Form No. 3361-372 Rev A Z500 Z Master®, With 52in or 60in 7-Gauge Side Discharge Mower Model No. 74291—Serial No. 290000001 and Up Model No. 74292—Serial No. 290000001 and Up Register at www.Toro.com.
Warning CALIFORNIA Proposition 65 Warning 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 the engine on any forest-covered, brush-covered, or grass-covered land. Other states or federal areas may have similar laws. Figure 1 1.
Using the Rollover Protection System (ROPS) .......................................................... 15 Think Safety First ............................................... 16 Operating the Parking Brake ............................... 17 Starting and Stopping the Engine ........................ 17 Operating the Power Take Off (PTO) ................. 18 The Safety Interlock System................................ 19 Driving Forward or Backward............................. 20 Stopping the Machine.............
Safety • Use extra care when handling gasoline and other fuels. They are flammable and vapors are explosive. – Use only an approved container – Never refuel or drain the machine indoors. – Never remove gas cap or add fuel with engine running. Allow engine to cool before refueling. Do not smoke. • Check that operator’s presence controls, safety switches and shields are attached and functioning properly. Do not operate unless they are functioning properly.
• Check the area to be mowed and never fold the ROPS in areas where there are slopes, drop offs or water. • Use extreme care when loading or unloading the machine into a trailer or truck. • Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision. • Lower the rollbar only when absolutely necessary. Do not wear the seat belt with the roll bar folded down. Slope Operation • Check carefully for overhead clearances (i.e.
Slope Chart 6
Safety and Instructional 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. 1-403005 54-9220 1-523552 58-6520 1.
98-4387 1. Warning—wear hearing protection.
107-1861 107-2102 107-1864 107-2112 109-7949 9
112-8651 1. 2. 3. 4. 5. 6. Interval Power Take-off (PTO) Parking brake Neutral Operator presence switch Battery 117-0905 1. Fast 2. Continuous variable setting 3. Slow Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 2. No fire, open flame, 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. 7.
106-7492 106-9989 107-8076 1. Fast 3. Neutral 2. Slow 11 4.
Controls Product Overview Become familiar with all the controls before you start the engine and operate the machine (Figure 3 and Figure 4). Figure 4 1. Ignition switch 2. Choke 3. Throttle Figure 3 1. 2. 3. 4. Motion control lever Parking brake lever Height-of-cut lever Fuel cap (both sides) 5. Controls 6. Seat belt 7. Roll bar 4. Power take off (PTO) 5. Hour meter Hour Meter The hour meter records the number of hours the engine has operated. It operates when the engine is running.
Attachments/Accessories The battery light turns on when the ignition is turned on and when the charge is below the correct operating level (Figure 5). A selection of Toro approved attachments and accessories are available for use with the machine to enhance and expand its capabilities. Contact your Authorized Service Dealer or Distributor or go to www.Toro.com for a list of all approved attachments and accessories. Figure 5 1. Safety interlock symbols 2. Hour meter 3.
Operation In certain conditions during fueling, static electricity can be released causing a spark which can ignite the gasoline vapors. A fire or explosion from gasoline can burn you and others and can damage property. Note: Determine the left and right sides of the machine from the normal operating position. Adding Fuel 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: Do not use fuel additives containing methanol or ethanol. Add the correct amount of gas stabilizer/conditioner to the gas. There is no rollover protection when the roll bar is in the down position. Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline. To minimize the chance of varnish deposits in the fuel system, use fuel stabilizer at all times. • Lower the roll bar only when absolutely necessary.
Important: Always use the seat belt with the roll bar in the raised position. Operating on wet grass or steep slopes can cause sliding and loss of control. 1 Wheels dropping over edges can cause rollovers, which may result in serious injury, death or drowning. 2 There is no rollover protection when the roll bar is down. Always keep the roll bar in the raised and locked position and use the seat belt. Read and follow the rollover protection instructions and warnings.
This machine produces sound levels in excess of 85 dBA at the operators ear and can cause hearing loss through extended periods of exposure. Wear hearing protection when operating this machine. The use of protective equipment for eyes, ears, feet and head is recommended. Figure 10 1. Parking brake-ON 2. Parking brake-OFF Figure 9 3. Brake Stop Starting and Stopping the Engine 1. Warning— wear hearing protection Starting the Engine Operating the Parking Brake 1.
Figure 14 1. Off 2. Run 7. After the engine starts, move the choke to off (Figure 12). If the engine stalls or hesitates, move the choke back to on for a few seconds, then move the throttle lever to desired setting. Repeat this as required. Figure 12 1. Choke—on 3. Start 2. Choke—off 5. Move the throttle control to the Fast position before starting a cold engine (Figure 13). Stopping the Engine 1. Push the PTO to the off position (Figure 11). 2.
