Form No. 3357-688 Rev A Z528 Z Master, With 52in or 60in 7-Gauge Side Discharge Mower Model No. 74237—Serial No. 270000001 and Up Model No. 74237CP—Serial No. 270000001 and Up Model No. 74238—Serial No. 270000001 and Up Model No. 74238CP—Serial No. 270000001 and Up Register your product at www.Toro.
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) ............................... 19 The Safety Interlock System............... 19 Driving Forward or Backward ............ 20 Stopping the Machine ........................ 21 Adjusting the Control Lever Resistance .........................
Safety hair, loose clothing or jewelry may get tangled in moving parts. 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.
• 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 and to the side before changing directions. • Slow down and use caution when crossing roads and sidewalks. Stop blades if not mowing. • Be aware of the mower discharge direction and do not point it at anyone. • Do not operate the mower under the influence of alcohol or drugs.
• Carefully release pressure from components with stored energy. • Disconnect battery or remove spark plug wire before making any repairs. Disconnect the negative terminal first and the positive last. Reconnect positive first and negative last. • Use care when checking blades. Wrap the blade(s) or wear gloves, and use caution when servicing them. Only replace blades. Never straighten or weld them. • Keep hands and feet away from moving parts. If possible, do not make adjustments with the engine running.
Slope Chart 7
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.
8-4387 1. Warning—wear hearing protection.
7-1864 107-1860 107-2102 107-1861 10
107-2112 110-5731 1. 2. 3. 4. 108-5278 1. Read the Operator’s Manual. Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 6. 2. No re, open ame, or smoking. 7. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 8. 5. Read the Operator’s Manual. 9. 10. Keep bystanders a safe distance from the battery. Wear eye protection; explosive gases can cause blindness and other injuries Battery acid can cause blindness or severe burns.
106-7492 106-9989 107-8076 1. Fast 2. Slow 3. Neutral 12 4.
Product Overview Controls Become familiar with all the controls before you start the engine and operate the machine (Figure 3 and Figure 4). Figure 4 Figure 3 1. 2. 3. 4. Motion control lever Parking brake lever Height-of-cut lever Fuel cap (both sides) 5. 6. 7. 1. 2. 3. Controls Seat belt Roll bar Gas cap Choke Ignition switch 4. 5. 6. Throttle Power take off (PTO) Hour meter Hour Meter The hour meter records the number of hours the engine has operated. It operates when the engine is running.
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 • Always place gasoline containers on the ground away from your vehicle before filling. Use Unleaded Regular Gasoline suitable for automotive use (85 pump octane minimum).
• Cleans the engine while it runs • Eliminates gum-like varnish buildup in the fuel system, which causes hard starting There is no rollover protection when the roll bar is in the down position. Important: Do not use fuel additives containing methanol or ethanol. • Lower the roll bar only when absolutely necessary. Add the correct amount of gas stabilizer/conditioner to the gas. • Do not wear the seat belt when the roll bar is in the down position.
Think Safety First 5. To raise the roll bar, remove the hairpin cotter pins and remove the two pins (Figure 6). 6. Raise the roll bar to the upright position and install the two pins and secure them with the hairpin cotter pins (Figure 6). Please read all safety instructions and symbols in the safety section. Knowing this information could help you or bystanders avoid injury. Important: Always use the seat belt with the roll bar in the raised position.
Setting the Parking Brake 1. Move the motion control levers (Figure 16) out to the neutral lock position. 2. Pull up and back on the parking brake lever to set the parking brake (Figure 10). 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 Figure 8 1. Safe Zone-use the Z Master 3.
3. Move the PTO (power take off) switch to the Off position (Figure 11). Figure 13 Figure 11 1. PTO—on 2. 1. Throttle—fast PTO—off 2. Throttle—slow 6. Turn the ignition key to Start (Figure 14). When the engines starts, release the key. 4. Move the choke control to the on position before starting a cold engine (Figure 12). Important: Do not engage starter for more than 10 seconds at a time. If engine fails to start, allow 30 second cool-down period between attempts.
4. Turn the ignition key to the off position and remove the key (Figure 14). 5. Close the fuel shut off valve before transporting or storing the machine. Refer to Fuel System Maintenance, page 32. 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 remove the key as the fuel pump may run and cause the battery to lose charge. Figure 15 1.
engaged or if you rise from the seat when the PTO is engaged. Machine can spin very rapidly. Operator may lose control of machine and cause personal injury or damage to machine. Testing the Safety Interlock System Test the safety interlock system before you use the machine each time. If the safety system does not operate as described below, have an Authorized Service Dealer repair the safety system immediately. • Use caution when making turns. • Slow the machine down before making sharp turns. 1.
