 1 1

Install wheels to traction unit

Install seat rod

Install motion control levers

Read before operating machine

Fill out and return to T

oro

Assembly

Install

Drive Wheels

1. Uncrate mower.

2. Remove wheel nuts from rear wheel hubs.

3. Align holes. Mount drive wheels with the valve

stem to the outside of the traction unit.

4. Secure using wheel nuts provided. Torque to

95ft–lbs (128 NSM).

Tire

Pressure

Check the air pressure in the front and rear tires (Fig. 1).

Pressure: 13 psi (90 kPa)

Install

Seat Retaining Rod

1. Tilt seat up. Remove 5/16” (8mm) locknut from

bolt attaching seat retaining rod to seat frame (Fig. 2).

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 mounting hardware (Fig. 2).

3. Place the seat retaining rod to the outside of the

mounting tab of the seat frame and secure with 5/16–18 x 1” (26 mm) bolt and 5/16” (8mm) locknut (Fig. 2).

4. Tighten until snug, then loosen so the rod pivots

freely.

Figure 1

1. Valve

stem

m–1872

m–3750

Figure 2

1. L

end of retaining rod

Locknut 5/16”

Bolt 5/16–18 x 1” (26 mm)

Assembly

Install

1. Remove the (4) 3/8–16 x 1” (26 mm) bolts and

2. Place the levers (with the mounting plate toward

3. Position the levers so the bolts are in the center

4. Align the front\rear position of the levers, with

Motion Control Levers

(4) 3/8” spring washers which attach the motion control levers to the control arm shafts for shipping (Fig. 3).

the rear) on the outside of the control arm shaft and secure with (4) 3/8–16 x 1” (26 mm) bolts and (4) 3/8” spring washers (Fig. 3).

of the slots on the lever mounting plate and tighten until snug.

each other, in the neutral position. Loosen hardware and adjustment by sliding/tilting the lever(s) forward or backward until properly aligned(Fig. 3).

5. If the ends of the levers hit against each other,

while in the drive position (Fig 4) (levers rotated in as far as possible) make adjustments by moving the levers outward to the neutral lock position and carefully bend them outward. Move them back to the drive position and check for clearance. Repeat if necessary.

Figure 4

1. Mounting

Bolt 3/8–18 x 1” (26 mm)

plate

Figure 3

Spring washer 3/8”

m–3751

Check

Remove plastic tie holding side discharge chute up and lower into place.

Check

Side Discharge Chute

the Leveling 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 51.

Assembly

Activate

the Battery

Bulk electrolyte with 1.260 specific gravity must be purchased from a local battery supply outlet.

1. Tilt seat up and remove battery.

2. First disconnect the negative battery cable and

ground wire from the negative (–) battery terminal.

3. Slide the red terminal boot off the positive (red)

battery terminal. Then remove positive (red) battery cable.

4. Remove battery hold down clamp. IMPORTANT: Be careful not to damage the

long vent tube when removing the battery box.

POTENTIAL HAZARD

• Battery electrolyte contains sulfuric acid

which is a deadly poison and it causes severe burns.

5. Remove filler caps from the battery. Slowly pour

electrolyte into each cell until the electrolyte level is up to the lower part of the tube (Fig. 5).

m–1262

Figure 5

1. Filler

2. Electrolyte

caps

Lower part of the tube

6. Leave the covers off and connect a 3 to 4 amp

battery charger to the battery posts (Fig. 6). Charge the battery at a rate of 4 amperes or less for 4 hours (12 volts).

WHAT CAN HAPPEN

• If you carelessly drink electrolyte you could

die or if it gets onto your skin you will be burned.

HOW TO AV

OID THE HAZARD

• Do not drink electrolyte and avoid contact

with skin, eyes or clothing. Wear safety glasses to shield your eyes and rubber 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.

1. Positive

Negative post

post

m–1254

Figure 6

Charger red (+) wire

Charger black (–) wire

+ 44 hidden pages