Toro 74202 Operator's Manual
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Toro 74202 Operator's Manual

250 series with 52" sfs side discharge mower
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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.

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Summary of Contents for Toro 74202

  • Page 1 250 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.
  • Page 2 The warning system in this manual identifies potential hazards and has special safety messages that All of us at Toro want you to be completely satisfied help you and others avoid personal injury, even death. with your new product, so feel free to contact your...

  • Page 3: Table Of Contents

    Contents Page Page Adjusting Height-of-Cut ....Safety ....... . . Adjusting Anti-Scalp Rollers .
  • Page 4 Contents...

  • Page 5: Safety

    Safety Safe Operating Practices This machine meets or exceeds CPSC blade safety requirements for rotary mowers and the B71.4 1990 specifications of the American This product is capable of amputating hands and feet National Standards Institute, in effect at time of and throwing objects.
  • Page 6 Safety General Operation 12. Stop the engine before removing the grass catcher or unclogging the chute. Read, understand, and follow all instructions in 13. Mow only in daylight or good artificial light. the operator’s manual and on the machine before starting.
  • Page 7 Safety Slope Operation Check carefully for overhead clearances (i.e. branches, doorways, electrical wires) before Slopes and ramps are a major factor related to driving under any objects and do not contact loss-of-control and tip-over accidents, which can them. result in severe injury or death. All slopes and ramps DO NOT require extra caution.
  • Page 8 Safety Never allow children to operate the machine. Mower blades are sharp and can cut. Wrap the blade(s) or wear gloves, and use extra caution Use extra care when approaching blind corners, when servicing them. shrubs, trees, the end of a fence or other objects that may obscure vision.

  • Page 9: Slope Chart

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

  • Page 11: Safety And Instruction Decals

    Safety 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. TOP OF CONSOLE UNDER SEAT (Part No. E513747) ON RIGHT SIDE OF HEIGHT OF ON LEFT SIDE OF ON TOP OF CONSOLE LEFT...
  • Page 12 Safety ON RUBBER FLAP BEHIND SEAT UNDER FOOTREST (Part No. E513748) (Part No. E633766) ON RUBBER FLAP BEHIND SEAT (Part No. E303517) ON TOP OF RIGHT ENGINE BAFFLE (Part No. E633771) ON CONSOLE AND RUBBER FLAP BEHIND SEAT (Part No. E633462) ON CONTROL PANEL (Part No.
  • Page 13 Safety ON LEFT SIDE GAS TANK ON TOP OF HYDRAULIC (Part No. 99–4632) RESERVOIR (Part No. E513890) ON HYDRAULIC RESERVOIR MOUNTING BRACKET (Part No. E513929) ON DECK SUPPORT FRAME (Part No. E633818)
  • Page 14 Safety UNDER FOOTREST AND (2) UNDER PULLEY COVERS (Part No. 98–5954) 115–149 N m 85–110 Ft Lbs...

  • Page 15: Gasoline And Oil

    Gasoline and Oil Recommended Gasoline Use UNLEADED Regular Gasoline suitable for POTENTIAL HAZARD automotive use (85 pump octane minimum). Leaded In certain conditions gasoline is extremely regular gasoline may be used if unleaded regular is flammable and highly explosive. not available. WHAT CAN HAPPEN IMPORTANT: Never use methanol, gasoline A fire or explosion from gasoline can burn...

  • Page 16: Stabilizer/Conditioner

    Gasoline and Oil Stabilizer/Conditioner Filling the Fuel Tank Add the correct amount of gas stabilizer/conditioner Shut the engine off and set the parking brake. to the gas. Using a stabilizer/conditioner in the Clean around each fuel tank cap and remove the machine: cap.

  • Page 17: Assembly

    Install seat rod Locknut 5/16” Control lever–right Control lever–left Install motion control levers Bolt 3/8–1 x 1” (26 mm) Spring washer 3/8” Operator’s Manual Read before operating machine Engine Operator’s Manual Parts Catalog Fill out and return to Toro Registration card...

  • Page 18: Install Drive Wheels

    Assembly Install Drive Wheels Install Seat Retaining Rod Uncrate mower. Tilt seat up. Remove 5/16” (8mm) locknut from bolt attaching seat retaining rod to seat frame Remove wheel nuts from rear wheel hubs. (Fig. 2). Align holes. Mount drive wheels with the valve Remove retaining rod from seat and insert the stem to the outside of the traction unit.

