Form No. 3352–110 Z588E Z Master with 72in TURBO FORCE Side Discharge Mower Model No. 74256–250000001 & Up Operator’s Manual Register your product at www.Toro.
Warning Using the Rollover Protection System (ROPS) . . Think Safety First . . . . . . . . . . . . . . . . . . . . . . . . Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating the Parking Brake . . . . . . . . . . . . . . . . Operating in Cool Weather . . . . . . . . . . . . . . . . . Starting and Stopping the Engine . . . . . . . . . . . . Operating the Power Take Off (PTO) . . . . . . . . . The Safety Interlock System . . . . . . . . . . . . . . . .
Cleaning Under the Mower . . . . . . . . . . . . . . . . . Inspecting the Belts . . . . . . . . . . . . . . . . . . . . . . . Replacing the Mower Belt . . . . . . . . . . . . . . . . . . Adjusting the Mower Belt Tension . . . . . . . . . . . Replacing the Grass Deflector . . . . . . . . . . . . . . . Cleaning and Storage . . . . . . . . . . . . . . . . . . . . . . Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
• Never operate without the PTO shield, or other guards securely in place. Be sure all interlocks are functioning properly. Training • Read the Operator’s Manual and other training material. If the operator(s) or mechanic(s) can not read English it is the owner’s responsibility to explain this material to them. • Never operate with the discharge deflector raised, removed or altered, unless using a grass catcher.
• Use jack stands to support components when required. • Watch for ditches, holes, rocks, dips, and rises that change the operating angle, as rough terrain could overturn the machine. • Carefully release pressure from components with stored energy. • Avoid sudden starts when mowing uphill because the mower may tip backwards. • Disconnect battery or remove spark plug wire before making any repairs. Disconnect the negative terminal first and the positive last. Reconnect positive first and negative last.
Slope Chart Fold along appropriate line Example: Compare slope with folded edge. Align this edge with a vertical surface (Tree, Building, Fence post, pole, etc.
Safety and Instruction 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. 98-5954 1-633462 1-643339 43-8480 1-523552 54-9220 98-4387 1. Warning—wear hearing protection.
4-4163 103-2750 1. Explosion hazard 2. No fire, open flames, 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. 58-6520 1.
107-1621 107-2102 106-9969 107-1622 11
107-2112 107-1860 107-1857 107-1861 107-2114 105-3646 12
107-8076 106-9989 13
106-7492 104-4164 1. Contains lead; do not discard. 2. Recycle 3. Wear eye protection; explosive gases can cause blindness and other injuries 4. No sparks, flame, or smoking 14 5. Sulfuric acid can cause blindness or severe burns. 6. Flush eyes immediately with water and get medical help fast. 7. Maximum fill line 8. Minimum fill line 9.
Gasoline and Oil Warning Gasoline is harmful or fatal if swallowed. Long–term exposure to vapors can cause serious injury and illness. Recommended Gasoline Use UNLEADED Regular Gasoline suitable for automotive use (85 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available. • Avoid prolonged breathing of vapors. • Keep face away from nozzle and gas tank or conditioner opening. • Keep gas away from eyes and skin.
Operation 2 Note: Determine the left and right sides of the machine from the normal operating position. 1 Using the Rollover Protection System (ROPS) m–7447 Figure 2 Warning 1. Full down position To avoid injury or death from rollover: keep the roll bar in the raised locked position and use the seat belt. Important Always use the seat belt with the roll bar in the raised position. Ensure that the rear part of the seat is secured with the seat latch.
7. Tighten the front handles against the center roll bar ends (Fig. 3). 2 1 1 m–6897 Figure 4 1. Front handle 3 Think Safety First m–6478 Figure 5 Please read all safety instructions and symbols in the safety section. Knowing this information could help you or bystanders avoid injury. 1. Safe Zone—use the Z Master here on slopes less than 15 degrees or flat areas. 2. Use walk behind mower and/or hand trimmer near drop–offs and water. 3.
Controls Using the Malfunction Indicator Light Become familiar with all the controls before you start the engine and operate the machine (Figures 7 and 8). The malfunction indicator light lets the user know there is a problem with the fuel injection system. 8 If the malfunction indicator light (MIL) illuminates, during operation, the electronic control unit (ECU) has detected a problem or fault in the electronic fuel injection (EFI) system.