Engaging the PTO • You are sitting on the seat. 1. If the engine is cold, allow the engine to warm up 5 to 10 minutes before engaging the PTO. 2. While seated in the seat, release the pressure on the traction control levers and place in neutral. 3. Place the throttle in the fast position. • The parking brake is engaged. Note: Engaging the PTO with the throttle at the half or less position will cause excessive wear to the drive belts. 4.
4. Sitting on the seat, engage the parking brake, move the 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 and move (forward or reverse); the engine should stop. Repeat for other motion control. 5. Sitting on the seat, disengage the parking brake, move the PTO switch to off and move the motion control levers to neutral lock position. Try starting the engine; the engine should not crank.
Children or bystanders may be injured if they move or attempt to operate the tractor while 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. Adjusting the Control Lever Resistance Figure 19 1. Height of cut lever The top damper mounting bolt can be adjusted to obtain a desired motion control lever resistance. Refer to Figure 18 for the mounting options. 2. Pin 2.
Figure 21 1. Outer roller 2. Spacer 3. Bushing Figure 20 1. Outer roller 2. Spacer 3. Bushing 4. Bolt 5. Nut 4. Bolt 5. Nut 4. Select a hole so that the center rollers are positioned to the nearest corresponding height-of-cut desired (Figure 21). 4. Select a hole so that the outer roller is positioned to the nearest corresponding height-of-cut desired (Figure 20). Note: Do not adjust the rollers to support the mower housing. 5. Install the outer roller, bushing, spacer, bolt, and nut (Figure 20). 5.
Important: Do not rotate by-pass valves more than 1 turn. This prevents valves from coming out of the body and causing fluid to run out. Figure 22 1. Adjustment lever Unlatching the Seat Push the seat latch rearward to unlatch the seat. This will allow access to the machine under the seat (Figure 23). Figure 24 1. By-pass valve 2. Hydraulic tank 3. Disengage parking brake before pushing. Changing to Machine Operation Rotate the by-pass valves clockwise 1 turn to operate machine (Figure 24).
Without the grass deflector, discharge cover, or complete grass catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris. Contact with rotating mower blade(s) and thrown debris will cause injury or death. Driving on the street or roadway without turn signals, lights, reflective markings, or a slow moving vehicle emblem is dangerous and can lead to accidents causing personal injury. Do not drive machine on a public street or roadway.
Loading a unit onto a trailer or truck increases the possibility of backward tip-over and could cause serious injury or death. 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. • Use extreme caution when operating a unit on a ramp.
the cutting height higher than usual and cut the grass at this setting. Then cut the grass again using the lower, normal setting. 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.
Maintenance Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 8 hours • Check the hydraulic fluid. After the first 25 hours • Change the hydraulic filter. After the first 100 hours • Check the wheel hub slotted nut. • Check the wheel lug nuts. Before each use or daily • • • • • Check the safety interlock system. Check the engine oil level. Clean the engine screen and the oil cooler. Check the mower blades. Clean the mower deck.
Lubrication Greasing and Lubrication Lubricate the machine when shown on the Check Service Reference Aid decal (Figure 27). Grease more frequently when operating conditions are extremely dusty or sandy. Grease Type: General-purpose grease. Figure 26 How to Grease 1. Seal guard 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2. Spacer nut with wrench flats 2. Remove the caster wheel from the caster forks. 2.
13. Torque the nut to 75-80 in-lb (8-9 N-m), loosen, then re-torque to 20-25 in-lb (2-3 N-m). Make sure axle does not extend beyond either nut. • Brake handle pivot. • Brake rod bushings. • Motion control bronze bushings. 14. Reinstall the seal guards over the wheel hub and insert wheel into caster fork. Reinstall caster bolt and tighten nut fully. Greasing the Bearings Service Interval: Every 25 hours Important: To prevent seal and bearing damage, check the bearing adjustment often.
Engine Maintenance Servicing the Primary Filter Service Interval: Every 200 hours Servicing the Air Cleaner • If the primary filter is dirty, bent, or damaged, replace it. Note: Check the filters more frequently if the operating conditions are extremely dusty or sandy. • Do not clean the primary filter. Removing the Filters Servicing the Safety Filter 1. Disengage the PTO, move the motion control levers to the neutral locked position, and set the parking brake. 2.
Changing the Oil Service Interval: Every 100 hours 1. Start the engine and let it run five minutes. This warms the oil so it drains better. 2. Park the machine so that the drain side is slightly lower than the opposite side to ensure the oil drains completely. 3. Disengage the PTO and set the parking brake. 4. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Figure 30 5. Place a pan below the drain.