  • Page 19: Install Motion Control Levers

    Assembly Install Motion Control Levers 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 Remove the (4) 3/8–16 x 1” (26 mm) bolts and moving the levers outward to the neutral lock (4) 3/8”...

  • Page 20: Activate The Battery

    Assembly Activate the Battery 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). Bulk electrolyte with 1.260 specific gravity must be purchased from a local battery supply outlet. Tilt seat up and remove battery.

  • Page 21: Install Battery

    Assembly Install Battery Position battery in tray with terminal posts POTENTIAL HAZARD toward the engine (Fig. 7). Charging battery produces gasses. 10. Install the positive (red) battery cable to positive WHAT CAN HAPPEN (+) battery terminal then negative battery cable Battery gasses can explode.

  • Page 22: Hydraulic System

    Assembly Hydraulic System Checking the Hydraulic Fluid Check the hydraulic fluid level before engine is first started. Fluid Type: Mobil 1 15W–50 synthetic motor oil. IMPORTANT: Use only oil specified. Other fluids could cause system damage. Figure 8 Hydraulic System Oil Capacity: 2.1 qt. (2.0 l) 1.

  • Page 23: Operation

    Operation Think Safety First Parking Brake Please carefully read all the safety instructions on Always set the parking brake when you stop the pages 3–8. Knowing this information could help you, machine or leave it unattended. your family, pets or bystanders avoid injury. Setting the Parking Brake Controls Move the motion control levers (Fig.

  • Page 24: Starting And Stopping The Engine

    Operation Releasing the Parking Brake Turn ignition key “START” to energize starter. When engines starts, release key (Fig. 6). Push forward and down on the parking brake IMPORTANT: Do not engage starter for lever to release the parking brake (Fig. 2). The more than 10 seconds at a time.

  • Page 25: Operating The Power Take Off (Pto)

    Operation Stopping Operating the Power Take Off (PTO) Move the throttle lever to “SLOW” (Fig. 5). Turn the ignition key to “OFF” (Fig. 6). The power take off (PTO) switch engages and disengages power to the electric clutch. Note: If the engine has been working hard or is hot, let it idle for a minute before turning the ignition key “OFF.”...

  • Page 26: The Safety Interlock System

    Operation The Safety Interlock System Testing the Safety Interlock System Test the safety interlock system before you use the Understanding the Safety Interlock machine each time. If the safety system does not System operate as described below, have an Authorized Service Dealer repair the safety system immediately.

  • Page 27: Driving Forward Or Backward

    Operation Driving Forward or Backward Backward Move levers to the center, un-locked position. The throttle control regulates the engine speed as measured in rpm (revolutions per minute). Place the To go backward, slowly pull the motion control throttle control in the “FAST” position for best levers rearward (Fig.

  • Page 28: Instruments

    Operation Instruments Fuel Tanks The unit has two fuel tanks, one located on the left Hour Meter side and on the right side. Each tank connects to the fuel shut off valve in the control panel. From there a The hour meter records the number of hours the common fuel line leads to the engine (Fig.

  • Page 29: Adjusting Height-Of-Cut

    Operation Adjusting Height-of-Cut Adjusting Anti-Scalp Rollers The height-of-cut is adjusted from 1-1/2” to 5” Whenever you change the height-of-cut it is (38 to 127 mm) in 1/4” (6 mm) increments by recommended to adjust the height of the anti-scalp relocating clevis pin in different hole locations. rollers.

  • Page 30: Positioning The Seat

    Operation Center Rollers Positioning the Seat Disengage the power take off (PTO) and turn the The seat can move forward and backward. Position ignition key to “OFF”. Move controllers to the seat where you have the best control of the neutral locked position and apply parking brake.

  • Page 31: Pushing The Machine By Hand

    Operation Pushing the Machine by Hand IMPORTANT: Always push the machine by hand. Never tow the machine because hydraulic damage may occur. To Push the Machine Disengage the power take off (PTO) and turn the ignition key to “OFF” to stop the engine. Move controllers to neutral locked position and apply parking brake.

  • Page 32: Tips For Mowing Grass

    File down any nicks and sharpen the blades first mow at a high cutting height; then mow again as necessary. If a blade is damaged or worn, replace it two days later at a lower height setting. immediately with a genuine TORO replacement blade.

  • Page 33: Maintenance

    Maintenance Service Interval Chart Each Storage Service Operation Hours Hours Hours Hours Hours Service Hydraulic fluid–check level Initial Initial Oil—check level Oil—change* Initial Oil Filter–change (200 hours or every other oil change)* Hydraulic filter–change Initial Safety System—check Chassis—grease* Linkage bushings—oil* Foam Air Cleaner—service* Paper Air Cleaner—replace* Spark Plug(s)—check...

