Form No. 3357-968 Rev D Z589 Z Master® with a 60in or 72in TURBO FORCE® Side Discharge Mower Model No. 74253—Serial No. 270000101 and Up Model No. 74254—Serial No. 270000101 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. Because in some areas there are local, state, or federal regulations requiring that a spark arrester be used on the engine of this machine, a spark arrester is incorporated with the muffler assembly. Figure 1 1. Model and serial number location Genuine Toro spark arresters are approved by the USDA Forestry Service.
Using the Rollover Protection System (ROPS) .......................................................... 15 Think Safety First ............................................... 16 Operating the Parking Brake ............................... 17 Starting and Stopping the Engine ........................ 18 Operating the Power Take Off (PTO) ................. 19 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. 58-6520 1. Grease 1-403005 66-1340 1-523552 65-2690 1-643253 68-8340 98-4387 1. Warning—wear hearing protection.
98-5954 105-7798 107-1860 107-1613 107-1857 107-1861 107-1864 8
107-2449 107-2102 108-5981 107-2112 110-2067 107-2114 9
110-3853 1. Cutting/dismemberment hazard, fan and entanglement hazard, belt. 110-2068 1. Read the Operator’s Manual. 2. Remove the ignition key and read the instructions before servicing or performing maintenance. 110-5772 1. Engine—stop 2. Engine—run 3. Engine—start 4. Fast 5. Continuous variable setting 6. Slow 7. Power take-off (PTO) 110-3851 1. Remove the ignition key and read the instructions before servicing or performing maintenance. 110-5794 110-3852 1.
Manufacturer’s Mark 1. Indicates the blade is identified as a part from the original machine manufacturer.
106-9989 107-9309 1. Warning—read the Operator’s Manual for information on charging the battery; contains lead; do not discard. 2. Read the Operator’s Manual.
Use these times for scheduling regular maintenance (Figure 4). Temperature Light The temperature light comes on when the engine is over heating (Figure 4). Audible Alarm This machine has an audible alarm that alerts the user to turn off the engine or engine damage can occur from over heating. Refer to Servicing the Cooling System in Cooling System Maintenance , page 40. Fuel Selector Valve Figure 3 1. 2. 3. 4. 5. Lift assist lever Height-of-cut lever Motion control levers Roll bar Seat belt 6. 7. 8. 9.
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. 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. Filling the Fuel Tank 1. Shut the engine off and set the parking brake. 2. Clean around each fuel tank cap and remove the cap. 3.
Important: Lower the roll bar only when absolutely necessary. 1 1. Remove the hairpin cotter pins and remove the two pins (Figure 7). 2 2. Lower the the roll bar to the down position. There are two down positions. See Figure 6 for the positions. 3. Install the two pins and secure them with the hairpin cotter pins (Figure 7). 3 4 G004955 Figure 7 1. Roll bar 2. Raised position 3. Pin 4. Hairpin cotter pin Figure 6 1. Full down position 2.
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 12 Figure 10 1. Parking brake-ON 2. Parking brake-OFF 1. Throttle—fast 3. Brake Stop 2. Throttle—slow 6. Turn the ignition key to the Start position (Figure 13). When the engines starts, release the key. Starting and Stopping the Engine Important: Do not engage starter for more than 5 seconds at a time. If the engine fails to start allow a 15 second cool-down period between attempts. Failure to follow these instructions can burn out the starter motor.
Disengaging the PTO 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. To disengage, push the PTO switch to the off position (Figure 14). The Safety Interlock System Children or bystanders may be injured if they move or attempt to operate the tractor while it is unattended.
the engine. While the engine is running, release the parking brake, engage the PTO and rise slightly from the seat; the engine should stop. 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.
2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Children or bystanders may be injured if they move or attempt to operate the tractor while it is unattended. 3. After adjusting the height-of-cut, adjust the rollers by removing the flange nut, bushing, spacer, and bolt (Figure 17 , Figure 18 and Figure 19 ). Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes.
Figure 20 3. Rotate cam to increase or decrease locking pressure 4. Slot 1. Cam lock 2. Lever Figure 19 1. Anti-scalp roller 2. Spacer 3. Bushing 4. Flange Nut 5. Bolt Positioning the Flow Baffle The following figures are only recommendations for use. Adjustments will vary by grass type, moisture content, and height of grass. 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.
Slide the seat to the desired position and release lever to lock in position. Figure 24 Figure 22 1. Adjustment lever Position C Unlatching the Seat This is the full open position. The suggested use for this position is as follows. • Use in tall, dense grass mowing conditions. • Use in wet conditions. • Lowers the engine power consumption. • Allows increased ground speed in heavy conditions. • This position is similar to the benefits of the Toro SFS mower.
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. 3. Disengage parking brake before pushing.
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 • • • • After the first 25 hours • Change the hydraulic filter and oil. After the first 100 hours • Change gear box oil. Before each use or daily • • • • • • Check the safety system. Check the engine oil. Check cooling system level. Clean the hyraulic oil cooler and radiator screen. Check the mower blades. Clean the mower deck.
