Form No. 3361-722 Rev A Z580 Z Master® with a 60in or 72in TURBO FORCE® Side Discharge Mower Model No. 74253—Serial No. 290000001 and Up Model No. 74254—Serial No. 290000001 and Up To register your product or download an Operator's Manual or Parts Catalog at no charge, go to 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) .......................................................... 16 Think Safety First ............................................... 18 Operating the Parking Brake ............................... 19 Starting and Stopping the Engine ........................ 19 Operating the Power Take Off (PTO) ................. 20 The Safety Interlock System................................ 20 Driving Forward or Backward............................. 21 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 65-2690 1-523552 66-1340 1-643253 68-8340 98-4387 1. Warning—wear hearing protection.
98-5954 107-1857 104-2449 107-1860 1.
107-1861 107-2102 107-1864 107-2112 107-2114 9
8-5981 109-7949 110-3851 1. Remove the ignition key and read the instructions before servicing or performing maintenance. 110-2067 110-3852 1. Remove the ignition key and read the instructions before servicing or performing maintenance. 2. Continuous tone signals the user that engine is overheating. 110-2068 1. Read the Operator’s Manual. 110-3853 1. Cutting/dismemberment hazard, fan and entanglement hazard, belt. 10 2.
0-6220 117-7839 Manufacturer’s Mark 110-6221 1. Indicates the blade is identified as a part from the original machine manufacturer. 112-8651 1. 2. 3. 4. 5. 6. Interval Power Take-off (PTO) Parking brake Neutral Operator presence switch Battery 117–0919 1. Fast 2. Continuous variable setting 117–2718 117-7838 11 3.
106-7492 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.
110-0819 Product Overview Figure 4 1. Fuel tank cap 2. Malfunction indicator light (MIL) 3. Engine Temperature light 4. Throttle control 5. PTO Switch 6. Hour meter/Safety interlock display 7. Ignition switch 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. 10. Hour Meter Controls Fuel cap (both sides) Parking brake lever Caster wheel Mower deck The hour meter records the number of hours the engine has operated.
Move the selector valve to the lefthand (LH) or righthand (RH) position for operation. Malfunction Indicator Light The electronic control unit (ECU) continuously monitors the operation of the fuel system. 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 5 1. Safety interlock symbols 2. Hour meter 3.
Operation Adding Fuel 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. Use unleaded regular gasoline suitable for automotive use (87 pump octane minimum). • Always place gasoline containers on the ground away from your vehicle before filling.
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 8). 2 2. Lower the rollbar to the down position. There are two down positions. See Figure 7 for the positions. 3. Install the two pins and secure them with the hairpin cotter pins (Figure 8). 3 4 G004955 Figure 8 1. Roll bar 2. Raised position Figure 7 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 9 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 digital 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.
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 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.
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 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 19 , Figure 20 and Figure 21 ). Note: The two middle rollers will not have a spacer (Figure 20). 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.
Position B Use this position when bagging. Figure 22 3. Rotate cam to increase or decrease locking pressure 4. Slot 1. Cam lock 2. Lever Positioning the Flow Baffle Figure 24 The following figures are only recommendations for use. Adjustments will vary by grass type, moisture content, and height of grass. Position C Note: If the engine power draws down and the mower ground speed is the same, open up the baffle. This is the full open position. The suggested use for this position is as follows.
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. To adjust, move the lever sideways to unlock seat (Figure 26). 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.
the machine with a low fuel level and do not run the machine out of fuel. Always allow the machine to cool before refilling the fuel tanks. Loading a unit onto a trailer or truck increases the possibility of backward tip-over and could cause serious injury or death. Fast Throttle Setting For best mowing and maximum air circulation, operate the engine at the fast throttle position.
Long Grass 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. 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. After the first 100 hours • Check the wheel hub slotted nut. • Check the wheel lug nuts. • 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 hydraulic oil cooler and radiator screen. Check the mower blades.
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 30). Grease more frequently when operating conditions are extremely dusty or sandy. Grease Type: General-purpose grease. How to Grease 1.
Greasing the Brake Pivot Service Interval: Every 200 hours—Grease the brake pivot. Figure 32 5. Grease the pump belt idler arm (Figure 33). Figure 31 Greasing the Mower Deck and Belt Idlers Service Interval: Every 25 hours—Grease the mower deck and spindles. Every 25 hours—Grease the mower belt idler arm. Every 25 hours—Grease the pump belt idler arm. Every 25 hours—Grease the drive belt idler arm. Figure 33 Grease with No. 2 general purpose lithium base or molybdenum base grease. 6.