Figure 33 1. Oil filter 2. Adapter gasket Figure 34 3. Adapter 1. Center electrode insulator 2. Side electrode 3. Pour new oil in through the center hole of the filter. Fill it up to the bottom of the threads inside. 3. Air gap (not to scale) Important: Always replace the spark plugs when it has a black coating, worn electrodes, an oily film, or cracks. 4. Allow the filter material to absorb the new oil for 1 to 2 minutes. 2. Check the gap between the center and side electrodes (Figure 34).
Installing the Spark Plugs 1. Install the spark plugs and the metal washer. Ensure that the air gap is set correctly. Fuel System Maintenance 2. Tighten the spark plugs to 18 to 22 ft-lb (24.4 to 29.8 N⋅m). Replacing the Fuel Filter 3. Connect the wires to the spark plugs (Figure 35). Service Interval: Every 200 hours or yearly, whichever occurs first. Never install a dirty filter if it is removed from the fuel line. 1.
Draining the Fuel Tank Electrical System Maintenance 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. Servicing the Battery Warning • Drain gasoline from the fuel tank when the engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills.
6. Remove both wing nuts (1/4 inch) securing the battery clamp (Figure 38). Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. 7. Remove the battery. Installing the Battery 1. Position battery in the tray with the terminal posts toward the engine (Figure 38). • Always Disconnect the negative (black) battery cable before disconnecting the positive (red) cable. 2.
Drive System Maintenance Adjusting the Tracking Note: Determine the left and right sides of the machine from the normal operating position. Note: Adjust the handle neutral and hydraulic pump neutral before adjusting the tracking. Refer to Adjusting the Handle Neutral and Adjusting the Hydraulic Pump Neutral. 1. Push both control levers forward the same distance. 2. Check if the machine pulls to one side. If it does, stop the machine and set the parking brake. 3.
Maintain the air pressure in the front and rear tires at 13 psi (90 kPa). Uneven tire pressure can cause uneven cut. Check the tires when they are cold to get the most accurate pressure reading (Figure 42). Figure 43 1. Slotted Nut 2. Two threads or less showing 3. Hole in threaded shaft 4. Washer (if needed) 5. Check the distance from bottom of slot in nut to inside edge of hole. Two threads or less should be showing (Figure 43). Figure 42 6.
Cooling System Maintenance Cleaning the Engine Screen and the Oil Cooler Service Interval: Before each use or daily Before each use, check and clean the engine screen and oil cooler. Remove any build-up of grass, dirt or other debris from the oil cooler screen and engine screen (Figure 45 and Figure 46). Figure 44 1. Spring Washers 2. Lock Nut 3. Dust Cap 4. Tighten the locknut until the spring washers are flat and then back off a 1/4 turn to properly set the pre-load on the bearings (Figure 44).
Brake Maintenance Belt Maintenance Adjusting the Parking Brake Inspecting the Belts Service Interval: Every 200 hours Service Interval: Every 100 hours Check the parking brake for proper adjustment. Check the belts for cracks, frayed edges, burn marks or any other damage. Replace damaged belts. 1. Disengage brake lever (lever down). 2. Measure the length of the spring. Replacing the Mower Belt The measurement should be 2-3/4 inch (70 mm) between washers (Figure 47).
Figure 49 1. Center bolt 2. Alignment hole 3. Left support plate 4. Spring loaded idler 5. If adjustment is required, loosen the idler plate to adjust it (Figure 50). 6. Insert a ratchet or breaker bar into the square hole in the idler plate to adjust the tension (Figure 50). Figure 48 1. 2. 3. 4. 5. Clutch Mower belt 1/4 trun belt twist Belt guide Mower spindle pulley 6. 7. 8. 9. 10. 7.
Figure 53 3. Install new belt around engine and hydro pump pulleys (Figure 53). Figure 51 1. Spring loaded idler pulley 2. Top alignment hole 3. 0 to 1/4 inch gap (0 to 6 mm) 4. Idler pulley arm 5. Belt 6. Rubber bumper 4. Pull spring loaded idler down and align below traction belt. Release the pressure on the spring loaded idler (Figure 53). 10. Adjust the belt tension and the idler plate, if necessary, and tighten all hardware securely (Figure 50). 11.
Controls System Maintenance 9. Apply slight rearward pressure on the motion control lever, turn the head of the adjustment bolt in the appropriate direction until the control lever is centered in the neutral lock position (Figure 55). Adjusting the Control Handle Neutral Position 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.
Hydraulic System Maintenance Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Checking the Hydraulic Fluid • 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. Service Interval: After the first 8 hours Every 25 hours Fluid Type: Mobil 1 15W-50 synthetic motor oil or equivalent synthetic oil.