Setting the Parking Brake Starting and Stopping the Engine 1. Move the motion control levers (Fig. 7) out to the neutral lock position. Starting the Engine 2. Pull back and up on the parking brake lever to set the parking brake (Fig. 10). The parking brake lever should stay firmly in the engaged position. Note: This machine does not have a manual choke. This machine is equipped with a electronic fuel injection (EFI) system. Warning 1.
1 Operating the Power Take Off (PTO) 2 3 The power take off (PTO) switch engages and disengages power to the electric clutch. Engaging the PTO M–4268 1. While seated in the seat, release pressure on the traction control levers and place in neutral. Figure 13 1. Off 2. Run 3. Start 2. Place the throttle to the fast position. 3. Pull out on the power take off (PTO) switch to engage (Fig. 14). Important Do not engage starter for more than 10 seconds at a time.
Understanding the Safety Interlock System Caution The safety interlock system is designed to prevent the engine from starting unless: Machine can spin very rapidly. Operator may lose control of machine and cause personal injury or damage to machine. • You are sitting on the seat. • Use caution when making turns. • Slow the machine down before making sharp turns. • The parking brake is engaged. • The power take off (PTO) is disengaged. • The motion control levers are in neutral locked position.
To go straight, apply equal pressure to both motion control levers (Fig. 15). 1 To turn, release pressure on the motion control lever toward the direction you want to turn (Fig. 15). 2 To stop push the motion control levers to the neutral position. Stopping the Machine To stop the machine, move the traction control levers to neutral and move to locked position, disengage the power take off (PTO), and turn the ignition key to off.
Note: The two middle rollers will not have a spacer (Fig. 19). 3. Select a hole so the anti–scalp roller is positioned to the nearest corresponding height-of-cut desired (Fig. 18). 1 4. Install the flange nut bushing, spacer, and bolt. Torque to 40–45 ft–lb (54–61 N m) (Fig. 18). 5. Repeat this adjustment on the other anti–scalp rollers. 2 5 1 3 m–6844 Figure 20 1. Anti–scalp roller 2. Spacer 3. Bushing 4 2 4. Flange Nut 5.
Positioning the Flow Baffle Position C The following figures are only recommendations for use. Adjustments will vary by grass type, moisture content, and height of grass. 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 wet conditions. Position A • Allows increased ground speed in heavy conditions. This is the full rear position.
Unlatching the Seat Push the seat latch rearward to unlatch the seat. This will allow access to the machine under the seat. 3 1 2 2 1 m–6861 Figure 25 1. Seat suspension knob 2. Seat position adjustment m–6840 Figure 27 1. Seat latch 2. Gas cap Changing the Back Position The back of the seat can be adjusted to provide a comfortable ride. Position the back of the seat where it is most comfortable. 3. Seat Pushing the Machine by Hand 1.
1 Breaking in a New Machine 2 New engines take time to develop full power. Mower decks and drive systems have higher friction when new, placing additional load on the engine. Allow 40 to 50 hours of break–in time for new machines to develop full power for best performance. 1 Transporting Machines Use a heavy–duty trailer or truck to transport the machine. Ensure that the trailer or truck has all necessary lighting and marking as required by law. Please carefully read all the safety instructions.
of the slope and the ramp extends up the slope. This will minimize the ramp angle. The trailer or truck should be as level as possible. 1 4 Important Do Not attempt to turn the unit while on the ramp; you may lose control and drive off the side. Avoid sudden acceleration when driving up a ramp and sudden deceleration when backing down a ramp. Both maneuvers can cause the unit to tip backward.
1. Raise the mower to the transport position. Warning 2. Remove the bracket pin (Fig. 30). Parking brake may not hold machine parked on Z Stand and could cause personal injury or property damage. 4 Do not park on Z Stand unless wheels are chocked or blocked. 2 8. Perform the maintenance. 5 1 3 Driving off the Z Stand m–5599 Figure 30 1. Z Stand 2. Latch 3. Bracket 1. Remove the chocks or blocks. 4. Bracket Pin 5. Bottom of slot 2. Raise the latch to the unlocked position (Fig. 32). 3.
