Form No. 3329–714 Z500 Z Master with 52in TURBO FORCE Side Discharge Mower Model No. 74242–240000001 & Up Operator’s Manual Register your product at www.Toro.
Warning Stopping the Machine . . . . . . . . . . . . . . . . . . . . . Adjusting the Height-of-Cut . . . . . . . . . . . . . . . . Using the Lift Assist Lever . . . . . . . . . . . . . . . . . Adjusting the Anti-Scalp Rollers . . . . . . . . . . . . . Adjusting the Flow Baffle . . . . . . . . . . . . . . . . . . Positioning the Flow Baffle . . . . . . . . . . . . . . . . . Positioning the Seat . . . . . . . . . . . . . . . . . . . . . . . Unlatching the Seat . . . . . . . . . . . . . . . . . . . . . . .
Introduction Safety Read this manual carefully to learn how to operate and maintain your product properly. The information in this manual can help you and others avoid injury and product damage. Although Toro designs and produces safe products, you are responsible for operating the product properly and safely. Improper use or maintenance by the operator or owner can result in injury.
• Use extreme care when loading or unloading the machine into a trailer or truck. • Use extra care when handling gasoline and other fuels. They are flammable and vapors are explosive. • Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision. • Use only an approved container • Never remove gas cap or add fuel with engine running. Allow engine to cool before refueling. Do not smoke. Slope Operation • Never refuel or drain the machine indoors.
• Check the area to be mowed and never fold the ROPS in areas where there are slopes, drop offs or water. • Lower the rollbar only when absolutely necessary. Do not wear the seat belt with the roll bar folded down. • Check carefully for overhead clearances (i.e. branches, doorways, electrical wires) before driving under any objects and do not contact them. Maintenance and storage • Disengage drives, lower implement, set parking brake, stop engine and remove key or disconnect spark plug wire.
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. 98-5954 1-633462 1-643339 43-8480 1-523552 54-9220 1-643401 98-4387 66-1340 1. Warning—wear hearing protection.
58-6520 1. Grease 105-7797 107-1613 104-7759 68-8340 104-8569 103-0368 105-7798 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.
107-1621 107-2102 106-9969 107-1622 11
107-2112 107-1860 107-1857 107-1861 103-2433 12
106-9989 106-7492 13
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 14 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.
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.
Operation 2 Note: Determine the left and right sides of the machine from the normal operating position. 1 Using the Rollover Protection System (ROPS) m–6836 Figure 2 Warning 1. Full down position To avoid injury or death from rollover: keep the roll bar in the raised locked position and use the seat belt. Important Always use the seat belt with the roll bar in the raised position. Ensure that the rear part of the seat is secured with the seat latch.
7. Tighten the front handles against the center roll bar ends (Fig. 3). 2 1 1 m–6897 Figure 4 1. Front handle 3 Think Safety First m–6478 Figure 5 Please read all safety instructions and symbols in the safety section. Knowing this information could help you or bystanders avoid injury. 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.
Controls Using the Hour Meter Become familiar with all the controls (Fig. 7 and 8) before you start the engine and operate the machine. The hour meter records the number of hours the engine has operated. It operates when the engine is running. Use these times for scheduling regular maintenance. 8 1 7 6 1 4 3 m–3077 Figure 9 5 1. Hour meter Operating the Parking Brake Always set the parking brake when you stop the machine or leave it unattended. 2 m–6834 Setting the Parking Brake Figure 7 1.
2 1 1 2 2 1 m–4201 m–2719 Figure 11 Figure 12 1. PTO-On 2. PTO-Off 3 1. Choke–On 2. Choke–Off m–4163 Figure 10 1. Parking brake-ON 2. Parking brake-OFF 3. Brake Stop 1 1 2 Starting and Stopping the Engine 3 2 Starting the Engine 1. Sit on the seat and move the motion controls to neutral locked position. M–4268 m–2720 Figure 13 2. Set the parking brake; refer to Setting the Parking Brake, page 18. 1. Throttle–Fast 2. Throttle–Slow 3. Move the PTO (power take off) switch to off (Fig. 11).
