Form No. 3354-678 Rev B Z588E Z Master® with 60in or 72in TURBO FORCE® Side Discharge Mower Model No. 74255—Serial No. 250000001 and Up Model No. 74256—Serial No. 250000001 and Up Register your product at www.Toro.
Warning the model and serial numbers of your product ready. Figure 1 identifies the location of the model and serial numbers on the product. Write the numbers in the space provided. 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.
Controls ........................................... 14 Operation.......................................................... 15 Adding Fuel ...................................... 15 Checking the Engine Oil Level ........... 16 Using the Rollover Protection System (ROPS).................. 16 Think Safety First .............................. 18 Operating the Parking Brake .............. 19 Starting and Stopping the Engine .............................. 19 Operating in Cool Weather.................
Safety hair, loose clothing or jewelry may get tangled in moving parts. • Inspect the area where the equipment is to be used and remove all objects such as rocks, toys and wire which can be thrown by the machine. • 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.
• Never carry passengers and keep pets and bystanders away. • 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. • Be aware of the mower discharge direction and do not point it at anyone. • Do not operate the mower under the influence of alcohol or drugs. • Use extreme care when loading or unloading the machine into a trailer or truck.
• Carefully release pressure from components with stored energy. • 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. • Use care when checking blades. Wrap the blade(s) or wear gloves, and use caution when servicing them. Only replace blades. Never straighten or weld them. • Keep hands and feet away from moving parts. If possible, do not make adjustments with the engine running.
Slope Chart 7
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. 98-5954 1-633462 1-403005 1-643339 1-523552 54-9220 98-4387 1. Warning—wear hearing protection.
103-2750 Battery Symbols Some or all of these symbols are on your battery 58-6520 1. Explosion hazard 2. No re, open ame, or smoking. 3. Caustic liquid/chemical burn hazard Wear eye protection 4. 1. Grease 5. Read the Operator’s Manual. 6. Keep bystanders a safe distance from the battery. 7. Wear eye protection; explosive gases can cause blindness and other injuries 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. 10.
5-7798 107-1864 107-2102 107-1621 107-1622 10
107-2114 106-9969 107-2112 107-1860 107-1857 11
107-1861 107-8076 1. Fast 2. Slow 3. Neutral 12 4.
106-9989 106-7492 13
Product Overview Hour Meter The hour meter records the number of hours the engine has operated. It operates when the engine is running. Use these times for scheduling regular maintenance (Figure 4). Malfunction Indicator Light The malfunction indicator light lets the user know there is a problem with the fuel injection system.
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 • Always place gasoline containers on the ground away from your vehicle before filling. Use Unleaded Regular Gasoline suitable for automotive use (85 pump octane minimum).
• Cleans the engine while it runs • Eliminates gum-like varnish buildup in the fuel system, which causes hard starting 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. Figure 5 1. Fuel shut-off valve Filling the Fuel Tank 1.
There is no rollover protection when the roll bar is in the down position. • Lower the roll bar only when absolutely necessary. • Do not wear the seat belt when the roll bar is in the down position. • Drive slowly and carefully. • Raise the roll bar as soon as clearance permits. Figure 7 • Check carefully for overhead clearances (i.e. branches, doorways, electrical wires) before driving under any objects and do not contact them. 1. Full down position 2. Down position with bagger installed 4.
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. There is no rollover protection when the roll bar is down. Always keep the roll bar in the raised and locked position and use the seat belt. Read and follow the rollover protection instructions and warnings. To avoid loss of control and possibility of rollover: • Do not operate near drop-offs or near water. Figure 8 1.
parking brake is disengaged and the lever will rest against the brake stop. This machine produces sound levels in excess of 85 dBA at the operators ear and can cause hearing loss through extended periods of exposure. Wear hearing protection when operating this machine. The use of protective equipment for eyes, ears, feet, and head is recommended. Figure 11 1. 2. Figure 10 Parking brake-ON Parking brake-OFF 3. Brake Stop 1.
Figure 14 1. Off 2. Run 2. Start Stopping the Engine Figure 12 1. PTO—on 3. PTO—off 1. Push the PTO to the Off position (Figure 12). 2. Move the throttle lever midway between the Slow and Fast positions (Figure 13). 4. Move the throttle control midway between the Slow and Fast positions (Figure 13). 3. Let the engine idle for 60 seconds. 4. Turn the ignition key to the Off position and remove the key (Figure 14). 5. Close the fuel shut off valve before transporting or storing the machine.
Operating the Power Take Off (PTO) Understanding the Safety Interlock System The power take off (PTO) switch starts and stops the mower blades and any powered attachments. The safety interlock system is designed to prevent the engine from starting unless: • You are sitting on the seat. Engaging the PTO 1. While seated in the seat, release the pressure on the traction control levers and place in neutral. 2. Place the throttle in the Fast position. • The parking brake is engaged.