  • Page 34: Cutting Blades

    File down any nicks and sharpen the blades as necessary. If a blade is damaged or worn, replace it immediately with a genuine TORO replacement blade. For convenient sharpening and replacement, you may want to keep extra blades on hand.
  • Page 35 Maintenance Inspecting the Blades Checking for Bent Blades Inspect the cutting edges (Fig 16). If the edges Rotate the blades until the ends face forward and are not sharp or have nicks, remove and sharpen backward (Fig. 17). Measure from a level the blades.
  • Page 36 Blades must be replaced if a solid object is hit, if the edges. blade is out of balance or is bent. To ensure optimum performance and continued safety conformance of the machine, use genuine TORO replacement blades. Replacement blades made by other manufacturers may result in non-conformance with safety standards. m–1854 Figure 19 1.

  • Page 37: Air Cleaner

    Maintenance Installing the Blades Air Cleaner Install the blade onto the spindle shaft (Fig. 21). Foam Element: Clean and re-oil after every 25 operating hours. IMPORTANT: The curved part of the blade must be pointing upward toward the inside of Paper Element: Replace after every 100 operating the mower to ensure proper cutting.
  • Page 38 Maintenance Carefully slide the foam element off the paper Paper Element element (Fig. 22). A. Lightly tap the element on a flat surface to Unscrew the cover nut and remove the cover and remove dust and dirt (Fig. 24). paper element (Fig. 22). B.

  • Page 39: Engine Oil

    Maintenance Engine Oil Checking Oil Level Note: Check oil when engine is cold. Change oil: Disengage the power take off (PTO) and turn the After the first 8 operating hours. ignition key to “OFF” to stop the engine. Move controllers to neutral locked position and apply After every 100 operating hours.
  • Page 40 Maintenance Changing/Draining Oil Change Oil Filter Start the engine and let it run five minutes. This Replace the oil filter every 200 hours or every other warms the oil so it drains better. oil change. Park the machine so that the drain side is slightly Note: Change oil filter more frequently when lower than the opposite side to assure the oil...

  • Page 41: Spark Plug

    Maintenance Spark Plug Checking the Spark Plug Look at the center of the spark plug(s) (Fig. 29). Check the spark plug(s) after every 200 operating If you see light brown or gray on the insulator, hours. Make sure the air gap between the center and the engine is operating properly.

  • Page 42: Greasing And Lubrication

    Maintenance Greasing and Lubrication Where to Add Grease Lubricate the grease fittings as shown on the CHECK Lubricate the machine when shown on the CHECK SERVICE REFERENCE AID decal (Fig. 30). SERVICE REFERENCE AID decal (Fig. 30). Grease more frequently when operating conditions are extremely dusty or sandy.

  • Page 43: Cleaning The Cooling Systems

    Maintenance Cleaning the Cooling Systems Fuel Filter Before each use, check and clean cooling screen. Replace the fuel filter after every 200 operating hours Remove any build–up of grass, dirt or other debris or yearly, whichever occurs first. from the oil cooler screen and engine air intake. Every 100 hours clean oil cooler, engine cylinder and Replacing the Fuel Filter cylinder head cooling fins.

  • Page 44: Fuel Tank

    Maintenance Fuel Tank Pull the fuel line off fuel filter (Fig. 34). Open fuel shut-off valve and allow gasoline to drain into a gas can or drain pan. Draining The Fuel Tank Note: Now is the best time to install a new fuel filter because the fuel tank is empty.

  • Page 45: Hydraulic System

    Maintenance 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. Figure 35 Fluid Type: Mobil 1 15W–50 synthetic motor oil. 1.
  • Page 46 Maintenance Replacing the Hydraulic Filter When fluid overflows filter turn the oil filter clockwise until the rubber gasket contacts the Change the hydraulic filter: filter adapter, then tighten the filter an additional 1/2 turn (Fig. 37). After the first 8 operating hours. Clean up any spilled fluid.
  • Page 47 Maintenance Bleeding Hydraulic System Check Hydraulic Lines The traction system is self bleeding, however, it may After every 100 operating hours, check hydraulic be necessary to bleed the system if fluid is changed or lines and hoses for leaks, loose fittings, kinked lines, after work is performed on the system.

