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Toro Z257 Z-Master, Operator'S Manual

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Toro Z257 Z-Master Operator'S Manual Download Page 55

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Summary of Contents for Z257 Z-Master

Page 1: ...Operator s Manual English EN Form No 3329 540 Z257 Z Master with 72 SFS Side Discharge Mower Model No 74232 Serial No 230006001 Up ...

Page 2: ...g the Seat Retaining Rod 14 Installing the Motion Control Levers 15 Activating the Battery 15 Installing the Air Cleaner 16 Checking the Hydraulic Fluid 17 Greasing the Bearings 17 Checking the Side Discharge Chute 17 Page Checking the Level of Mower Deck 17 Checking the Engine Oil Level 17 Operation 18 Think Safety First 18 Controls 18 Operating the Parking Brake 19 Starting and Stopping the Engi...

Page 3: ...ords to highlight information Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention Safety This machine meets or exceeds the B71 4 1999 specifications of the American National Standards Institute in effect at time of production Note The addition of attachments made by other manufacturers that do not meet American National St...

Page 4: ...rator s position for any reason including emptying the catchers or unclogging the chute Stop equipment and inspect blades after striking objects or if an abnormal vibration occurs Make necessary repairs before resuming operations Keep hands and feet away from the cutting units Never carry passengers and keep pets and bystanders away Be alert slow down and use caution when making turns Look behind ...

Page 5: ...up oil or fuel spillage Let engine cool before storing and do not store near flame Shut off fuel while storing or transporting Do not store fuel near flames or drain indoors Park machine on level ground Never allow untrained personnel to service machine Use jack stands to support components when required Carefully release pressure from components with stored energy Disconnect battery or remove spa...

Page 6: ...6 Slope Chart ...

Page 7: ...7 ...

Page 8: ...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 633345 1 633706 1 633462 1 643339 1 523552 1 633766 1 643401 ...

Page 9: ...9 1 633818 98 3798 98 4387 1 Warning wearhearing protection 98 5954 43 8480 54 9220 66 1340 67 5360 103 0262 ...

Page 10: ...N m 85 110 lb 99 4632 1 Engine stop 2 Engine run 3 Engine start 99 4686 103 0368 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 104 7759 104 8172 104 8569 ...

Page 11: ...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 7 Maximum fill line 8 Minimum fill line 9 Instructions for activating the battery 103 2433 106 6570 ...

Page 12: ...12 106 6571 ...

Page 13: ...ible 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 is harmful or fatal if swallowed Long term exposure to vapors can cause serious injury and illness Avoid ...

Page 14: ...erator s Manual Engine Operator s Manual Parts Catalog Registration card 2 1 1 1 1 Read before operating machine Fill out and return to Toro Installing the Drive Wheels 1 Uncrate the 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 95 ft lb 128 N M Important Make sure...

Page 15: ...unting plate toward the rear on the outside of the control arm shaft and secure with 4 bolts 3 8 x 1 inch and 4 spring washers 3 8 in Fig 4 3 Position the levers so the bolts are in the center of the slots on the lever mounting plate and tighten until snug 4 Align the front rear position of the levers with each other in the neutral position Loosen hardware and adjustment by sliding tilting the lev...

Page 16: ...an cause severe corrosion and damage to the chassis 5 Wait five to ten minutes after filling the battery cells Add electrolyte if necessary until the electrolyte level is up to the upper line Fig 6 on the battery case 6 Reinstall battery filler caps 1 2 3 m 5004 Figure 6 1 Filler caps 2 Upper line 3 Lower line Charging battery produces gasses that can explode and cause serious injury Keep cigarett...

Page 17: ...luid Check the hydraulic fluid level before the engine is first started Refer to Checking the Hydraulic Fluid on page 37 Greasing the Bearings Important Make sure cutting unit spindles are full of grease before engine is first started Grease with No 2 general purpose lithium base or molybdenum base grease 1 Grease the fittings on the three spindle bearings Grease until it comes out lower seals Fig...