Bleeding the Hydraulic System The traction system is self bleeding, however, it may be necessary to bleed the system if fluid is changed or after work is performed on the system. 1. Raise rear of the machine so wheels are off the ground and support with jack stands. 2. Start the engine and run at low idle speed. Engage the lever and traction on one side and spin the wheel by hand. Figure 57 1. Hydraulic filter 3. When the wheel begins to spin on its own, keep it engaged until wheel drives smoothly.
Setting the Hydraulic Pump Neutral Position Note: Adjust the handle neutral first. That needs to be correct before the following adjustment can be made. Mechanical or hydraulic jacks may fail to support machine and cause a serious injury. • Use jack stand when supporting machine. • Do not use hydraulic jacks. Figure 59 1. Pump rod 2. Double nuts 3. Lock nut Engine must be running so motion control adjustment can be performed. Contact with moving parts or hot surfaces may cause personal injury. 4.
Electrical system will not perform proper safety shut off with jumper wire installed. • 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. 7. After both pump neutrals are set, shut off the machine. 8. Remove the jumper wire from the wire harness connector and plug the connector into the seat switch. 9. Install the seat rod and lower the seat into position. Figure 60 1. 2.
Mower Deck Maintenance Leveling the Mower at Three Positions Important: There are only three measuring positions needed to level the mower. Setting Up the Machine 1. Position mower on a flat surface. Figure 61 2. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 1. Measure here from blade to hard surface 3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 2. Measure at B and C 2.
8. Loosen the jam nut under the rear support arm and adjust the adjustment bolt to get a measurement of 3-1/8 to 3-1/4 inches (80 to 83 mm) (Figure 62). (6 to 10 mm) lower in front at A than in the rear at B (Figure 62). 9. Tighten both swivel jam nuts against the front swivel to lock the height. Note: It is recommended that both sides of the mower are adjusted the same distance. 9. Tighten the jam nut under the rear support arm and tighten the bolt securing the chain to the rear support arm. 10.
Checking for Bent Blades grass brown at the edges, which slows growth and increases the chance of disease. 1. Disengage the blade control switch (PTO), move the motion control levers to the neutral locked position and set the parking brake. Check the cutter blades daily for sharpness, and for any wear or damage. 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.
Removing the Blades Blades must be replaced if a solid object is hit, if the 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. Figure 68 1. Sharpen at original angle 1. Hold the blade end using a rag or thickly-padded glove. 2. Check the balance of the blade by putting it on a blade balancer (Figure 69).
Figure 71 Figure 70 1. Sail Area of Blade 2. Blade 3. Spring Disk 1. Bolt 2. Spacer 3. Locknut 4. Blade Bolt 5. Cone Towards Bolt Head 4. Spring Replacing the Grass Deflector 5. Spring installed 6. Grass Deflector 7. Place behind deck edge before installing bolt 8. Hook end of spring 2. Remove the damaged or worn grass deflector. 3. Install the bolt and nut. 4. Place the J hook end of the spring around the grass deflector (Figure 71).
Cleaning Storage Cleaning Under the Mower 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. 2. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine and hydraulic system. Clean dirt and chaff from the outside of the engine’s cylinder head fins and blower housing. Service Interval: Before each use or daily Remove the grass buildup under the mower daily. 1.
C. Stop engine, allow to cool and drain the fuel tank; refer to Servicing the Fuel Tank in Fuel System Maintenance , page 33. D. Restart engine and run it until it stops. E. Choke the engine. Start and run engine until it will not start. F. Dispose of fuel properly. Recycle as per local codes. Important: Do not store stabilizer/conditioned gasoline over 90 days. 12. Remove the spark plug(s) and check its condition; refer to Servicing the Spark Plug in Engine Maintenance , page 30.
Troubleshooting Problem Starter does not crank Engine will not start, starts hard, or fails to keep running. Possible Cause 1. Blade control (PTO) is engaged. 1. Move blade contro (PTO) to disengaged. 2. 3. 4. 5. Parking brake is not on. Operator is not seated. Battery is dead. Electrical connections are corroded or loose. 6. Fuse is blown. 7. Relay or switch is defective. 2. 3. 4. 5. 1. Fuel tank is empty. 1. Fill fuel tank with fuel. 2. Air cleaner is dirty. 2.
Problem Uneven cutting height. Blades do not rotate. Possible Cause Corrective Action 1. Blade(s) not sharp. 1. Sharpen the blade(s). 2. Cutting blade(s) is/are bent. 3. Mower is not level. 4. Underside of mower is dirty. 5. Tire pressure is not correct. 6. Blade spindle bent. 2. Install new cutting blade(s). 3. Level mower from side-to-side and front-to-rear. 4. Clean the underside of the mower. 5. Adjust the tire pressure. 6. Contact an Authorized Service Dealer. 1.
Schematics Wire Diagram (Rev.
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The Toro Total Coverage Guarantee A Limited Warranty (see warranty periods below) Conditions and Products Covered 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.
