Form No. 3329–744 Z588E Z Master with 72in TURBO FORCE Side Discharge Mower Model No. 74256–240000001 & 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 . . . . . . . . . . . . . . . . Starting and Stopping the Engine . . . . . . . . . . . . Operating the Power Take Off (PTO) . . . . . . . . . The Safety Interlock System . . . . . . . . . . . . . . . . Driving Forward or Backward . . . . . . . . . . . . . . . Stopping the Machine . . .
Replacing the Mower Belt . . . . . . . . . . . . . . . . . . Adjusting the Mower Belt Tension . . . . . . . . . . . Replacing the Grass Deflector . . . . . . . . . . . . . . . Mercury Tilt Switch . . . . . . . . . . . . . . . . . . . . . . . Disposing the Mercury Tilt Switch . . . . . . . . . . . Cleaning and Storage . . . . . . . . . . . . . . . . . . . . . . Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
• Never carry passengers and keep pets and bystanders away. Preparation • Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job. Only use accessories and attachments approved by the manufacturer. • Be alert, slow down and use caution when making turns. Look behind and to the side before changing directions. • Slow down and use caution when crossing roads and sidewalks. Stop blades if not mowing.
• Use extreme care with grass catchers or other attachments. These can change the stability of the machine and cause loss of control. • Charge batteries in an open well ventilated area, away from spark and flames. Unplug charger before connecting or disconnecting from battery. Wear protective clothing and use insulated tools. Using the Rollover Protection System (ROPS) • Keep all parts in good working condition and all hardware tightened. Replace all worn or damaged decals.
Slope Chart 7
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 1-643401 98-4387 66-1340 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 103-2433 12
106-9989 106-7492 13
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–6836 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 1. Sit on the seat and move the motion controls to neutral locked position. 1. Move the motion control levers (Fig. 7) out to the neutral lock position. 2. Set the parking brake; refer to Setting the Parking Brake, page 19. 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. 3. Move the PTO (power take off) switch to the off positions (Fig. 11).
Important Do not engage starter for more than 10 seconds at a time. If engine fails to start allow 60 second cool-down period between attempts. Failure to follow these instructions can burn out starter motor. 2 1 Stopping the Engine 1. Push the PTO to the off position (Fig. 11). 2. Move the throttle lever midway between the slow and fast positions (Fig. 12). m–4201 Figure 14 3. Let the engine idle for 60 seconds (Fig. 12). 1. PTO—Off 2. PTO—On 4.
Testing the Safety Interlock System 3. To go forward, slowly push the motion control levers forward (Fig. 15). Test the safety interlock system before you use the machine each time. If the safety system does not operate as described below, have an Authorized Service Dealer repair the safety system immediately. Note: The engine will kill if the traction control levers are moved with the parking brake engaged. To go straight, apply equal pressure to both motion control levers (Fig. 15). 1.
Using the Lift Assist Lever Caution The lift assist lever is used along with the height–of–cut lever for raising the mower. This allows for easier raising of the mower. Children or bystanders may be injured if they move or attempt to operate the tractor while it is unattended. 1. Place your foot onto lift assist lever. Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes. 2.
1 4 2 2 5 1 3 5 Figure 20 Figure 18 1. Anti–scalp roller 2. Spacer 3. Bushing 1 3 m–6844 m–6821 1. Anti–scalp roller 2. Spacer 3. Bushing 4. Flange Nut 5. Bolt 4. Flange Nut 5. Bolt 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. 1. To adjust the cam locks, swing the lever up to loosen the cam lock (Fig. 21). 3 2.
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.
Transporting Machines 1 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. Knowing this information could help you, your family, pets or bystanders avoid injury. To transport the machine: • Lock the brake and block the wheels. • Securely fasten the machine to the trailer or truck with straps, chains, cable, or ropes.
Warning Warning Loading a unit onto a trailer or truck increases the possibility of backward tip–over and could cause serious injury or death. Unit could fall onto someone and cause serious injury or death. • Use extreme caution when operating unit on Z Stand. • Use only for cleaning mower and removing blades. • Do not keep unit on Z Stand for extended periods of time. • Always turn the engine off, set the parking brake and remove the key before performing any maintenance to mower.
3. Raise the latch. Swing the stand foot out front and slide stand toward machine, into the bottom of slot (Fig. 30 and 31). 4. Set the foot of stand on the ground and rest the latch on the pivot tab (Fig. 31). 5. Start the engine and put it at half throttle. Note: For best results, place the foot of stand into seams in sidewalks or into the turf (Fig. 31). 6. Drive onto the stand. Stop when the latch drops over the tab into the locked position (Fig. 31).
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 Important filter. Do not press on the soft inside area of the 4. Install the air cleaner cover with the side indicated as UP facing up and secure the latches (Fig. 40). Servicing the Engine Oil 1 Change oil: • After every 100 operating hours.
Note: Dispose of the used oil at a certified recycling center. Important Do not overfill the crankcase with oil because this may cause engine damage. Do not run the engine with oil below the low mark because the engine may be damaged as a result. 2 1 5. Slowly pour approximately 80% of the specified oil into the filler cap (Fig. 41). Refer to Servicing the Engine Oil, page 34. 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.
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.
Important Check and make sure the belt is installed into both the front and rear belt guides (Fig 75). 1 3 3 5 4. Check the belt tension. The spring loaded idler center bolt needs to be near the top alignment hole in left support plate (Fig 75). 3 4 1 3 2 4 6 2 m–6825 Figure 73 1. Clutch 2. Mower belt 3. 1/4 turn belt twist 4. Belt guide 5. Mower spindle pulley 6. Mower idler pulley 3 M–4417 1 Figure 75 6. Adjust the belt tension, refer to Adjusting the Mower Belt Tension; page 51. 1.
Replacing the Grass Deflector 10. Adjust the belt tension and the idler plate, if necessary, and tighten all hardware securely (Fig. 76). 6 4 Warning 3 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. 5 • Never operate the lawn mower unless you install a cover plate, a mulch plate, or a grass chute and catcher.
Mercury Tilt Switch The tilt switch on this unit contains mercury, a hazardous material. Mercury that is outside a sealed container vaporizes at room temperature. The vapors are harmful. Mercury can be absorbed through the skin. Do not attempt to open or repair this switch. A very small amount of mercury is contained in a hermetically sealed body. The steel switch is then potted in a hard epoxy in a plastic case. It is unlikely that the mercury will ever escape from the enclosure.
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.
TVS DIODE GND BK BK VIO VIO SW5 SHOWN WITH (NEUTRAL)LEVER IN NEUTRAL POSITION Y W SHOWN WITH SW4 (NEUTRAL)LEVER IN NEUTRAL POSITION SHOWN WITH PARK BRAKE DISENGAGED SW3 (BRAKE) PTO CLUTCH BN Y SHOWN IN OFF POSITION GY BN OR BK P1–B Y K1 (START RELAY) P2–C T SW6 (SEAT SW) SHOWN WITH OPERATOR IN SEAT SW7 (TILT SW) SWITCH OPENS WHEN TILTED PAST 60 DEGREES FROM VERTICAL P1–A DELAY MODULE 100–6186 P1–C PK GY BN BK Y BU PK OR BN PK PK 2 5 SW2 (PTO) I S 1 4 3 A B KEY SW TERMINAL
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. 1. Cutting blade(s) is/are bent or unbalanced. 1. Install new cutting blade(s). 2. Blade mounting bolt is loose. 2. Tighten blade mounting bolt. 3.
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.
