Form No. 3358-874 Rev A Z500 Z Master® With 52in or 60in 7-Gauge Side Discharge Mower Model No. 74237CP—Serial No. 280000001 and Up Model No. 74238CP—Serial No. 280000001 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) .......................................................... 13 Think Safety First ............................................... 14 Operating the Parking Brake ............................... 15 Starting and Stopping the Engine ........................ 16 Operating the Power Take Off (PTO) ................. 17 The Safety Interlock System................................ 17 Driving Forward or Backward............................. 18 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.
107-1860 107-2102 107-2112 107-1861 107-1864 9
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. Wear eye protection; explosive gases can cause blindness and other injuries 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. 10. Contains lead; do not discard.
106-9989 107-8076 1. Fast 3. Neutral 2. Slow Product Overview 4. Reverse 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) 1. Gas cap 2. Choke 3. Ignition switch 5. Controls 6. Seat belt 7. Roll bar 11 4. Throttle 5. Power take off (PTO) 6.
Hour Meter Operation 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 (Figure 4). Note: Determine the left and right sides of the machine from the normal operating position. Adding Fuel Throttle Control 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. 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. Add the correct amount of gas stabilizer/conditioner to the gas. Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline.
Important: Always use the seat belt with the roll bar in the raised position. There is no rollover protection when the roll bar is in the down position. 1 • Lower the roll bar only when absolutely necessary. 2 • Do not wear the seat belt when the roll bar is in the down position. • Drive slowly and carefully. • Raise the roll bar as soon as clearance permits. • Check carefully for overhead clearances (i.e. branches, doorways, electrical wires) before driving under any objects and do not contact them.
Operating on wet grass or steep slopes can cause sliding and loss of control. This machine produces sound levels in excess of 85 dBA at the operators ear and can cause hearing loss through extended periods of exposure. Wheels dropping over edges can cause rollovers, which may result in serious injury, death or drowning. Wear hearing protection when operating this machine. There is no rollover protection when the roll bar is down.
Figure 11 Figure 9 1. Parking brake-ON 2. Parking brake-OFF 1. Choke—on 2. Choke—off 3. Brake Stop 5. Move the throttle control to the Fast position before starting a cold engine (Figure 12). Starting and Stopping the Engine Starting the Engine 1. Sit on the seat and move the motion controls to neutral locked position. 2. Set the parking brake; refer to Setting the Parking Brake. 3. Move the PTO (power take off) switch to the Off position (Figure 10). Figure 12 1. Throttle—fast 2. Throttle—slow 6.
Engaging the PTO 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. Note: Engaging the PTO with the throttle at the half or less position will cause excessive wear to the drive belts. 4. Pull out on the power take off (PTO) switch to engage it (Figure 14). Figure 13 1. Off 2. Run 3. Start 7.
• You are sitting on the seat. • The parking brake is engaged. Machine can spin very rapidly. Operator may lose control of machine and cause personal injury or damage to machine. • The power take off (PTO) is disengaged. • The motion control levers are in the neutral locked position • Use caution when making turns.
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. Refer to Figure 16 for the mounting options. Torque the bolt to 200 in-lb (22.6 N⋅m). Figure 15 1.
Figure 17 1. Height of cut lever 2. Clevis Pin Figure 18 2. To adjust, remove the clevis pin from the height-of-cut bracket (Figure 17). 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 17). 4. Bolt 5. 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 18).
Figure 20 Figure 19 1. Outer roller 2. Spacer 3. Bushing 1. Adjustment lever 4. Bolt 5. Nut Unlatching the Seat 4. Select a hole so that the center rollers are positioned to the nearest corresponding height-of-cut desired (Figure 19). Push the seat latch rearward to unlatch the seat. This will allow access to the machine under the seat (Figure 21). Note: Do not adjust the rollers to support the mower housing. 5. Install the center rollers, bushing, spacer, bolt, and nut (Figure 19). 6.