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 before you do any maintenance. Lubrication Greasing and Lubrication Lubricate the machine when shown on the Check Service Reference Aid decal (Figure 28). Grease more frequently when operating conditions are extremely dusty or sandy. Grease Type: General-purpose grease. How to Grease 1.
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. Grease the idler pulley pivot (Figure 29). 4. Grease the fittings on the 3 spindle bearings (Figure 29). Figure 31 Figure 29 5. Grease the pump belt idler arm (Figure 30). Figure 30 6. Grease the PTO drive belt idler arm (Figure 31).
Engine Maintenance Contact with hot surfaces may cause personal injury. Keep hands, feet, face, clothing and other body parts away the muffler and other hot surfaces. Servicing the Air Cleaner Note: Check the filters more frequently if operating conditions are extremely dusty or sandy. Removing the Air Filter Service Interval: Every 250 hours (more often in dirty or dusty conditions) Figure 32 1. Air cleaner cover 2. Air filter 1.
Figure 33 Figure 34 Note: Using multi grade oils (5W-20, 10W-30, and 10W-40) will increase oil consumption. Check the oil level more frequently when using them. 1. Muffler 2. Dipstick 3. Right side fuel cap 6. Pull the oil dipstick and wipe the metal end clean (Figure 34). 7. Slide the oil dipstick fully into the engine. Pull the dipstick out and look at the metal end (Figure 34). If oil level is low, slowly pour only enough oil into the filler tube to raise the level to the full mark.
Figure 37 1. Engine oil filter 3. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Figure 38). 4. Install the replacement oil filter to the filter adapter. Turn the oil filter clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 1/2 turn (Figure 38). Figure 35 1. Oil drain valve 2. Oil drain hose 9. Slowly pour approximately 80% of the specified oil into the filler tube (Figure 36). 10.
Removing the Spark Plug 2. Check the gap between the center and side electrodes (Figure 40). Bend the side electrode (Figure 40) 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 39).
Fuel System Maintenance Servicing the Electronic Fuel Injection System This machine contains an electronic fuel injection system. It controls the fuel flow under different operating conditions. Checking the Malfunction Indicator Light If the malfunction indicator light (MIL) illuminates, during operation, the electronic control unit (ECU) has detected a problem or fault in the direct fuel injection (DFI) system. Figure 41 1. Fuel filter 2.
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.
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. Make sure the filler caps are installed in battery. Charge battery for 10 to 15 minutes at 25 to 30 amps or 30 minutes at 10 amps. 2. When the battery is fully charged, unplug the charger from the electrical outlet, then disconnect the charger leads from the battery posts (Figure 44). 3.
Drive System Maintenance Adjusting the Tracking The machine has a knob for adjusting the tracking located under the seat. Important: Adjust the handle neutral and hydraulic pump neutral before adjusting the tracking. Refer to Adjusting the Handle Neutral in Controls System Maintenance , page 45 and Adjusting the Hydraulic Pump Neutral in Hydraulic System Maintenance , page 46. Figure 45 1. Fan-30 amp 2. Engine-10amp 3. Optional accessory 4. Ignition-30amp 5. Left side of machine 1.
Checking the Wheel Hub Slotted Nut Service Interval: Every 500 hours The slotted nut needs to be torqued to 125 ft-lb (170 N•m). 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. Remove the cotter pin. 4. Torque the slotted nut to 125 ft-lb (170 N•m) (Figure 48). Figure 46 1. Tracking knob 2. Hydraulic tank 3. Hydraulic pumps 4.
6. Remove the right rear wheel from the machine. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the dust cap from caster and tighten lock nut (Figure 49). 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 49). 7. Locate the hole in the frame and remove the side plug in the gear box. (Figure 50). 8.
Cooling System Maintenance 1. Position the machine on a level surface, stop the engine, and set the parking brake. 2. Unlatch the seat and tilt the seat up. 3. With the engine cool, check the overflow bottle level. The fluid needs to be up to the bump on the outside of the overflow bottle (Figure 51). Servicing the Cooling System 4. If the coolant level is low, add a 50/50 mix of extended life antifreeze/Dex-Cool® and water to the overflow bottle (Figure 51).
Brake Maintenance Adjusting the Parking Brake Service Interval: Every 25 hours Every 200 hours 1. Engage the parking brake, lever up. 2. Measure the length of the spring. Measurement should be 2-1/2 inch (64 mm) between the washers (Figure 53). 3. If adjustment is necessary, release the parking brake, loosen the jam nut below the spring and adjust the nut directly below the spring (Figure 53). Turn the nut until the correct measurement is obtained.
Belt Maintenance Inspecting the Belts Service Interval: Every 100 hours Check the belts for 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. Replacing the Mower Belt for 60in Mower Decks 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. Figure 55 1. Mower belt 2. Mower spindle pulley 3.