The Safety Interlock System Caution Caution Children or bystanders may be injured if they move or attempt to operate the tractor while it is unattended. If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes. • Do not tamper with the interlock switches.
To turn, move the motion control lever toward neutral in the direction you want to turn (Fig. 16). While the engine is running, center either motion control and move (forward or reverse); the engine should stop. Repeat for other motion control. The farther you move the traction control levers in either direction, the faster the machine will move in that direction. 5.
3. Select a hole in height-of-cut bracket corresponding to the height-of-cut desired and, insert clevis pin (Fig. 17). Adjusting the Anti-Scalp Rollers 4. Move lever to selected height. Whenever you change the height-of-cut, it is recommended to adjust the height of the anti-scalp rollers. 1 1. Disengage the power take off (PTO) and turn the ignition key to off. Move the levers to the neutral locked position and apply the parking brake. Remove the key. 2 2.
Adjusting the Flow Baffle The mower discharge flow can be adjusted for different types of mowing conditions. Position the cam locks and baffle to give the best quality of cut. 1. To adjust the cam locks, swing the lever up to loosen the cam lock (Fig. 26). 3 2. Adjust the baffle and cam locks in the slots to the desired discharge flow. 3. Swing the lever back over to tighten the baffle and cam locks. 4 1 2 4.
Positioning the Flow Baffle Position C The following figures are only recommendations for use. Adjustments will vary by grass type, moisture content, and height of grass. This is the full open position. The suggested use for this position is as follows. Note: If the engine power draws down and the mower ground speed is the same, open up the baffle. • Use in wet conditions. Position A • Allows increased ground speed in heavy conditions. This is the full rear position.
Unlatching the Seat Changing to Machine Operation Push the seat latch rearward to unlatch the seat. This will allow access to the machine under the seat. 1. Rotate the by-pass valves clockwise 1 turn to operate machine (Fig. 28). Note: Do not over tighten the by–pass valves. 3 Note: The machine will not drive unless the by-pass valves are turned in. 2 1 1 m–6840 Figure 27 1. Seat latch 2. Gas cap m–6124 3. Seat Figure 28 1.
Transporting Machines Warning 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. Loading a unit onto a trailer or truck increases the possibility of backward tip–over and could cause serious injury or death. • Use extreme caution when operating a unit on a ramp.
Tips for Mowing Grass Long Grass Fast Throttle Setting If the grass is ever allowed to grow slightly longer than normal, or if it contains a high degree of moisture, raise the cutting height higher than usual and cut the grass at this setting. Then cut the grass again using the lower, normal setting. For best mowing and maximum air circulation, operate the engine at fast.
Maintenance Recommended Maintenance Schedule Maintenance Service Interval After first 5 hours Each Use Maintenance Procedure • Hydraulic fluid—check level • Hydraulic filter—change • • • • Oil—check level Safety System—check Mower Housing—clean Engine air intake—clean1 Every 8 Hours • Cutting Blades—check Every 25 Hours • • • • • • • • Every 50 Hours • Belts—adjust tension • Belts—check for wear/cracks • Tires—check pressure Every 100 Hours • Engine Oil—change1 • Hydraulic lines—check • Engine Co
Important Refer to your engine operator’s manual for additional maintenance procedures. 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. Note: Determine the left and right sides of the machine from the normal operating position.
Checking for Bent Blades machine, use genuine TORO replacement blades. Replacement blades made by other manufacturers may result in non-conformance with safety standards. 1. Rotate the blades until the ends face forward and backward (Fig. 31). Measure from a level surface to the cutting edge of the blades (Fig. 32). Note this dimension. Warning Front Contact with sharp blade can cause serious injury. Wear gloves or wrap sharp edges of the blade with a rag. 1.