Set the parking brake when you leave the machine; refer to Setting the Parking Brake. Remember to remove the key from the ignition switch. 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 The top damper mounting bolt can be adjusted to obtain a desired motion control lever resistance.
Figure 18 1. Height of cut lever 2. Clevis Pin Figure 19 2. To adjust, remove the clevis pin from the height-of-cut bracket (Figure 18). 1. Outer roller 2. Spacer 3. Bushing 3. Select a hole in the height-of-cut bracket corresponding to the height-of-cut desired and, insert the clevis pin (Figure 18). 4. 5. Bolt Nut 4. Move the lever to the selected height. 4. Select a hole so that the outer roller is positioned to the nearest corresponding height-of-cut desired (Figure 19).
Figure 21 Figure 20 1. Outer roller 2. Spacer 3. Bushing 4. 5. 1. Bolt Nut Adjustment lever Unlatching the Seat 4. Select a hole so that the center rollers are positioned to the nearest corresponding height-of-cut desired (Figure 20). Push the seat latch rearward to unlatch the seat. This will allow access to the machine under the seat (Figure 22). Note: Do not adjust the rollers to support the mower housing. 5. Install the center rollers, bushing, spacer, bolt, and nut (Figure 20). 6.
to neutral locked position and apply parking brake. Remove the key. 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. 2. Rotate the by-pass valves counterclockwise 1 turn to push. This allows hydraulic fluid to by-pass the pump enabling the wheels to turn (Figure 23).
Important: Do not use the motion control levers as anchors for tieing the machine down. Loading a unit onto a trailer or truck increases the possibility of backward tip-over and could cause serious injury or death. • Secure a trailer to the towing vehicle with safety chains. • Use extreme caution when operating a unit on a ramp.
Operating Tips 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 the fast throttle position.
Maintenance Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the rst 8 operating hours • Change the engine oil. • Check the hydraulic uid. After the rst 25 operating hours Before each use or daily • Change the hydraulic lter and oil. • • • • Check the safety interlock system. Check the engine oil. Check the mower blades. Clean the mower deck. Every 25 hours • Check the hydraulic uid. Every 50 hours • Grease the mower bearings.
How to Grease 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Clean the grease fittings with a rag. Make sure to scrape any paint off the front of the fitting(s). 4. Connect a grease gun to the fitting. Pump grease into the fittings until grease begins to ooze out of the bearings. 5. Wipe up any excess grease.
5. Gently slide the primary filter out of the air cleaner body (Figure 27). Avoid knocking the filter into the side of the body. 6. Remove the safety filter only if you intend to replace it. 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. 7. Inspect the primary filter for damage by looking into the filter while shining a bright light on the outside of the filter. Holes in the filter will appear as bright spots.
2. If the safety filter is being replaced, carefully slide it into the filter body (Figure 27). 3. Carefully slide the primary filter over the safety filter (Figure 27). Ensure that it is fully seated by pushing on the outer rim of the filter while installing it. 3. Clean around the oil dipstick (Figure 29) so dirt cannot fall into engine. Note: Do not press on the soft inside area of the filter. 4. Install the air cleaner cover with the side indicated as UP facing up and secure the latches (Figure 27).
7. When oil has drained completely, close the drain valve. 8. Remove the drain hose (Figure 30). Note: Dispose of the used oil at a recycling center. Figure 31 1. 3. Pour new oil of the proper type into the center hole in the new oil filter. Stop pouring when the oil reaches the bottom of the threads. Allow a minute or two for the oil to be absorbed by filter material. 4. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Figure 32). 5.
tool/feeler gauge to check and adjust the air gap. Install a new spark plug(s) if necessary. • Type: NGK® BPR4ES or equivalent • Air Gap: 0.030 inch (0.75 mm) Removing the Spark Plug 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. Figure 34 1. Canter electrode insulator 2. Side electrode 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Air gap (not to scale) 2.
3. Close fuel shut-off valve (Figure 36). Figure 35 1. Filter 2. Hose clamp 3. Figure 36 Fuel shut-off valve 1. 2. 5. Squeeze the ends of the hose clamps together and slide them away from the filter (Figure 35). 6. Remove the filter from the fuel lines. 7. Install a new filter and move the hose clamps close to the filter to secure the fuel line (Figure 35). 8. Wipe up any spilled fuel. 9. Open the fuel shut-off valve. Filter Fuel shut-off valve 3. Hose clamp 4.