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. 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. • Never remove the grass deflector from the mower because the grass deflector routes material down toward the turf.
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. 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. Do not drive machine on a public street or roadway. • Use only a single, full width ramp; Do Not use individual ramps for each side of the unit.
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. 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.
Maintenance Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 8 hours • Change the engine oil. • Check the hydraulic fluid level. After the first 25 hours • Change the hydraulic filter. Before each use or daily • • • • • Check the safety interlock system. Check the engine oil. 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 24). Grease more frequently when operating conditions are extremely dusty or sandy. Grease Type: General-purpose grease. 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.
Engine Maintenance Servicing the Air Cleaner Note: Check the filters more frequently (every few hours) if operating conditions are extremely dusty or sandy. Removing the Filters 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. Figure 25 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 4. Grease the idler pulley pivot (Figure 25). 3.
Replacing the Primary Air Filter Checking the Engine Oil Level Service Interval: Every 250 hours Service Interval: Before each use or daily Do not clean the primary filter. Note: Check the oil when the engine is cold. 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.
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. 5. Slide the drain hose over the oil drain valve. 6. Place a pan below the drain hose. Rotate oil drain valve to allow oil to drain (Figure 29). 7. When oil has drained completely, close the drain valve. 8. Remove the drain hose (Figure 29). Figure 30 1. Engine oil filter Note: Dispose of the used oil at a recycling center. 3.
Removing the Spark Plug 2. Check the gap between the center and side electrodes (Figure 33). Bend the side electrode (Figure 33) if the gap is not correct. 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. Pull the wire(s) off the spark plug(s) (Figure 32).
Draining the Fuel Tank Fuel 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. Replacing the Fuel Filter Service Interval: Every 200 hours or yearly, whichever occurs first. • Drain gasoline from the fuel tank when the engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills. Never install a dirty filter if it is removed from the fuel line. 1.
Electrical System Maintenance Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. Servicing the Battery • Always Disconnect the negative (black) battery cable before disconnecting the positive (red) cable.
6. Remove both wing nuts (1/4 inch) securing the battery clamp (Figure 36). 7. Remove the battery. Installing the Battery 1. Position battery in the tray with the terminal posts toward the engine (Figure 36). 2. First, install the positive (red) battery cable to positive (+) battery terminal. 3. Then install the negative battery cable and ground wire to the negative (-) battery terminal. 4. Secure the cables with 2 bolts (1/4 x 3/4 inch), 2 washers (1/4 inch), and 2 locknuts (1/4 inch) (Figure 36).
Drive System Maintenance Check the pressure at the valve stem (Figure 40). 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. Adjusting the Tracking Note: Determine the left and right sides of the machine from the normal operating position. Important: Adjust the handle neutral and hydraulic pump neutral before adjusting the tracking.
Figure 41 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 41). Figure 42 6. If more than two threads are showing remove nut and install washer between hub and nut. 1. Spring Washers 2. Lock Nut 7. Torque the slotted nut to 125 ft-lb. (170 N⋅m) (Figure 41). 3. Dust Cap 4.
Cooling System Maintenance Brake Maintenance Cleaning the Engine Screen and the Oil Cooler Service Interval: Every 200 hours Service Interval: Before each use or daily 1. Disengage brake lever (lever down). Before each use, check and clean engine screen and oil cooler. Remove any build-up of grass, dirt or other debris from the oil cooler screen and engine screen (Figure 43 and Figure 44). 2. Measure the length of the spring. Adjusting the Parking Brake Check the parking brake for proper adjustment.
Belt Maintenance Inspecting the Belts Service Interval: Every 100 hours Check the belts for cracks, frayed edges, burn marks or any other damage. Replace damaged belts. 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. 1.