Installing the Blades Important Never attempt to clean the safety filter. If the safety filter is dirty, then the primary filter is damaged and you should replace both filters. 1. Install the blade onto the spindle shaft (Fig. 35). Important The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting. 3 4 1 2. Install the spring disk and blade bolt (Fig. 35). Torque the blade bolt to 85–110 ft-lb (115–150 N m).
Servicing the Engine Oil 2 1 3 Change oil: • After every 100 operating hours. Note: Change oil more frequently when operating conditions are extremely dusty or sandy. Oil Type: Detergent oil (API service SH, SJ, SL or higher) Crankcase Capacity: w/filter, 67 oz. (2.0 l) Viscosity: See table below m–4811 m–3219 Figure 37 USE THESE SAE VISCOSITY OILS 1. Oil dipstick 2. Filler tube 3. Metal end 10W–30 Changing the Oil 5W–20, 5W–30 –20 F 0 –30 C –20 20 –10 1.
Change the Oil Filter Removing the Spark Plug(s) Replace the oil filter every 200 hours or every other oil change. 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. Note: Change the oil filter more frequently when operating conditions are extremely dusty or sandy. 2. Pull the wire(s) off the spark plug(s) (Fig. 40).
Installing the Spark Plug(s) Servicing the Fuel Tank 1. Install the spark plug(s). Make sure the air gap is set correctly. Draining The Fuel Tank 2. Tighten the spark plug(s) to 20 ft-lb (27 N.m). Danger 3. Push the wire(s) onto the spark plug(s) (Fig. 40). 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.
Greasing and Lubrication Where to Add Grease Lubricate the machine when shown on the Check Service Reference Aid decal (Fig. 44). Grease more frequently when operating conditions are extremely dusty or sandy. Lubricate the grease fittings as shown on the Check Service Reference Aid decal (Fig. 44). Grease Type: General-purpose grease. 1. Disengage the power take off (PTO) and turn the ignition key to off. Move the levers to the neutral locked position and apply parking brake. Remove the key. 2.
Greasing the Spindles Cleaning the Cooling Systems The cutting unit must be lubricated weekly or every 25 hours. Refer to the Service Interval Chart on page 28. Grease with No. 2 general purpose lithium base or molybdenum base grease. Cleaning the Engine Screen and the Oil Cooler Important Make sure cutting unit spindles are full of grease weekly. Before each use, check and clean engine screen and oil cooler.
1 Checking the Tire Pressure 4 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. 3 2 Pressure: 13 psi (90 kPa) drive wheels and caster wheels. m–4638 Figure 49 1. Slotted nut 2. Two threads or less showing 1 3. Hole in threaded rod 4.
Servicing the Hydraulic System 1 2 Checking the Hydraulic Fluid 4 Check the hydraulic fluid level: 3 • Before the engine is first started. • After the first 8 operating hours. • After every 25 operating hours. m–5615 Fluid Type: Mobil 1 15W-50 synthetic motor oil or equivalent synthetic oil. Figure 51 1. Cap 2. Baffle Important Use oil specified or equivalent. Other fluids could cause system damage. 3. Cold fluid level—full 4. Hot fluid level—full Hydraulic System Oil Capacity: 67 oz. (2.
Replacing the Hydraulic Filter 10. Recheck the fluid level while the fluid is warm. The fluid should be between cold and hot. Change the hydraulic filter: 11. If required, add fluid to the hydraulic tank. Do not overfill. • After the first 8 operating hours. • After every 200 operating hours. Use summer filter above 32°F (0°C) 1 Use winter filter below 32°F (0°C) 3 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2 2.
9 2 Warning 1 6 7 Hydraulic fluid escaping under pressure can penetrate skin and cause injury. 3 • 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.
Note: Keeping rearward pressure on the lever will keep the pin at the end of the slot and allow the adjustment bolt to move the lever to the appropriate position. 2. Adjust the pump rod length by rotating the knob, in the appropriate direction, until the wheel is still or slightly creeping in reverse (Fig. 56). 10. Tighten the nut and jam nut (Fig. 54). 3. Move the motion control lever forward and reverse, then back to neutral. The wheel must stop turning or slightly creep in reverse. 11.