  • Page 48: Adjusting Motion Controls

    Maintenance Adjusting Motion Controls Adjusting Handle Neutral If motion control levers do not align, or move easily into the console notch, adjustment is required. Adjust each lever, spring and rod separately. Note: Motion control levers must be installed correctly. See Install Motion Control Levers on page 17.
  • Page 49 Maintenance 10. Disconnect electrical connector from the seat 16. Repeat on opposite side of unit. Tighten locknuts safety switch. Temporarily install a jumper wire against ball joints. across terminals in the wiring harness connector. 11. Loosen locknut at ball joint on pump control rod (Fig.

  • Page 50: Replacing The Pump Drive Belt

    Maintenance Replacing the Pump Drive Belt Adjustment Parking Brake Check pump drive belt for wear after every 50 hours Check parking brake for proper adjustment. of operation. Disengage brake lever (lever down). Pull spring loaded idler down and remove Measure the length of the spring. Measurement traction belt from the engine and hydro pump should be 2.75”...

  • Page 51: Fuse

    Maintenance Fuse Service Interval/Specification The electrical system is protected by fuses. It requires no maintenance, however, if a fuse blows check component/circuit for malfunction or short. Fuse: Main F1–20 amp, blade-type Alternator F2–20 amp, blade-type Raise the seat to gain access to fuse holder (Fig. 41).

  • Page 52: Battery

    Maintenance Battery IMPORTANT: Do not overfill the battery because electrolyte (sulfuric acid) can cause severe corrosion and damage to the chassis. Check the electrolyte level in the battery every 25 hours. Always keep the battery clean and fully Press the filler caps onto the battery. charged.

  • Page 53: Mower Leveling

    Maintenance Mower Leveling Lift up on four (4) top chain attachment bolts, in the slots, to take slack out of chains and tighten flange lock nuts (Deck is still supported by two Position mower on a flat surface. Stop the rear and one front blocks under mower) engine, set the parking brake, remove the key and disconnect the spark plug wire(s) from the...

  • Page 54: Greasing The Bearings

    Maintenance Compression Spring Adjustment Greasing the Bearings Raise deck lift lever to the transport position, The cutting unit must be lubricated regularly. Refer to (Fig. 43). the Service Interval Chart on page 31. Grease with No. 2 general purpose lithium base or molybdenum Springs are compressed so the distance between base grease.

  • Page 55: Replacing The Deck Belt

    Maintenance Replacing the Deck Belt Replacing the PTO Drive Belt Squealing when the belt is rotating, blades slipping Squealing when the belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks and when cutting grass, frayed belt edges, burn marks and cracks are signs of a worn deck belt.
  • Page 56 Maintenance Note: Check position of center bolt in Low If the fixed idler contacts the end of the Height of Cut. The center bolt must be adjustment slot and more belt tension is at or below the top alignment hole. required, a small change in the lengthen the push Check position of center bolt in a High arms can be made (Fig.

  • Page 57: Replacing The Grass Deflector

    Maintenance Replacing the Grass Deflector Remove the locknuts, bolts and springs holding the deflector mounts to the pivot brackets (Fig. 52). If the pivot brackets need to be replaced, remove the carriage bolts and cone locknuts holding the old brackets to the top of the discharge opening, then install the replacement pivot brackets.

  • Page 58: Wiring Diagram

    Maintenance Wiring Diagram...

  • Page 59: Cleaning And Storage

    Maintenance Cleaning and Storage 11. For long-term storage (more than 90 days) add stabilizer/conditioner additive to fuel in the tank (1 oz. per gallon). Disengage the power take off (PTO), set the parking brake and turn the ignition key to “OFF” A.

  • Page 60: Troubleshooting

    Troubleshooting PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION Starter does not crank Blade control (PTO) is Move blade control (PTO) to ENGAGED. DISENGAGED. Parking brake is not on. Set parking brake. Operator is not seated. Sit on the seat. Battery is dead. Charge the battery.
  • Page 61 Troubleshooting PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION Engine overheats. Engine load is excessive. Reduce ground speed. Oil level in crankcase is low. Add oil to crankcase. Cooling fins and air passages Remove obstruction from under engine blower housing cooling fins and air passages. are plugged.
  • Page 62 Troubleshooting PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION Blades do not rotate. Drive belt is worn, loose or Install new drive belt. broken. Drive belt is off pulley. Install drive belt and check adjusting shafts and belt guides for correct position. Deck belt is worn, loose or Install new deck belt.

  • Page 64: Warranty

    What Is Covered By This Express Warranty? analysis of the defect in materials or workmanship or if you need a referral to a TORO ProLine Service Dealer, please feel free to The Toro Company promises to repair any TORO Product...

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