Toro Z-Master 250 Series User manual

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.
FORM NO. 3322–728
Z–Master
250 Series
Z255
with 62” SFS Side
Discharge Mower
Model No. 74203–994001 & Up

The Toro Company – 1999
All Rights Reserved
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 .
1
1. Model and Serial Number Plate
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.
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.
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.

1
Contents
Page
Safety 3.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Operating Practices 3 . . . . . . . . . . . . . .
Slope Chart 7 . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 9 . . . . . . . . . .
Gasoline and Oil 13 . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Gasoline 13 . . . . . . . . . . . . . .
Stabilizer/Conditioner 14 . . . . . . . . . . . . . . . .
Filling the Fuel Tank 14 . . . . . . . . . . . . . . . . .
Check Engine Oil Level 14 . . . . . . . . . . . . . . .
Assembly 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts 15 . . . . . . . . . . . . . . . . . . . . . . . . .
Install Drive Wheels 16 . . . . . . . . . . . . . . . . . .
Tire Pressure 16 . . . . . . . . . . . . . . . . . . . . . . . .
Install Seat Retaining Rod 16 . . . . . . . . . . . . .
Install Motion Control Levers 17 . . . . . . . . . .
Check Side Dischar ge Chute 17 . . . . . . . . . . .
Check the Leveling of Mower Deck 17 . . . . .
Activate the Battery 18 . . . . . . . . . . . . . . . . . .
Install Battery 19 . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic System 20 . . . . . . . . . . . . . . . . . . . .
Operation 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . .
Page
Adjusting Height-of-Cut 27 . . . . . . . . . . . . . .
Adjusting Anti-Scalp Rollers 27 . . . . . . . . . . .
Positioning the Seat 28 . . . . . . . . . . . . . . . . . .
Pushing the Machine by Hand 28 . . . . . . . . . .
Tips for Mowing Grass 29 . . . . . . . . . . . . . . .
Maintenance 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Interval Chart 30 . . . . . . . . . . . . . . . .
Cutting Blades 31 . . . . . . . . . . . . . . . . . . . . . .
Air Cleaner 34 . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Oil 36 . . . . . . . . . . . . . . . . . . . . . . . . .
Spark Plug 38 . . . . . . . . . . . . . . . . . . . . . . . . .
Greasing and Lubrication 39 . . . . . . . . . . . . . .
Cleaning the Cooling Systems 40 . . . . . . . . . .
Tire Pressure 40 . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter 40 . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank 41 . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic System 42 . . . . . . . . . . . . . . . . . . . .
Adjusting Motion Controls
45 . . . . . . . . . . . .
Replacing the Pump Drive Belt 47 . . . . . . . . .
Adjustment Parking Brake 47 . . . . . . . . . . . . .
Fuse 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mower Leveling 50 . . . . . . . . . . . . . . . . . . . . .
Greasing the Bearings 51 . . . . . . . . . . . . . . . .
Belt Inspection 51 . . . . . . . . . . . . . . . . . . . . . .
Replacing the Deck Belt 52 . . . . . . . . . . . . . .
Replacing the PTO Drive Belt 52 . . . . . . . . . .
Replacing the Grass Deflector 54 . . . . . . . . . .
Wiring Diagram 55 . . . . . . . . . . . . . . . . . . . . .
Cleaning and Storage 56 . . . . . . . . . . . . . . . . .
Troubleshooting 57 . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty 62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THE ENCLOSED ENGINE OWNER’S MANUAL IS SUPPLIED FOR
CALIFORNIA EMISSION CONTROL REGULATION INFORMATION ON
EMISSION SYSTEMS, MAINTENANCE AND WARRANTY.

Contents
2
KEEP THIS ENGINE OWNER’S MANUAL WITH YOUR UNIT. SHOULD THIS
ENGINE OWNER’S MANUAL BECOME DAMAGED OR ILLEGIBLE,
REPLACE IMMEDIATELY. REPLACEMENTS MA
Y BE ORDERED THROUGH
THE ENGINE MANUFACTURER.