Tips for Mowing Grass Long Grass Fast Throttle Setting If the grass is ever allowed to grow slightly longer than normal, or if it contains a high degree of moisture, raise the cutting height higher than usual and cut the grass at this setting. Then cut the grass again using the lower, normal setting. For best mowing and maximum air circulation, operate the engine at the fast throttle position.
Maintenance Recommended Maintenance Schedule Maintenance Service Interval After first 5 hours Each Use Maintenance Procedure • Hydraulic fluid—check level • Hydraulic filter—change • • • • • Oil—check level Safety System—check Mower Housing—clean Air cleaner filter minder—check1 Engine air intake—clean1 Every 8 Hours • Cutting Blades—check Every 25 Hours • • • • • • • • Idler arm—grease Traction belt idler arm—grease Brake lever—grease Mower support arms—grease Linkage bushings—oil1 Hydraulic fluid—
1More often in dusty, dirty conditions Important Refer to your engine operator’s manual for additional maintenance procedures. Caution 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 and disconnect the wire from the spark plug(s) before you do any maintenance. Set the wire aside so that it does not accidentally contact the spark plug.
F ront Warning A Contact with sharp blade can cause serious injury. A A Wear gloves or wrap sharp edges of the blade with a rag. 1. Hold the blade end using a rag or thickly-padded glove. Remove the blade bolt, spring disk and blade from the spindle shaft (Fig. 38). m–1078 Figure 34 Sharpening the Blades Warning MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE When sharpening blade, pieces of blade could be thrown and cause serious injury. Wear proper eye protection when sharpening blade.
Installing the Blades 2. Reset the gauge by depressing the button in the bottom of the canister until the plunger returns to the lowest point (Fig. 39). 1. Install the blade onto the spindle shaft (Fig. 38). 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 (Fig. 38). Torque the blade bolt to 85–110 ft-lb (115–150 N m). 3 2 1 5 M–4824 4 2 Figure 39 1. Filter minder 2.
7. Inspect the primary filter for damage by looking into the filter while shining a bright light on the outside of the filter. Holes in the filter will appear as bright spots. If the filter is damaged discard it. 3 4 4. Install the air cleaner cover with the side indicated as UP facing up and secure the latches (Fig. 40). Servicing the Engine Oil Change oil: 1 • After every 100 operating hours. Note: Change oil more frequently when operating conditions are extremely dusty or sandy.
2 1 3 6. Check the oil level; refer to Checking the Oil Level, page 34. 7. Slowly add additional oil to bring it to the full mark. Change the Oil Filter Replace the oil filter every 200 hours or every other oil change. Note: Change the oil filter more frequently when operating conditions are extremely dusty or sandy. m–4811 m–3219 1. Drain the oil from the engine; refer to Changing/Draining Oil, page 35. Figure 41 1. Oil dipstick 2. Filler tube 3. Metal end 2.
Servicing the Spark Plug 2 Check the spark plug(s) after every 200 operating hours. Make sure the air gap between the center and side electrodes is correct before installing the spark plug. Use a spark plug wrench for removing and installing the spark plug(s) and a gapping tool/feeler gauge to check and adjust the air gap. Install a new spark plug(s) if necessary. 3 1 0.030 inch (0.76 mm) Type: Champion RC12YC (or equivalent) Air Gap: 0.030 inch (0.76 mm) m–3215 Figure 45 1.
Servicing the Fuel Filter 4. Connect a grease gun to the fitting. Pump grease into the fittings until grease begins to ooze out of the bearings. Replace the high pressure fuel filter after every 1500 operating hours or more frequently under extremely dusty or dirty conditions. 5. Wipe up any excess grease. Ensure that an Authorized Service Dealer replaces the fuel filter and any components for the fuel system. Greasing the Front Caster Pivots Lubricate the front caster pivots once a year. Warning 1.
