Form No. 3358-911 Rev A Z580 Z Master® with a 60in or 72in TURBO FORCE® Side Discharge Mower Model No. 74253—Serial No. 280000001 and Up Model No. 74254—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. 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 ............................................... 17 Operating the Parking Brake ............................... 18 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 1.
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 42. 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 Figure 6 1. Full down position 2.
Think Safety First Please read all safety instructions and symbols in the safety section. Knowing this information could help you or bystanders avoid injury. Operating on wet grass or steep slopes can cause sliding and loss of control. Wheels dropping over edges can cause rollovers, which may result in serious injury, death or drowning. Figure 8 There is no rollover protection when the roll bar is down. 1. Safe Zone-use the Z Master here on slopes less than 15 degrees or flat areas. 2.
Operating the Parking Brake Starting and Stopping the Engine Always set the parking brake when you stop the machine or leave it unattended. Starting the Engine Setting the Parking Brake Note: This machine does not have a manual choke. This machine is equipped with an direct fuel injection (DFI) system. 1. Raise the ROPS up and lock into place, sit on the seat and fasten the seat belt. 2. Move the motion controls to neutral locked position. 3. Set the parking brake; refer to Setting the Parking Brake. 4.
Operating the Power Take Off (PTO) 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. The power take off (PTO) switch starts and stops the mower blades and any powered attachments. Note: Additional starting cycles may be required when starting the engine for the first time after the fuel system has been without fuel completely.
Understanding the Safety Interlock System the throttle control in the fast position for best performance. Always operate in the full throttle position when mowing. The safety interlock system is designed to prevent the engine from starting unless: • You are sitting on the seat. • The parking brake is engaged. • The power take off (PTO) is disengaged. • The motion control levers are in the neutral locked position Machine can spin very rapidly.
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 Height-of-Cut The height-of-cut is adjusted from 1-1/2 to 5 inch (38 to 127 mm) in 1/4 inch (6 mm) increments by relocating the clevis pin into different hole locations. 1.
2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 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 ). Note: The two middle rollers will not have a spacer (Figure 18). 4. Select a hole so the anti-scalp roller is positioned to the nearest corresponding height-of-cut desired. 5. Install the flange nut bushing, spacer, and bolt.
Figure 20 3. Rotate cam to increase or decrease locking pressure 4. Slot 1. Cam lock 2. Lever Figure 22 Positioning the Flow Baffle The following figures are only recommendations for use. Adjustments will vary by grass type, moisture content, and height of grass. Position C This is the full open position. The suggested use for this position is as follows. Note: If the engine power draws down and the mower ground speed is the same, open up the baffle. • Use in tall, dense grass mowing conditions.
Positioning the Seat Pushing the Machine The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable. 1. Disengage the power take off (PTO) and turn the ignition key to off. Move the levers to neutral locked position and apply parking brake. Remove the key. Important: To adjust, move the lever sideways to unlock seat (Figure 24). 2. Rotate the by-pass valves counterclockwise 1 turn to push.
Using the Side Discharge The mower has a hinged grass deflector that disperses clippings to the side and 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. 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 • • • • After the first 25 hours • Change the hydraulic filter. After the first 100 hours • Change gear box oil. Before each use or daily • • • • • • Check the safety system. Check the engine oil. Check the engine 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.
Greasing the Mower Deck and Belt Idlers Service Interval: Every 25 hours—Grease the mower deck and spindles. Every 25 hours—Grease the pump belt idler arm. Grease with No. 2 general purpose lithium base or molybdenum base grease. Important: Make sure cutting unit spindles are full of grease weekly. 1. Disengage the PTO, move the motion control levers to the neutral locked position, and set the parking brake. Figure 30 2.
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. Figure 31 Removing the Air Filter Service Interval: Every 250 hours (more often in dirty or dusty conditions) 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake.
Figure 33 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. Figure 32 1. Air cleaner cover 2. Air filter Checking the Engine Oil Level 3. Air filter body Service Interval: Before each use or daily Note: Check the oil when the engine is cold. Installing the Air Filter 1. If installing a new filter, check the filter for shipping damage. Do not use a damaged filter.
Figure 34 1. Muffler 2. Dipstick 3. Right side fuel cap Figure 35 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. 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 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). Now clean around the spark plug(s) to prevent dirt from falling into the engine and potentially causing damage. Figure 37 1. Engine oil filter 4. Remove the spark plug(s) and metal washer. 3.
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. Figure 40 1. Canter electrode insulator 2. Side electrode 3. Air gap (not to scale) Checking the Malfunction Indicator Light 2. Check the gap between the center and side electrodes (Figure 40). Bend the side electrode (Figure 40) if the gap is not correct.
Electrical System Maintenance Servicing the Battery Warning CALIFORNIA Proposition 65 Warning Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. Figure 41 1. Fuel filter 2. Hydraulic tank Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns.
Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. • Always Disconnect the negative (black) battery cable before disconnecting the positive (red) cable. • Always Reconnect the positive (red) battery cable before reconnecting the negative (black) cable. 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2.