3
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 Operating Practices
This product is capable of amputating hands and feet
and throwing objects. Always follow all safety
instructions to avoid serious injury or death.
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
4
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.
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.
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 belt are
attached to prevent the seat from pivoting
forward.

Safety
5
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.
DO
•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. Tall grass can hide obstacles.
•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.
•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.
•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.

Safety
6
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.
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.
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.
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.
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.

Safety
7
Slope Chart
Read all safety instructions on pages 4–6.

8

Safety
9
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 TE
(Part No E633345)
T OP OF CONSOLE UNDER SEA T
(Part No. E513747)
ON T OP OF CONSOLE LEFT
AND RIGHT SIDES
(Part No. E633354)
BELOW CENTER OF CONSOLE
(Part No. E633346)
ON LEFT SIDE OF
HEIGHT–OF–CUT PLA TE
(Part No E633706)

Safety
10
UNDER FOOTREST
(Part No. E633766)
ON CONTROL P ANEL
(Part No. 99–461 1)
ON T OP OF RIGHT
ENGINE BAFFLE
(Part No. E633771)
ON RUBBER FLAP BEHIND SEA T
(Part No. E513748)
ON RUBBER FLAP
BEHIND SEA T
(Part No. E303517)
ON CONSOLE AND RUBBER
FLAP BEHIND SEA T
(Part No. E633462)

Safety
11
ON LEFT SIDE GAS T ANK
(Part No. 99–4632)
ON HYDRAULIC RESER VOIR
MOUNTING BRACKET
(Part No. E513929)
ON DECK SUPPORT FRAME
(Part No. E633818)
ON T OP OF HYDRAULIC
RESERVOIR
(Part No. E513890)

Safety
12
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%'( & 
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%'( & 
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%'( & 
$    ) 
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%'( & 
UNDER FOOTREST AND (2)
UNDER PULLEY COVERS
(Part No. 98–5954)

13
Gasoline and Oil
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.
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
•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 emove gas–power ed
equipment from the truck or trailer and
refuel the equipment with its wheels on the
round.
•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
14
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 the Fuel T ank
1. Shut the engine off and set the parking brake.
2. Clean around each fuel tank cap and remove the
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.
3. Install fuel tank caps securely. Wipe up any
gasoline that may have spilled.
Check Engine Oil Level
Before you start the engine and use the machine,
check the oil level in the engine crankcase; refer to
Checking Oil Level, page 36.

15
Assembly
Loose Parts
Note: Use the chart below to verify all parts have been shipped.
DESCRIPTION QTY. USE
Rear Wheels 2 Install wheels to traction unit
Retaining rod
Bolt 5/16–18 x 1” (26 mm)
Locknut 5/16”
1
1
1
Install seat rod
Control lever–right
Control lever–left
Bolt 3/8–1 x 1” (26 mm)
Spring washer 3/8”
1
1
4
4
Install motion control levers
Key
Operator’
s Manual
Engine Operator ’ s Manual
Parts Catalog
Registration card
2
1
1
1
1
Read before operating machine
Fill out and return to T oro

Assembly
16
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)
1
m–1872
Figure 1
1. Valve stem
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.
3
1
m–3750
2
Figure 2
1. L end of retaining rod
2. Locknut 5/16”
3. Bolt 5/16–18 x 1” (26 mm)

Assembly
17
Install Motion Control Levers
1. Remove the (4) 3/8–16 x 1” (26 mm) bolts and
(4) 3/8” spring washers which attach the motion
control levers to the control arm shafts for
shipping (Fig. 3).
2. Place the levers (with the mounting plate toward
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).
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
lever(s) forward or backward until properly
aligned(Fig. 3).
m–3751
1
2
3
Figure 3
1. Mounting plate
2. Bolt 3/8–18 x 1” (26 mm)
3. Spring washer 3/8”
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
Check Side Discharge Chute
Remove plastic tie holding side discharge chute up
and lower into place.
Check 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 50.

Assembly
18
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.
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.
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).
1
2
3
m–1262
Figure 5
1. Filler caps
2. Electrolyte 3.
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).
4
1
23
m–1254
Figure 6
1. Positive post
2. Negative post
3. Charger red (+) wire
4. Charger black (–) wire