Page 18: ...d and use extreme caution on slopes Avoid sudden turns or rapid speed changes 2 3 1 m 6478 Figure 9 1 Safe Zone use the Z Master here on slopes less than 15 degrees or flat areas 2 Use walk behind mower and or hand trimmer near drop offs and water 3 Water The use of protective equipment for eyes ears feet and head is recommended This machine produces sound levels in excess of 85 dBA at the operato...

Page 19: ...otion control levers Fig 11 out to the neutral lock position 2 Pull back and up on the parking brake lever to set the parking brake Fig 14 The parking brake lever should stay firmly in the engaged position Parking brake may not hold machine parked on a slope and could cause personal injury or property damage Do not park on slopes unless wheels are chocked or blocked Warning Releasing the Parking B...

Page 20: ...Pull wire off spark plug s to prevent possibility of someone accidentally starting the machine before transporting or storing machine 6 Close fuel shut off valve on front panel before transporting or storing machine 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 r...

Page 21: ...otion control levers to neutral lock position Now start the engine While the engine is running release the parking brake engage the PTO and rise slightly from the seat the engine should stop 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 a...

Page 22: ...ile it is unattended Always remove the ignition key and set the parking brake when leaving the machine unattended even if just for a few minutes Caution Adjusting the Height of Cut 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 1 Raise the height of cut lever to the transport position also the 5 inch ...

Page 23: ...rward and backward Position the seat where you have the best control of the machine and are most comfortable 1 To adjust move the lever sideways to unlock seat Fig 24 2 Slide the seat to the desired position and release lever to lock in position 1 m 3655 Figure 24 1 Adjustment lever Pushing the Machine by Hand Important Always push the machine by hand Never tow the machine because hydraulic damage...

Page 24: ...lic street or roadway Warning Loading Machines 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 26 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 r...

Page 25: ... tipping backward Warning m 6841 1 4 1 2 3 Figure 26 1 Trailer 2 Full width ramp 3 Not greater than 15 degrees 4 Full width ramp side view Using the Z Stand 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 Unit could fall onto someone and cause serious injury or death Use extreme caution when operating unit on Z Stand Use o...

Page 26: ...ips for Mowing Grass Fast Throttle Setting For best mowing and maximum air circulation operate the engine at fast Air is required to thoroughly cut grass clippings so do not set the height of cut so low as to totally surround the mower by uncut grass Always try to have one side of the mower free from uncut grass which allows air to be drawn into the mower Cutting a Lawn for the First Time Cut gras...

Page 27: ...When Stopping If the machine s forward motion must be stopped while mowing a clump of grass clippings may drop onto your lawn To avoid this move onto a previously cut area with the blades engaged Keep the Underside of the Mower Clean Clean clippings and dirt from the underside of the mower after each use If grass and dirt build up inside the mower cutting quality will eventually become unsatisfact...

Page 28: ...ic fluid check level Battery check electrolyte Every 50 Hours Belts check for wear cracks Tires check pressure Every 100 Hours Engine Oil change1 Hydraulic lines check Engine Cooling System clean1 Every 200 Hours Oil Filter change 200 hours or every other oil change 1 Hydraulic filter change Spark Plug s check Fuel Filter replace Primary air cleaner service1 Every 500 Hours or at Storage Caster Pi...

Page 29: ...a blades on hand Danger A worn or damaged blade can break and a piece of the blade could be thrown into the operator s or bystander s area resulting in serious personal injury or death Inspect the blade periodically for wear or damage Replace a worn or damaged blade Before Inspecting or Servicing the Blades Disengage the blade control PTO and set the parking brake Turn the ignition key to off Remo...

Page 30: ... can cause serious injury Wear gloves or wrap sharp edges of the blade with a rag Warning 1 Hold the blade end using a rag or thickly padded glove Remove the blade bolt spring disk and blade from the spindle shaft Fig 35 Sharpening the Blades When sharpening blade pieces of blade could be thrown and cause serious injury Wear proper eye protection when sharpening blade Warning 1 Use a file to sharp...

Page 31: ...into the filter while shining a bright light on the outside of the filter Holes in the filter will appear as bright spots If the filter is damaged discard it 4 3 5 1 2 1 m 4815 Figure 36 1 Latches 2 Air cleaner cover 3 Air filter body 4 Primary filter 5 Safety filter Servicing the Primary Filter Check and or replace it after 200 operating hours If the primary filter is dirty bent or damaged then r...