Figure 47 1. Center bolt 2. Alignment hole 3. Left support plate 4. Spring loaded idler Figure 49 1. Spring loaded idler pulley 2. Top alignment hole 3. 0 to 1/4 inch gap (0 to 6 mm) 5. If adjustment is required, loosen the idler plate to adjust it (Figure 48). 6. Insert a ratchet or breaker bar into the square hole in the idler plate to adjust the tension (Figure 48). 4. Idler pulley arm 5. Belt 6. Rubber bumper 10.
Controls System Maintenance Adjusting the Control Handle Neutral Position If motion control levers do not align, or move easily into the console notch, adjustment is required. Adjust each lever, spring and rod separately. Figure 51 3. Install new belt around engine and hydro pump pulleys (Figure 51). Note: Motion control levers must be installed correctly. See Installing the Motion Control Levers in the set up instructions. 4. Pull spring loaded idler down and align below traction belt.
Hydraulic 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 53). Checking the Hydraulic Fluid Level 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. Service Interval: After the first 8 hours 10.
Note: The fluid level should be to the top of the hot level of the baffle, when the fluid is hot (Figure 54). 8. Install cap on filler neck. Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • 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. Figure 55 1. Hydraulic filter 2.
Bleeding the Hydraulic System Setting the Hydraulic Pump Neutral Position 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. Note: Adjust the handle neutral first. That needs to be correct before the following adjustment can be made. 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.
Figure 58 1. 2. 3. 4. 5. 6. Figure 57 1. Pump rod 2. Double nuts 3. Lock nut 4. Ball joint 5. Yoke 6. Adjustment bolt 4. Move the motion control lever forward and reverse, then back to neutral. The wheel must stop turning or slightly creep in reverse. Clevis pin in slot Nut against yoke Adjustment bolt Pump rod Double nuts Jam nut 7. 8. 9. 10. 11. Spring Pivot shaft Yoke Locknut Ball joint 2. Start the engine, open throttle 1/2 way, and release parking brake.
Mower Deck Maintenance 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. Leveling the Mower at Three Positions 9. Install the seat rod and lower the seat into position. 10. Remove the jack stands. Important: There are only three measuring positions needed to level the mower. Setting Up the Machine 1. Position mower on a flat surface. 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 60). 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. Adjust the opposite side if needed. Adjusting the Front-to-Rear Mower Pitch Figure 59 1. Measure here from blade to hard surface 1.
8. Adjust the lift nuts on both the left and the right side of the machine to achieve 1/4 to 3/8 inch (6 to 10 mm) lower in front at A than in the rear at B (Figure 60). 9. Tighten both swivel jam nuts against the front swivel to lock the height. 10. Check to make sure there is equal tension on the chains and adjust again if needed. shredding the grass blades. Tearing and shredding turns grass brown at the edges, which slows growth and increases the chance of disease.
A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders. • Always replace bent or damaged blade with a new blade. • Never file or create sharp notches in the edges or surfaces of blade. Figure 63 1. Cutting Edge 2. Curved Area 3. Wear/slot Forming 4. Crack Removing the Blades 2. Inspect the blades, especially the curved area (Figure 63). Blades must be replaced if a solid object is hit, if the blade is out of balance or is bent.
Replacing the Grass Deflector An uncovered discharge opening could allow the lawn mower to throw objects in the operator’s or bystander’s direction and result in serious injury. Also, contact with the blade could occur. Figure 65 1. Sharpen at original angle • Never operate the lawn mower unless you install a cover plate, a mulch plate, or a grass chute and catcher. 2. Check the balance of the blade by putting it on a blade balancer (Figure 66).
Cleaning Storage Cleaning Under the Mower Deck 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 1.
C. Stop engine, allow to cool and drain the fuel tank; refer to Servicing the Fuel Tank in Fuel System Maintenance , page 31. 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 27.
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.
Notes: 54
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The Toro Warranty Conditions and Products Covered Instructions for Obtaining Warranty Service The Toro® Company and its afliate, Toro Warranty Company, pursuant to an agreement between them, jointly promises to the original purchaser* to repair any Toro Product used for normal residential purposes* if defective in materials or workmanship.