5. Slide the red terminal boot off the positive (red) battery terminal. Then remove the positive (red) battery cable (Figure 37). 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 rubber gloves to protect your hands. Removing the Battery Battery terminals or metal tools could short against metal machine components causing sparks.
Charging the Battery The fuses are as follows: • Main F1-30 amp, blade-type • Alternator F2-25 amp, blade-type Charging the battery produces gasses that can explode. 1. Unlatch the seat and raise the seat to gain access to fuse holder (Figure 39). Never smoke near the battery and keep sparks and flames away from battery. Important: Always keep the battery fully charged (1.265 specific gravity). This is especially important to prevent battery damage when the temperature is below 32°F (0°C). 1.
Drive System Maintenance Checking the Tire Pressure Check the pressure at the valve stem after every 50 operating hours or monthly, whichever occurs first (Figure 41). Adjusting the Tracking 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. Note: Determine the left and right sides of the machine from the normal operating position.
Figure 42 1. Slotted Nut 2. Two threads or less showing 3. 4. Hole in threaded shaft 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 42). Figure 43 6. If more than two threads are showing remove nut and install washer between hub and nut. 1. 2. 7. Torque the slotted nut to 125 ft-lb. (170 N⋅m) (Figure 42). Spring Washers Lock Nut 3. Dust Cap 4.
Figure 44 Figure 46 1. Oil cooler 1. Brake lever 2. Spring (2-3/4 inches/70 mm) 3. Adjusting nuts Cleaning the Engine Fins Every 100 hours clean the engine cylinder and cylinder head cooling fins. Also clean around carburetor, governor levers and linkage. This will make sure adequate cooling to hydraulic pumps, motors and engine and will reduce the possibility of overheating and mechanical damage. 1. Remove the engine shroud. 2. Clean the engine cooling fins. 3. Install the engine shroud. 4. 5.
Adjusting the Mower Belt Tension 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the belt covers. 4. Loosen the nut securing the idler plate and move the idler plate to relieve the belt tension on the idler pulley (Figure 47). 5. Remove the nut, washer and belt guide from the rear leftside pulley. 6. Remove the mower belt from the belt guides and remove the belt (Figure 47). 7.
idler can create more belt tension adjustment (Figure 51). Figure 51 Figure 49 1. Rachet with short extension 2. or breaker bar 1. Fixed idler Replacing the Pump Drive Belt Check pump drive belt for wear after every 50 hours of operation. 1. Pull the spring loaded idler down and remove traction belt from the engine and hydro pump pulleys (Figure 52). Remove belt between pulleys. Figure 50 4. 5. 6. Adjustment slot Idler plate with Square hole 9.
Controls System Maintenance centered allowing lever to pivot outward to the neutral lock position. 8. If adjustment is needed, loosen the nut and jam nut against the yoke (Figure 54). Adjusting the Control Handle Neutral Position 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 54).
Hydraulic System Maintenance A very small amount of mercury is contained in a hermetically sealed body. The steel switch is then potted in a hard epoxy in a plastic case. It is unlikely that the mercury will ever escape from the enclosure. These high performance and reliable inexpensive switches are recyclable. Checking the Hydraulic Fluid Mercury is an important and beneficial compound but requires special care in handling and disposal.
Important: Do not substitute automotive oil filter or severe hydraulic system damage may result. 6. Recheck the fluid level while the fluid is warm. The fluid should be between cold and hot. 7. If required, add fluid to the hydraulic tank. 3. Place drain pan under filter, remove the old filter and wipe the filter adapter gasket surface clean (Figure 56). Note: The fluid level should be to the top of the hot level of the baffle, when the fluid is hot (Figure 55). 8. Install cap on filler neck.
the engine and check for leaks. If one or both wheels will not drive, refer Bleeding Hydraulic System. Hydraulic fluid escaping under pressure can penetrate skin and cause injury. 10. Recheck the fluid level while the fluid is warm. The fluid should be between cold and hot. • 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. 11. If required, add fluid to the hydraulic tank.
This adjustment must be made with drive wheels turning. 3. Move the motion control lever forward and reverse, then back to neutral. The wheel must stop turning or slightly creep in reverse. 1. Raise the frame and use jack stands to hold up the machine so drive wheels can rotate freely. 4. Open the throttle to fast. Make sure wheel remains stopped or slightly creeps in reverse, adjust if necessary. 2. Unlatch the seat, tilt the seat forward and disconnect electrical connector from the seat safety switch.