Page 32: ...tube to raise the level to the full mark Important Do not overfill the crankcase with oil because the engine may be damaged Do not run engine with oil below the low mark because the engine may be damaged 3 m 3219 1 2 m 4811 Figure 37 1 Oil dipstick 2 Filler tube 3 Metal end Changing the Engine Oil 1 Start the engine and let it run five minutes This warms the oil so it drains better 2 Park the mach...

Page 33: ...e sure the air gap between the center and side electrodes is correct before installing the spark plug Use a spark plug wrench for removing and installing the spark plug s and a gapping tool feeler gauge to check and adjust the air gap Install a new spark plug s if necessary Type Champion RC12YC or equivalent Air Gap 0 030 inch 0 76 mm Removing the Spark Plug s 1 Disengage the power take off PTO an...

Page 34: ...43 6 Wipe up any spilled fuel 7 Open fuel shut off valve on console 1 2 m 3217 Figure 42 1 Filter 2 Hose clamp Servicing the Fuel Tank Draining The Fuel Tank Danger 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 Drain gasoline from the fuel tank when the engine is cold Do this outdoors in ...

Page 35: ...s Keep dust cap off until greasing is done 2 Adjust the caster pivot bearing Refer to Adjusting the Caster Pivot Bearing page 37 3 Remove the hex plug Thread a grease zerk into hole 4 Pump grease into zerk until it oozes out around top bearing 5 Remove grease zerk in hole Reinstall hex plug and cap Where to Add Grease Lubricate the grease fittings as shown on the Check Service Reference Aid decal ...

Page 36: ...gine shroud 3 Screws 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 48 Check the tires when they are cold to get the most accurate pressure reading Pressure 13 psi 90 kPa drive wheels and caster wheels 1 m...

Page 37: ...pring Washers 2 Lock Nut 3 Dust Cap Servicing the Hydraulic System Checking the Hydraulic Fluid Check the hydraulic fluid level before engine is first started Check the hydraulic fluid level after first 8 operating hours Check the hydraulic fluid level after every 25 operating hours Fluid Type Mobil 1 15W 50 synthetic motor oil or equivalent synthetic oil Important Use oil specified or equivalent ...

Page 38: ...Warning Replacing the Hydraulic Filter Change the hydraulic filter After the first 8 operating hours After every 200 operating hours 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 Do not substitute automotive oil filter or severe hydraulic system damage may result 2 Remove hydro cap and tem...

Page 39: ...f 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 Safely relieve all pressure in the hydraulic system before performing any wor...

Page 40: ...rting machine Do not use hydraulic jacks Engine must be running so motion control adjustment can be performed Contact with moving parts or hot surfaces may cause personal injury Keep hands feet face clothing and other body parts away from rotating parts muffler and other hot surfaces Warning This adjustment must be made with drive wheels turning 1 Raise the frame and block up the machine so drive ...

Page 41: ...m wire harness connector and plug connector into seat switch when adjustment is completed Never operate this unit with jumper installed and seat switch bypassed Warning 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 Adjusting the Tracking The right han...

Page 42: ...t until the correct measurement is obtained Tighten the two nuts together and repeat on opposite side of unit 4 Turn nuts clockwise to shorten spring length and turn counter clockwise to lengthen the spring 5 Engage parking brake lever up 6 Measure the distance between the trunnion roller and the collar on brake rod Measurement should be 3 16 1 4 inch 5 7 mm Fig 59 7 If adjustment is necessary loo...

Page 43: ...1 2 3 m 5004 Figure 61 1 Filler caps 2 Upper line 3 Lower line Danger Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns 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 ...

Page 44: ...negative black cable Warning 1 Disengage the power take off PTO set the parking brake and turn the ignition key to off Remove the key 2 Tilt seat up 3 First disconnect the negative battery cable and ground wire from the negative battery terminal Fig 62 4 Slide the red terminal boot off the positive red battery terminal Then remove positive red battery cable Fig 62 5 Remove both wing nuts 1 4 inch ...