Charging the Battery • Optional Accessory • Ignition, 30 amp, blade-type 1. Unlatch the engine hood and raise the engine hood to gain access to fuse holder (Figure 45). Charging the battery produces gasses that can explode. 2. To replace the fuses, pull out on the fuse to remove it. Never smoke near the battery and keep sparks and flames away from battery. 3. Install a new fuse (Figure 45). Important: Always keep the battery fully charged (1.265 specific gravity).
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 48 and Adjusting the Hydraulic Pump Neutral in Hydraulic System Maintenance , page 49. 1. Push both control levers forward the same distance. 2. Check if the machine pulls to one side.
Checking the Wheel Hub Slotted Nut 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). Service Interval: Every 100 hours The slotted nut needs to be torqued to 125 ft-lb (170 N-m). 1.
6. Remove the right rear wheel from the machine. 7. Locate the hole in the frame and remove the side plug in the gear box. (Figure 50). 8. The oil needs be up to the opening of the gear box hole. 9. Add oil if needed to bring it to the correct level. Figure 51 1. PTO drive belt 2. Gear box 6. Unplug the electric connection for the clutch (Figure 52). 7. Remove the two bolts holding the rubber clutch strap to the mower frame (Figure 52). 8.
Cooling System Maintenance 11. Repeat this for the remaining slots. 12. Check each slot again and make slight adjustments until the feeler gauge between the rotor and armature with very slight contact between them. Servicing the Cooling System Discharge of hot pressurized coolant or touching hot radiator and surrounding parts can cause severe burns. • Do not remove the radiator cap when the engine is hot.
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 54). 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 54). 5.
Brake Maintenance Belt Maintenance Adjusting the Parking Brake Inspecting the Belts Service Interval: Every 25 hours 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. Every 200 hours 1. Engage the parking brake, lever up. 2. Measure the length of the spring.
Figure 59 Figure 58 1. Mower belt 2. Mower spindle pulley 3. Mower idler pulley 1. Belt cover 2. Latch 4. Belt guide 5. Gearbox pulley 6. Spring 3. Insert slot into the tab 4. Loosen the idler plate bolts holding the idler plate (Figure 62). 5. Remove the idler spring. 6. Remove the belt guide on the spring loaded idler pulley shown in Figure 60 and Figure 62. 7. Remove the existing belt. 8. Install the new belt around the mower pulleys and the gearbox pulley under the engine (Figure 60).
10. Install the idler spring to the two posts (Figure 58 and Figure 62). 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 62. 11. Adjust the belt tension, refer to Adjusting the Mower Belt Tension. 8. While holding the belt tension and spring length, tighten the idler plate bolts that secure the idler plate (Figure 62). 12.
Replacing the Pump Drive Belt Service Interval: Every 50 hours—Check the pump drive belt. 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. 2. Remove the PTO drive belt. 3. Remove the spring from the idler arm (Figure 65). 4. Install the new belt around the engine and hydraulic pump pulley (Figure 65). 5. Install the PTO drive belt. 6. Install the spring to the idler arm (Figure 65). Figure 63 1. Knob 2.
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 67). 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 Servicing the Hydraulic System Fluid Type: Mobil 1 15W-50 synthetic motor oil or equivalent synthetic oil. Figure 68 Important: Use oil specified or equivalent. Other fluids could cause system damage. 1. Cap 2. Baffle 3. Cold fluid level-full 4. Hot fluid level-full Hydraulic System Oil Capacity: 132 ounces (3.9 l) Checking the Hydraulic Fluid Hydraulic fluid escaping under pressure can penetrate skin and cause injury.
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 69). 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.
1. Raise the frame and block up the machine so drive wheels can rotate freely. Hydraulic fluid escaping under pressure can penetrate skin and cause injury. 2. Disconnect the electrical connector from the seat safety switch. Temporarily install a jumper wire across terminals in the wiring harness connector. • 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. 3.
Figure 73 Figure 72 1. Tracking knob 2. Hydraulic tank 3. Hydraulic pumps 1. Double nuts 2. Pump rod 3. Adjustment bolt 4. Turn this way to track right 5. Turn this way to track left Setting the Left-hand Hydraulic Pump Neutral Position 4. Locknut 5. Ball joint 6. Pumps Electrical system will not perform proper safety shut off with jumper wire installed. 1. Loosen the locknuts at the ball joints on the pump control rod (Figure 73).
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 74 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 75). 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 75). Note: It is recommended that both sides of the mower are adjusted the same distance. 9. Tighten both swivel jam nuts against the front swivel to lock the height. 9.
Servicing the Cutting Blades Maintain sharp blades throughout the cutting season because sharp blades cut cleanly without tearing or shredding the grass blades. Tearing and shredding turns grass brown at the edges, which slows growth and increases the chance of disease. 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.
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. Figure 80 1. Sharpen at original angle • Never file or create sharp notches in the edges or surfaces of blade. 2. Check the balance of the blade by putting it on a blade balancer (Figure 81). If the blade stays in a horizontal position, the blade is balanced and can be used.
Replacing the Grass Deflector Cleaning Cleaning Under the Mower 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. 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. • Never operate the lawn mower unless you install a cover plate, a mulch plate, or a grass chute and catcher. 2.
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 35. 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.
Notes: 62
Notes: 63
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.