Where to Add Light Oil or Spray Lubrication Cleaning the Cooling Systems Cleaning the Engine Screen and the Oil Cooler Lubricate the machine in the following areas with spray type lubricant or light oil. Lubricate every 160 hours. 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 and engine air intake screen (Fig. 48). • Seat switch actuator. • Brake handle pivot. • Brake rod bushings. • Motion control bronze bushings.
Adjusting the Caster Pivot Bearing 1 Check after every 500 operating hours or at storage, which ever comes first. 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. m–1872 Figure 50 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 1. Valve stem 3. Remove dust cap from caster and tighten lock nut (Fig. 52). Checking the Wheel Hub Slotted Nut 4.
Servicing the Hydraulic System 5. Run the machine at low idle for 15 minutes to allow any air to purge out of the system and warm the fluid. Refer to Starting and Stopping the Engine on page 19. Checking the Hydraulic Fluid 6. Recheck the fluid level while the fluid is warm. The fluid should be between cold and hot. Check the hydraulic fluid level: 7. If required, add fluid to the hydraulic tank. • Before the engine is first started. • After the first 8 operating hours.
Bleeding the Hydraulic System 3. Place drain pan under filter, remove the old filter and wipe the filter adapter gasket surface clean (Fig. 54). 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. 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. Engage the lever and traction on one side and spin the wheel by hand.
Note: Motion control levers must be installed correctly. See Installing the Motion Control Levers in the set up instructions. 2 9 1 6 7 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 3 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Unlatch the seat and tilt the seat forward. 4. Begin with either the left or right motion control lever. 5.
1. Raise the frame and use jack stands to hold up the machine so drive wheels can rotate freely. Setting the Left–hand Hydraulic Pump Neutral 2. Unlatch the seat, tilt the seat forward and disconnect electrical connector from the seat safety switch. 1. Loosen the locknuts at the ball joints on pump control rod (Fig. 57). 3. Temporarily install a jumper wire across terminals in the wiring harness connector. 2. Start the engine, open throttle 1/2 way and release parking brake.
Adjusting the Tracking Replacing the Pump Drive Belt The right hand pump has a knob for adjusting the tracking. Check pump drive belt for wear after every 50 hours of operation. Important Adjust the handle neutral and hydraulic pump neutral before adjusting the tracking. Refer to Adjusting the Handle Neutral on page 41 and Adjusting the Hydraulic Pump Neutral on page 42. 1. Pull the spring loaded idler down and remove traction belt from the engine and hydro pump pulleys (Fig. 60).
6. If adjustment is necessary, loosen the jam nut directly below the yoke. Turn the bottom rod until the correct measurement is obtained (Fig. 61). Tighten jam nut at yoke 2 3 4 5 1 6 m–4823 1 Figure 63 1. Engine-20 amp 2. Fuel Pump-10 amp 3. Plastic clip 2 m–3788 3 Servicing the Battery Figure 61 1. Brake lever 2. Spring 2.75 inch (70 mm) 3. Adjusting nuts Warning 4. Collar on brake rod 5. 3/16–1/4 inch (5–7 mm) 6.
1 4 5 11 7 6 2 3 2 7 9 3 m–5004 Figure 64 1. Filler caps 2. Upper line 3. Lower line 10 1 8 m–5598 Figure 65 Danger 1. 2. 3. 4. 5. 6. Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns. • Do not drink electrolyte and avoid contact with skin, eyes or clothing. Wear safety glasses to shield your eyes and robber gloves to protect your hands. • Fill the battery where clean water is always available for flushing the skin.
2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 1. Remove the battery from the chassis; refer to Removing the Battery, page 46. 2. Check the electrolyte level; refer to Checking Electrolyte Level, page 45. 3. Unlatch the seat and tilt the seat up. 4. First disconnect the negative battery cable and ground wire from the negative (–) battery terminal (Fig. 65). 3. Make sure the filler caps are installed in battery.
F ront Leveling the Mower at Three Positions Important There are only three measuring positions needed to level the mower. Setting Up the Machine B C 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. m–1078 Figure 67 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.