Lubricate Caster Wheel Hubs 13. Torque the nut to 75-80 in-lb (8-9 N-m), loosen, then re-torque to 20-25 in-lb (2-3 N-m). Make sure axle does not extend beyond either nut. Service Interval: Yearly 1. Stop the engine, wait for all moving parts to stop, and remove the key. Engage the parking brake. 14. Reinstall the seal guards over the wheel hub and insert wheel into caster fork. Reinstall caster bolt and tighten nut fully. Important: To prevent seal and bearing damage, check the bearing adjustment often.
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 36 1. Air cleaner cover 2. Air filter 1.
Figure 37 Figure 38 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 38). 7. Slide the oil dipstick fully into the engine. Pull the dipstick out and look at the metal end (Figure 38). If oil level is low, slowly pour only enough oil into the filler tube to raise the level to the full mark.
Figure 41 1. Engine oil filter 3. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Figure 42). 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 42). Figure 39 1. Oil drain valve 2. Oil drain hose 9. Slowly pour approximately 80% of the specified oil into the filler tube (Figure 40). 10.
Removing the Spark Plug 2. Check the gap between the center and side electrodes (Figure 44). Bend the side electrode (Figure 44) 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 43).
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 45 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.
Charging the Battery Charging the battery produces gasses that can explode. 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. 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.
Drive System Maintenance 2. To replace the fuses, pull out on the fuse to remove it. 3. Install a new fuse (Figure 49). 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 , page and Adjusting the Hydraulic Pump Neutral in , page . 1. Push both control levers forward the same distance. 2. Check if the machine pulls to one side.
Checking the Wheel Hub Slotted Nut Service Interval: After the first 100 hours—Check the wheel hub slotted nut. Every 500 hours—Check the wheel hub slotted nut. After the first 100 hours—Check the wheel lug nuts. Every 500 hours—Check the wheel lug nuts. 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.
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 dust cap from caster and tighten lock nut (Figure 53). 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 53). 6. Remove the right rear wheel from the machine. 7.
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. Figure 55 1. PTO drive belt 2. Gear box Figure 57 3. Spring loaded idler pulley 1. Slot 2. Adjusting nut 6. Unplug the electric connection for the clutch (Figure 56). 7. Remove the two bolts holding the rubber clutch strap to the mower frame (Figure 56). 8.
Cooling System Maintenance 1. Position the machine on a level surface, stop the engine, and set the parking brake. 2. 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 58). Servicing the Cooling System 3. If the coolant level is low, add a 50/50 mix of extended life antifreeze/Dex-Cool® and water to the overflow bottle (Figure 58).
Brake Maintenance Adjusting the Parking Brake Service Interval: Every 200 hours—Check the parking brake adjustment. 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 60). 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 60). Turn the nut until the correct measurement is obtained.
Belt Maintenance 8. Install the new belt around the mower pulleys and the gearbox pulley under the engine (Figure 62). 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.
Figure 64 1. Belt guide install at a 45 4. Ratchet or breaker bar degree angle 2. Idler spring length 5. Idler plate bolt (between 10 and 10-1/4 inches (25.4 and 26.0 cm)) 3. Idler plate Figure 63 1. Belt cover 2. Latch 3. Insert slot into the tab Adjusting the Mower Belt Tension for 72in Mowers Only Replacing the PTO Drive Belt Service Interval: After the first 8 hours Service Interval: Every 50 hours—Check the PTO drive belt.
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. Refer to Replacing the PTO Drive Belt. 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 67). 4. Install the new belt around the engine and hydraulic pump pulley (Figure 67). 5. Install the PTO drive belt. 6.
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 69). 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 70 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 71). 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 75 Figure 74 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 75).
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 76 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 77). 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 77). 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 82 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 83). 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. Service Interval: Before each use or daily • Never operate the lawn mower unless you install a cover plate, a mulch plate, or a grass chute and catcher. 2.
Storage B. Run the engine to distribute conditioned fuel through the fuel system (5 minutes). Cleaning and Storage C. Stop the engine, allow it to cool, and drain the fuel tank; refer to Servicing the Fuel Tank in , page . 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to Off. Remove the key. 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 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. The fuel shut-off valve is not open completely. 3.
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: 63
The Toro Total Coverage Guarantee A Limited Warranty (see warranty periods below) Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair the listed Toro Products if defective in materials or workmanship.