5. Open the throttle to fast. Make sure the wheel remains stopped or slightly creeps in reverse, re-adjust if necessary. 2 6. Tighten the locknuts at the ball joints (Fig. 54). 3 4 Warning Electrical system will not perform proper safety shut off with jumper wire installed. 1 • Remove jumper wire from wire harness connector and plug connector into seat switch when adjustment is completed. • Never operate this unit with jumper installed and seat switch bypassed. m–6280 Figure 57 1. Pump rod 2.
Adjusting the Parking Brake Servicing the Fuse Check parking brake for proper adjustment. Service Interval/Specification 1. Disengage brake lever (lever down). The electrical system is protected by fuses. It requires no maintenance, however, if a fuse blows check component/circuit for malfunction or short. 2. Measure the length of the spring. Measurement should be 2-3/4 inch (70 mm) between washers (Fig. 59). Fuse: Main F1–20 amp, blade-type Alternator F2–20 amp, blade-type 3.
9 5 4 11 2 1 7 2 6 3 7 m–5004 3 Figure 61 1. Filler caps 2. Upper line 3. Lower line 8 10 1 Danger m–5598 Figure 62 Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns. 1. 2. 3. 4. 5. 6. • 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.
Charging the Battery Warning Warning Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. Charging the battery produces gasses that can explode. Never smoke near the battery and keep sparks and flames away from battery. • Always Disconnect the negative (black) battery cable before disconnecting the positive (red) cable.
F ront Leveling the Mower at Three Positions Important There are only three measuring positions needed to level the mower. Setting Up the Machine B C 1. Position mower on a flat surface. 2. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. m–1078 Figure 64 3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 4. Check tire pressure of all four tires.
9. Tighten both swivel jam nuts against the front swivel to lock the height. 9. Tighten the jam nut under the rear support arm and tighten the bolt securing the chain to the rear support arm. 10. Adjust the opposite side if needed. 10. Check to make sure there is equal tension on the chains and adjust again if needed. Adjusting the Front–to–Rear Mower Pitch Adjusting the Compression Spring 1. Position the right blade front-to-rear (Fig. 67). 1.
Inspecting Belts 2 1 Inspect all belts every 100 hours. 1. Check the belts for cracks, frayed edges, burn marks or any other damage. Replace damaged belts. 1 Replacing the Mower Belt Squealing when the belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks and cracks are signs of a worn mower belt. Replace the mower belt if any of these conditions are evident. m–6824 1.
5. If adjustment is required, loosen the mower idler plate and adjust it (Fig. 73). 10. Adjust the belt tension and the idler plate, if necessary, and tighten all hardware securely (Fig. 73). 6. Insert a ratchet or breaker bar into the square hole in the mower idler plate to adjust the tension (Fig. 73). 11. If the mower idler plate contacts the end of the adjustment slot and more belt tension is required, a small change to the right side fixed idler can create more belt tension adjustment (Fig. 75). 7.
6 2 Disposing the Mercury Tilt Switch 4 8 7 Several states have passed laws concerning the disposal of devices containing mercury. In all the remaining states it is advisable to follow similar procedures. The laws state that these sealed devices contain mercury and should not be placed in the garbage until the mercury is removed and reused, recycled or otherwise managed to insure that it does not become part of solid waste or waters.
BK BK PTO CLUTCH GND GY DK.GN SHOWN WITH LEVER IN NEUTRAL POSITION LT.GN (NEUTRAL) SW5 LT.BU SHOWN WITH LEVER IN NEUTRAL POSITION LT.BU SW4 (NEUTRAL) SHOWN WITH PARK BRAKE DISENGAGED SW3 (BRAKE) SHOWN IN OFF POSITION DK.
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 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 the listed Toro Products if defective in materials or workmanship. The following time periods apply from the date of purchase: You must maintain your Toro Product by following the maintenance procedures described in the operator’s manual.