Front 2 6 MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE m–2539 Figure 71 2 3 3. Record this measurement. 7 1 4. Measure the right blade at the B location (Fig. 70), from a level surface to the cutting edge of the blade tip (Fig. 71). 4 1 5 m–6830 5. Record this measurement. Figure 69 1. 2. 3. 4. Rear chain Rear support arm Bolt Jam Nut 5. Adjustment bolt 6. Front swivel 7. Front support arm 6.
3. Adjust this distance, by loosening the spring jam nut and turning the nut in front of each spring (Fig. 72). Turning the nut clockwise will shorten the spring; counter–clockwise will lengthen the spring. Warning Unit could fall onto someone and cause serious injury or death. 4. Lock the nut into position by tightening the spring jam nut (Fig. 72). 8 • Use extreme caution when operating unit on Z Stand. • Use only for cleaning mower and removing blades.
8. Install the belt guide with a washer and nut onto the rear leftside pulley (Fig. 73). 2 1 Important Check the amount of twist in the belt between the pulleys. Make sure it is only what is specified in Figure 73. 1 1 3 4 8 9 5 4 m–6824 3 Figure 74 1. Belt cover 2. Latch 4 3 2 Adjusting the Mower Belt Tension 4 6 10 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 7 2.
6 4 3 1 5 2 3 M–4417 1 2 Figure 75 1. Center bolt 2. Alignment hole m–6825 3. Left support plate 4. Spring loaded idler 1 Figure 77 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 mower idler plate and adjust it (Fig. 76). 6. Insert a ratchet or breaker bar into the square hole in the mower idler plate to adjust the tension (Fig. 76). 4. Idler pulley arm 5. Belt 6. Rubber bumper 11.
1. Remove the locknut, bolt, spring and spacer holding the deflector to the pivot brackets (Fig. 79). Remove damaged or worn grass deflector. 2. Place spacer and spring onto grass deflector. Place the L end of spring behind deck edge. Note: Make sure the L end of spring is installed behind deck edge before installing the bolt as shown in figure 79. 3. Install bolt and nut. Place J hook end of spring around grass deflector (Fig. 79). Important The grass deflector must be able to lower down into position.
Cleaning and Storage 12. Charge the battery; refer to Servicing the Battery page 45. 1. Disengage the power take off (PTO), set the parking brake and turn the ignition key to off. Remove spark plug wire. Remove the key. Note: Disconnect the negative battery cable before storing the machine. 13. Check and tighten all bolts, nuts, and screws. Repair or replace any part that is damaged or defective. 2.
Wiring Diagram 55
Troubleshooting Problem Starter does not crank Engine g will not start,, starts hard,, or f il to fails t keep k running. i Engine g loses power. Engine g overheats. Possible Causes Corrective Action 1. Blade control (PTO) is Engaged. 1. Move blade control (PTO) to Disengaged. 2. Parking brake is not on. 2. Set parking brake. 3. Operator is not seated. 3. Sit on the seat. 4. Battery is dead. 4. Charge the battery. 5. Electrical connections are corroded or loose. 5.
Problem Machine does not drive. Abnormal vibration. Uneven cutting g height. g Blades do not rotate. Possible Causes Corrective Action 1. Traction belt is worn, loose or broken. 1. Contact Authorized Service Dealer. 2. Traction belt is off pulley. 2. Contact Authorized Service Dealer. 3. Hydro fluid level low. 3. Add hydro fluid to reservoir. 4. Tension spring is not connected. 4. Connect the tension spring. 1. Cutting blade(s) is/are bent or unbalanced. 1. Install new cutting blade(s). 2.
Problem Malfunction Indicator Light (MIL) comes on. Possible Causes Corrective Action 1. Old gas in gas tank or fuel shut off valve not open completely. 1. Use new gas and ensure shut off valve is open. 2. Fuel tank vent cap is blocked. 2. Make sure fuel tank vent cap is not blocked and working properly. 3. Air cleaner is dirty. 3. Make sure air cleaner and precleaner is clean. Replace if necessary. 4. Incorrect fuel filters used or dirty fuel filters. 4.
The Toro Total Coverage Guarantee LCE A Limited Warranty Conditions and Products Covered Owner Responsibilities 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. The following time periods apply from the date of purchase: You must maintain your Toro Product by following the maintenance procedures described in the operator’s manual.