Try starting the engine; the engine should not crank. Driving Forward or Backward The throttle control regulates the engine speed as measured in rpm (revolutions per minute). Place the throttle control in the fast position for best performance. Always operate in the full throttle position when mowing. Figure 16 1. Motion control lever-neutral lock position 2. Center un-lock position Machine can spin very rapidly. Operator may lose control of machine and cause personal injury or damage to machine.
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. Raise the height-of-cut lever to the transport position (also the 5 inch (127 mm) cutting height position) (Figure 17). Figure 18 1. 2. To adjust, remove the clevis pin from the height-of-cut bracket (Figure 17). 3.
Adjusting the Flow Bafe 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. 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. To adjust the cam locks, swing the lever up to loosen the cam lock (Figure 22). 4.
• Use in dry conditions. • For smaller grass clippings. • Propels grass clippings farther away from the mower. Figure 23 Figure 25 Position B Positioning the Seat Use this position when bagging. Changing the Seat Position The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable. 1. To adjust, move the lever sideways to unlock seat (Figure 26). Figure 24 Position C This is the full open position.
Figure 26 1. Seat suspension knob 2. Figure 27 Seat position adjustment lever 1. Back rest knob 2. Slide the seat to the desired position and release lever to lock in position. 2. Right-side arm rest Unlatching the Seat Push the seat latch rearward to unlatch the seat. This will allow access to the machine under the seat (Figure 28). Changing the Seat Suspension The seat can be adjusted to provide a smooth and comfortable ride. Position the seat where you are most comfortable.
Pushing the Machine by Hand Using the Side Discharge The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. Important: Always push the machine by hand. Never tow the machine because hydraulic damage may occur. Pushing the Machine 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. 2. Rotate the by-pass valves counterclockwise 1 turn to push.
Important: Do not use the motion control levers as anchors for tieing the machine down. Loading a unit onto a trailer or truck increases the possibility of backward tip-over and could cause serious injury or death. • Secure a trailer to the towing vehicle with safety chains. • Use extreme caution when operating a unit on a ramp.
Using the Z Stand® The Z Stand raises the front end of the machine to allow you to clean the mower and remove the blades. The machine could fall onto someone and cause serious injury or death. Figure 32 1. 2. • Use extreme caution when operating the machine on the Z Stand. • Use only for cleaning the mower and removing the blades. Z Stand (Positioned in slot) 3. Crack in side walk or turf Latch resting on pivot tab 4. Set the foot of stand on the ground and rest the latch on the pivot tab (Figure 32).
Mowing Direction Alternate mowing direction to keep the grass standing straight. This also helps disperse clippings which enhances decomposition and fertilization. Mow at Correct Intervals Normally, mow every four days. But remember, grass grows at different rates at different times. So to maintain the same cutting height, which is a good practice, mow more often in early spring. As the grass growth rate slows in mid summer, mow less frequently.
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.
Maintenance Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the rst 8 operating hours • Check the hydraulic uid. After the rst 25 operating hours Before each use or daily • Change the hydraulic lter and oil. • • • • • • Check the safety system. Check the air lter minder. Check the engine oil level. Cleaning the engine screen and the oil cooler. Check the mower blades. Clean under the mower. Every 25 hours • Grease the mower deck and spindles.
Lubrication Greasing and Lubrication Lubricate the machine when shown on the Check Service Reference Aid decal (Figure 34). Grease more frequently when operating conditions are extremely dusty or sandy. Grease Type: General-purpose grease. How to Grease 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.
3. Remove the belt covers. and restricted. When it changes red, air cleaner maintenance is required. 4. Grease the three spindle bearings under the pulleys until grease comes out the lower seals (Figure 35). 1. Start by visually checking the condition of the primary element. If the element is visually dirty, replace the primary element. Do not attempt to clean it. 5. Grease the fittings on the push arms (Figure 35). 2.
Installing the Filters Important: To prevent engine damage, always operate the engine with both air filters and cover installed. 1. If installing new filters, check each filter for shipping damage. Do not use a damaged filter. 2. If the safety filter is being replaced, carefully slide it into the filter body (Figure 37). 3. Carefully slide the primary filter over the safety filter (Figure 37). Ensure that it is fully seated by pushing on the outer rim of the filter while installing it. Figure 37 1. Latches 2.
Checking the Oil Level Note: Check the oil when the engine is cold. 4. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 5. Place a pan below the oil drain. Rotate the oil drain valve to allow oil to drain (Figure 40). 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3.