10. Install the idler spring to the two posts (Figure 55 and Figure 59). 11. Adjust the belt tension, refer to Adjusting the Mower Belt Tension. 12. Install the belt covers by sliding the cover into the tab, install the bolts, and close the latches (Figure 58). Figure 56 1. Belt cover 2. Latch 3. Insert slot into the tab 4. Loosen the idler plate bolts holding the idler plate (Figure 59). 5. Remove the idler spring. 6.
7. Rotate the ratchet or breaker bar to move the idler plate until the idler spring is between 10 and 10-1/4 inches (25.4 and 26.0 cm) from post to post as shown in Figure 59. 8. While holding the belt tension and spring length, tighten the idler plate bolts that secure the idler plate (Figure 59). Figure 60 1. Knob Figure 59 2. Front engine panel 4. Remove the spring from the idler arm (Figure 61). 1. Belt guide install at a 45 4. Ratchet or breaker bar degree angle 2. Idler spring length 5.
Controls System Maintenance Note: Remove the PTO drive belt first if the pump drive belt needs to be replaced. 1. Tilt the seat forward and remove the front engine panel. Adjusting the Control Handle Neutral Position 2. Remove the PTO drive belt. 3. Remove the spring from the idler arm (Figure 62). 4. Install the new belt around the engine and hydraulic pump pulley (Figure 62). If motion control levers do not align, or move easily into the console notch, adjustment is required.
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 64). 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. Servicing the Hydraulic System Fluid Type: Mobil 1 15W-50 synthetic motor oil or equivalent synthetic oil. 10.
Important: Do not substitute automotive oil filter or severe hydraulic system damage may result. 3. Place drain pan under filter, remove the old filter and wipe the filter adapter gasket surface clean (Figure 66). Figure 65 1. Cap 2. Baffle 3. Cold fluid level-full 4. Hot fluid level-full Figure 66 1. Hydraulic filter Hydraulic fluid escaping under pressure can penetrate skin and cause injury. 4. Remove the righthand hydraulic line that comes into the adapter (Figure 67). 5.
12. Start the engine and let it run for about two minutes to purge air from the system. Stop the engine and check for leaks. If one or both wheels will not drive, refer to Bleeding Hydraulic System. 13. Recheck the fluid level while the fluid is warm. The fluid should be between cold and hot. 14. If required, add fluid to the hydraulic tank. Do not overfill. Hydraulic fluid escaping under pressure can penetrate skin and cause injury.
1. Raise the frame and block up the machine so drive wheels can rotate freely. 2. Disconnect the electrical connector from the seat safety switch. Temporarily install a jumper wire across terminals in the wiring harness connector. 3. Unlatch the seat and slide seat forward. 4. Disconnect the seat rod and tilt the seat fully forward. Setting the Right-hand Hydraulic Pump Neutral Position 1. Start the engine, open the throttle 1/2 way and release parking brake.
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. 2. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 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.
Adjusting the Front-to-Rear Mower Pitch 1. Position the right blade front-to-rear (Figure 73). 2. Measure the right blade at the A location, from a level surface to the cutting edge of the blade tip (Figure 73). Figure 71 1. Measure here from blade to hard surface 2. Measure at B and C 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 72). Figure 73 8.
2. Check the distance between the two large washers, it needs to be 10-1/2 inches (26.7 cm) for 60 inch mower decks or 11–1/2 inches (29.2 cm) for 72 inch mower decks (Figure 74). A worn or damaged blade can break, and a piece of the blade could be thrown into the operator’s or bystander’s area, resulting in serious personal injury or death. 3. Adjust this distance, by loosening the spring jam nut and turning the nut in front of each spring (Figure 74).
Figure 76 1. Measure here from blade to hard surface 2. Position A 4. Rotate the opposite ends of the blades forward. 5. Measure from a level surface to the cutting edge of the blades at the same position as in step 3 above. The difference between the dimensions obtained in steps 3 and 4 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 75 1. Cutting Edge 2. Curved Area 3.
Installing the Blades 1. Install the blade onto the spindle shaft (Figure 79). Contact with a sharp blade can cause serious injury. Important: The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting. 2. Install the spring disk and blade bolt. The spring disk cone must be installed toward the bolt head (Figure 79). Torque the blade bolt to 85-110 ft-lb (115-150 N•m). Wear gloves or wrap sharp edges of the blade with a rag. 1.
Cleaning 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. Cleaning Under the Mower Service Interval: Before each use or daily 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. Raise the mower to the transport position.
Storage Note: A fuel stabilizer/conditioner is most effective when mixed with fresh fuel and used at all times. Cleaning and Storage B. Run the engine to distribute conditioned fuel through the fuel system (5 minutes). 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to Off. Remove the key. C. Stop the engine, allow it to cool, and drain the fuel tank; refer to Servicing the Fuel Tank in Fuel System Maintenance , page 34. 2.
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 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. Drive belt is worn, loose or broken. 1.
Schematics Wire Diagram (Rev.
The Toro Total Coverage Guarantee Landscape Contractor Equipment (LCE) A Limited Warranty Conditions and Products Covered Owner Responsibilities 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.