Page 45: ... parking brake remove the key and disconnect the spark plug wire s from the spark plug s 2 Check tire pressure of all four 4 tires If needed adjust to 13 psi 90 kPa 3 Set anti scalp rollers to top holes or remove them completely for this adjustment 4 Raise the deck to the transport position and take all force off of the two large deck lift springs by loosening nut in front of each spring Fig 65 5 ...

Page 46: ...ansport position 3 Raise the front of the machine by using the Z Stand refer to Using the Z Stand page 25 Unit could fall onto someone and cause serious injury or death 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 Always shut engine off and set parking brake before performing any maintenan...

Page 47: ...emove bolt nut washer and spacer from idler pulley bracket assembly Remove belt from bracket assembly Fig 68 5 Install new PTO drive belt over clutch around rear idler pulleys and onto mower top center pulley Note Check that belt has only 1 4 twist between each pulley and idler 6 Install belt into idler pulley bracket assembly Install bolt nut washer and spacer into assembly Fig 68 Note Idler belt...

Page 48: ...portant If the push arm lengths are changed then the mower deck must be leveled See Leveling the Mower on page 45 4 3 2 1 m 6273 Figure 71 1 Push arm 2 15 5 16 inch 389 mm nominal 3 Jam nut 4 Ball joint Replacing the Grass Deflector An uncovered discharge opening could allow the lawn mower to throw objects in the operator s or bystander s direction and result in serious injury Also contact with th...

Page 49: ...reat to people or the environment This information is presented to users so that they are aware that these switches contain mercury and will apply sound disposal practices when these devices reach their normal end of life or are damaged Disposing the Mercury Tilt Switch Several states have passed laws concerning the disposal of devices containing mercury In all the remaining states it is advisable...

Page 50: ... IN OFF POSITION GY S X Y B BN BU IGNITION BROWN WIRE COLOR CODES NEUTRAL SW5 VIO BRAKE SW3 SHOWN WITH PARK BRAKE DISENGAGED P1 A SW6 SEAT SW F1 20A BATTERY GND ORANGE GREEN DELAY MODULE 100 6186 2 3 5 4 1 SHOWN WITH OPERATOR IN SEAT ST B STARTER SW4 NEUTRAL PTO SW2 REG MAG FUEL OIL AC FUEL SOLINIOD OIL SWITCH SPARK PLUG SPARK PLUG IGNITION MODULES AC PTO CLUTCH TERMINAL VIEW FROM BACK OF SWITCH O...

Page 51: ...ioner to fuel in the tank Follow mixing instructions from stabilizer manufacture Do not use an alcohol based stabilizer ethanol or methanol Note A fuel stabilizer conditioner is most effective when mixed with fresh gasoline and used at all times B Run engine to distribute conditioned fuel through the fuel system 5 minutes C Stop engine allow to cool and drain the fuel tank refer to Servicing the F...

Page 52: ... gap is incorrect 5 Install new correctly gapped spark plugs 6 Dirt in fuel filter 6 Replace fuel filter 7 Dirt water or stale fuel is in fuel system 7 Contact Authorized Service Dealer Engine loses power 1 Engine load is excessive 1 Reduce ground speed g 2 Air cleaner is dirty 2 Clean air cleaner element 3 Oil level in crankcase is low 3 Add oil to crankcase 4 Cooling fins and air passages under ...

Page 53: ...ent 6 Contact Authorized Service Dealer Uneven cutting height 1 Blade s not sharp 1 Sharpen blade s g g 2 Cutting blade s is are bent 2 Install new cutting blade s 3 Mower is not level 3 Level mower from side to side and front to rear 4 Gage wheel not set correctly 5 Underside of mower is dirty 4 Adjust gage wheel height 5 Clean the underside of the mower 6 Tire pressure is incorrect 6 Adjust tire...

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Page 56: ...vered There is no other express warranty except for special emission system coverage on some products This express warranty does not cover the following Cost of regular maintenance service or parts such as filters fuel lubricants tune up parts blade sharpening brake and clutch adjustments Any product or part which has been altered or misused or required replacement or repair due to normal wear acc...

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