Figure 42 Figure 41 1. Oil lter 2. Gasket 3. 1. Spark plug wire 2. Spark plug Adapter 4. Clean around the spark plug(s) to prevent dirt from falling into the engine and potentially causing damage. 3. Pour new oil of the proper type in through the center hole. Stop pouring when the oil reaches the bottom of the threads. Allow a minute or two for the oil to be absorbed by filter material. 5. Remove the spark plug(s) and metal washer. Checking the Spark Plug 4.
2. Tighten the spark plug(s) to 20 ft-lb (27 N⋅m). 3. Push the wire(s) onto the spark plug(s) (Figure 42). Fuel system components are under high pressure. Use of improper components can result in system failure, gasoline leakage and possible explosion. Servicing the Spark Arrester • Ensure that an Authorized Service Dealer replace the fuel filter and any components for the fuel system. Inspect the spark arrester every 50 hours for damage, such as holes in the screen, and for buildup on the screen.
Removing the Battery Battery terminals or metal tools could short against metal machine components causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. • When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine. • Do not allow metal tools to short between the battery terminals and metal parts of the machine. Figure 44 1. 2. 3. 4. 5. 6.
Servicing the Fuses Charging the Battery The electrical system is protected by fuses. It requires no maintenance, however, if a fuse blows check component/circuit for malfunction or short. Charging the battery produces gasses that can explode. Fuse: Main F1-30 amp, blade-type (Figure 46) Never smoke near the battery and keep sparks and flames away from battery. 1. Raise the seat to gain access to fuse holder. 2. To replace fuses pull out on the fuse to remove it (Figure 46).
Drive System Maintenance Checking the Tire Pressure Check the pressure at the valve stem after every 50 operating hours or monthly, whichever occurs first (Figure 49). Adjusting the Tracking Maintain the air pressure in the front and rear tires at 13 psi (90 kPa). Uneven tire pressure can cause uneven cut. Check the tires when they are cold to get the most accurate pressure reading. Note: Determine the left and right sides of the machine from the normal operating position.
Figure 50 1. Slotted Nut 2. Two threads or less showing 3. 4. Hole in threaded shaft Washer (if needed) 5. Check the distance from bottom of slot in nut to inside edge of hole. Two threads or less should be showing (Figure 50). 6. If more than two threads are showing remove nut and install washer between hub and nut. Figure 51 7. Torque the slotted nut to 125 ft-lb (170 N⋅m) (Figure 50). 1. Spring Washers 2. Lock Nut 8.
governor levers and linkage. This will make sure adequate cooling to hydraulic pumps, motors and engine and will reduce the possibility of overheating and mechanical damage. 1. Remove the panels from the engine shroud. 2. Clean the engine cooling fins. 3. Install the panels onto the engine shroud. below the yoke (Figure 54). Turn the nut until the correct measurement is obtained. Tighten the two nuts together and repeat on opposite side of unit. 4.
Adjusting the Mower Belt Tension Important: Check the amount of twist in the belt between the pulleys. Make sure it is only what is specified in Figure 55. 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Raise the mower to the transport position. Important: Check the amount of twist in the belt between the pulleys.
Figure 58 1. Mower idler plate 2. Square hole 3. 4. Ratchet or breaker bar Idler plate bolt Figure 59 1. 2. 3. 6. Insert a ratchet or breaker bar into the square hole in the mower idler plate to adjust the tension (Figure 58). Spring loaded idler pulley Top alignment hole 0 to 1/4 inch gap (0 to 6 mm) 4. 5. 6. Idler pulley arm Belt Rubber bumper 10. Adjust the belt tension and the idler plate, if necessary, and tighten all hardware securely (Figure 58). 11.
pulleys (Figure 61). Remove belt between pulleys. Figure 61 Figure 62 1. Neutral locked position 2. Control lever 2. Install new belt around engine and hydro pump pulleys (Figure 61). 3. Neutral position 3. Pull spring loaded idler down and align below traction belt. Release the pressure on the spring loaded idler (Figure 61). 6. Pull the lever back until the clevis pin (on arm below pivot shaft) contacts the end of the slot (just beginning to put pressure on the spring) (Figure 62).
2. Clean the area around filler neck of hydraulic tank (Figure 64). Figure 64 1. 2. Clevis pin in slot Nut against yoke Adjustment bolt Pump rod Double nuts Jam nut 7. 8. 9. 10. 11. 3. 4. Cold uid level-full Hot uid level-full 3. Remove the cap from the filler neck. Look inside to check if there is fluid in the reservoir (Figure 64). Figure 63 1. 2. 3. 4. 5. 6. Cap Bafe Spring Pivot shaft Yoke Locknut Ball joint 4.
Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • 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. Figure 65 1. Hydraulic lter • Keep body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid. 4. Apply a thin coat hydro fluid to the rubber gasket on the replacement filter (Figure 66).
Bleeding the Hydraulic System Hydraulic fluid escaping under pressure can penetrate skin and cause injury. 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. • 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. 1.