4. Move the motion control lever forward and reverse, then back to neutral. The wheel must stop turning or slightly creep in reverse. 5. Open the throttle to fast. Make sure the wheel remains stopped or slightly creeps in reverse, adjust if necessary. 6. Tighten the locknuts at the ball joints (Figure 59). 5. Lower the mower to the 3 inch (76 mm) height-of-cut position. 6. Inspect the four chains. The chains need to have tension.
7. If the measurements at positions B or C are not correct, loosen the bolt attaching the rear chain to the rear support arm (Figure 61). Figure 62 1. Figure 61 1. 2. 3. 4. Rear chain Rear support arm Bolt Jam Nut 5. 6. 7. Adjustment bolt Front swivel Front support arm Measure here from blade to hard surface 2. Measure at A and B 2. Measure the right blade at the A location, from a level surface to the cutting edge of the blade tip (Figure 62). 3. Record this measurement. 8.
Adjusting the Compression Spring 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. 1. Raise the mower lift lever to the transport position. 2. Check the distance between the two large washers, it needs to be 11-1/8 inches (28.2 cm) for 52 inch mower decks and 10-1/2 inches (26.7 cm) for 60 inch mower decks (Figure 63).
2. Rotate the opposite ends of the blades forward. 3. Measure from a level surface to the cutting edge of the blades at the same position as in step 1 above. The difference between the dimensions obtained in steps 1 and 2 must not exceed 1/8 inch (3 mm). If this dimension exceeds 1/8 inch (3 mm), the blade is bent and must be replaced; refer to Removing the Blades and Installing the Blades. Figure 64 1. Cutting Edge 2. Curved Area 3.
Sharpening the Blades When sharpening blade, pieces of blade could be thrown and cause serious injury. Wear proper eye protection when sharpening blade. 1. Use a file to sharpen the cutting edge at both ends of the blade (Figure 66). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges. Figure 68 1. Sail Area of Blade 2. Blade 3. Spring Disk 4. 5. Blade Bolt Cone Towards Bolt Head 3.
Figure 69 1. Bolt 2. Spacer 3. Locknut 5. 6. 7. 4. Spring 8. Spring installed Grass Deector Place behind deck edge before installing bolt 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 69). Important: The grass deflector must be able to lower down into position. Lift the deflector up to test that it lowers into the full down position.
Storage 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. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine and hydraulic system.
Troubleshooting Problem Starter does not crank Possible Cause Corrective Action 1. Blade control (PTO) is engaged. 2. Parking brake is not on. 3. Operator is not seated. 4. Battery is dead. 5. Electrical connections are corroded or loose. 1. Move blade contro (PTO) to disengaged. 2. Set the parking brake. 3. Sit on the seat. 4. Charge the battery. 5. Check the electrical connections for good contact. 6. Replace fuse. 7. Contact an Authorized Service Dealer. 6. Fuse is blown. 7.
Problem Machine does not drive. Abnormal vibration. Possible Cause 1. By pass valve is not closed tight. 2. Drive or pump belt is worn, loose or broken. 3. Drive or pump belt is off a pulley. 4. Broken or missing idler spring. 5. Hydraulic uid level is low or too hot. 1. Tighten the by pass valve. 2. Change the belt. 1. Cutting blade(s) is/are bent or unbalanced. 2. Blade mounting bolt is loose. 3. Engine mounting bolts are loose. 4. Loose engine pulley, idler pulley, or blade pulley. 5.
Problem Blades do not rotate. Possible Cause 1. Drive belt is worn, loose or broken. 2. Drive belt is off pulley. 3. Deck belt is worn, loose or broken. 4. Deck belt is off pulley. 5. Broken or missing idler spring. 55 Corrective Action 1. Check the belt tension. 2. Install drive belt and check adjusting shafts and belt guides for correct position. 3. Install new deck belt. 4. Install deck pulley and check the idler pulley, idler arm and spring for correct position and function. 5. Replace the spring.
Schematics Wire Diagram (Rev.
Evaporative Emission Control Warranty Statement California Evaporative Emission Control Warranty Statement Your Warranty Rights and Obligations Introduction The California Air Resources Board and The Toro® Company are pleased to explain the evaporative emission control system’s warranty on your 2006 model year equipment. In California, new equipment that use small off-road engines must be designed, built, and equipped to meet the State’s stringent anti-smog standards.
LCE The Toro Total Coverage Guarantee A Limited Warranty Conditions and Products Covered Items and Conditions Not Covered The Toro® Company and its afliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair the listed Toro Products if defective in materials or workmanship.