This adjustment must be made with drive wheels turning. 3. Move the motion control lever forward and reverse, then back to neutral. The wheel must stop turning or slightly creep in reverse. 1. Raise the frame and use jack stands to hold up the machine so drive wheels can rotate freely. 4. Open the throttle to fast. Make sure wheel remains stopped or slightly creeps in reverse, adjust if necessary. 2. Unlatch the seat, tilt the seat forward and disconnect electrical connector from the seat safety switch.
4. Move the motion control lever forward and reverse, then back to neutral. The wheel must stop turning or slightly creep in reverse. 5. Open the throttle to fast. Make sure the wheel remains stopped or slightly creeps in reverse, adjust if necessary. 6. Tighten the locknuts at the ball joints (Figure 68). 5. Lower the mower to the 3 inch (76 mm) height-of-cut position. 6. Inspect the four chains. The chains need to have tension.
a measurement of 3-1/8 to 3-1/4 inches (Figure 70). Note: It is recommended that both sides of the mower are adjusted the same distance. 9. Tighten the jam nut under the rear support arm and tighten the bolt securing the chain to the rear support arm. 10. Adjust the opposite side if needed. Figure 71 1. Measure here from blade to hard surface 2. Measure at A and B 3. Record this measurement. 4.
2. Check the distance between the two large washers, it needs to be 10-1/2 inches (26.7 cm) (Figure 72). A worn or damaged blade can break, and a piece of the blade could be thrown into the operator’s or bystander’s area, resulting in serious personal injury or death. 3. Adjust this distance, by loosening the spring jam nut and turning the nut in front of each spring (Figure 72). Turning the nut clockwise will shorten the spring; counter-clockwise will lengthen the spring.
Removing the Blades 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Blades must be replaced if a solid object is hit, if the blade is out of balance or is bent. To ensure optimum performance and continued safety conformance of the machine, use genuine Toro replacement blades. Replacement blades made by other manufacturers may result in non-conformance with safety standards. 3.
Replacing the Grass Deector (Figure 77). Repeat this procedure until the blade is balanced. 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. Figure 76 1. Blade 2. Balancer • Never operate the lawn mower unless you install a cover plate, a mulch plate, or a grass chute and catcher. Installing the Blades 1. Install the blade onto the spindle shaft (Figure 77).
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 shut engine off and set parking brake before performing any maintenance to mower. Figure 78 1. Bolt 2. Spacer 3. Locknut 5. 6. 7. 4. Spring 8.
Storage Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline and used at all times. 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. B. Run engine to distribute conditioned fuel through the fuel system (5 minutes). Important: Do not store stabilizer/conditioned gasoline over 90 days. 2.
Troubleshooting Problem Starter does not crank Possible Cause 1. Blade control (PTO) is engaged. 2. Parking brake is not on. 3. Operator is not seated. 4. Battery is dead. 5. Electrical connections are corroded or loose. 6. Fuse is blown. 7. Relay or switch is defective. Engine will not start, starts hard, or fails to keep running. 1. Fuel tank is empty. 2. Air cleaner is dirty. 3. Spark plug wire is loose or disconnected 4. Spark plug(s) is pitted, fouled, or the gap is incorrect. 5.
Problem Engine overheats. Possible Cause Corrective Action 1. Engine load is excessive. 1. Reduce the ground speed. 2. Add oil to the crankcase. 2. Oil level in the crankcase is low. 3. Cooling ns and air passages above the engine are plugged. 3. Remove the obstruction from the cooling ns and air passages. Machine does not drive. 1. Tension spring not connected. 2. By pass valve is not closed tight. 3. Traction belt is worn, loose or broken. 4. Traction belt is off a pulley. 5.
Problem Blades do not rotate. Possible Cause 1. Drive belt is worn, loose or broken. 2. Drive belt is off pulley. 3. Deck belt is worn, loose or broken. 4. Deck belt is off pulley. 5. Broken or missing idler spring. Malfunction Indicator Light (MIL) comes on. 1. Old gas in the gas tank 2. The fuel shut-off valve is not open completely 3. Fuel tank vent cap is blocked. 4. Air cleaner is dirty. 5. Battery is not charged. 6. Incorrect fuel lters used or dirty fuel lters. 7.
Schematics Wiring Diagram (Rev.
Evaporative Emission Control Warranty Statement California Evaporative Emission Control Warranty Statement Your Warranty Rights and Obligations Introduction The California Air Resources Board and The Toro® Company are pleased to explain the evaporative emission control system’s warranty on your 2006 model year equipment. In California, new equipment that use small off-road engines must be designed, built, and equipped to meet the State’s stringent anti-smog standards.
LCE The Toro Total Coverage Guarantee A Limited Warranty Conditions and Products Covered Items and Conditions Not Covered 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.