Form No. 3356-190 Rev B Z500 Z Master, with 52in or 60in Turbo Force® Side Discharge Mower or a Z557 Z Master, with 72in Turbo Force® Side Discharge Mower Model No. 74261—Serial No. 270000001 and Up Model No. 74262—Serial No. 270000001 and Up Model No. 74263—Serial No. 270000001 and Up Register your product at www.Toro.
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. Important: This engine is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate the engine on any forest-covered, brush-covered, or grass-covered land. Other states or federal areas may have similar laws. Figure 1 1.
Using the Rollover Protection System (ROPS).................. 16 Think Safety First .............................. 17 Operating the Parking Brake .............. 18 Starting and Stopping the Engine .............................. 18 Operating the Power Take Off (PTO) ............................... 20 The Safety Interlock System............... 20 Driving Forward or Backward ............ 21 Stopping the Machine ........................ 22 Adjusting the Control Lever Resistance .........................
Safety hair, loose clothing or jewelry may get tangled in moving parts. Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means CAUTION, WARNING, or DANGER-“personal safety instruction." Failure to comply with the instruction may result in personal injury or death.
• Keep hands and feet away from the cutting units. • 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.
• 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. 1-403005 54-9220 1-523552 58-6520 1.
8-4387 1. Warning—wear hearing protection.
7-1857 107-1861 107-2112 107-1864 107-1613 107-1860 10
Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 6. 2. No re, open ame, or smoking. 7. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 8. 5. Read the Operator’s Manual. 9. 10. Keep bystanders a safe distance from the battery. Wear eye protection; explosive gases can cause blindness and other injuries Battery acid can cause blindness or severe burns. Flush eyes immediately with water and get medical help fast. Contains lead; do not discard.
110-5731 1. 2. 3. 4. Engine—stop Engine—run Engine—start Fast 5. 6. 7.
106-9989 107-8076 1. Fast 2. Slow 3. Neutral 13 4.
Product Overview Controls Become familiar with all the controls before you start the engine and operate the machine (Figure 3 and Figure 4). Figure 4 Figure 3 1. 2. 3. 4. Motion control lever Parking brake lever Height-of-cut lever Fuel cap (both sides) 5. 6. 7. 1. Gas cap 2. Choke 3. Ignition switch Controls Seat belt Roll bar 4. 5. 6. Throttle Power take off (PTO) Hour meter Hour Meter The hour meter records the number of hours the engine has operated. It operates when the engine is running.
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 There is no rollover protection when the roll bar is in the down position. Important: Do not use fuel additives containing methanol or ethanol. • Lower the roll bar only when absolutely necessary. Add the correct amount of gas stabilizer/conditioner to the gas. • Do not wear the seat belt when the roll bar is in the down position.
Think Safety First 5. To raise the roll bar, remove the hairpin cotter pins and remove the two pins (Figure 6). 6. Raise the roll bar to the upright position and install the two pins and secure them with the hairpin cotter pins (Figure 6). Please read all safety instructions and symbols in the safety section. Knowing this information could help you or bystanders avoid injury. Important: Always use the seat belt with the roll bar in the raised position.
Setting the Parking Brake 1. Move the motion control levers (Figure 16) out to the neutral lock position. 2. Pull up and back on the parking brake lever to set the parking brake (Figure 10). The parking brake lever should stay firmly in the engaged position. Parking brake may not hold machine parked on a slope and could cause personal injury or property damage. Do not park on slopes unless wheels are chocked or blocked Figure 8 1. Safe Zone-use the Z Master 3.
3. Move the PTO (power take off) switch to the Off position (Figure 11). Figure 13 Figure 11 1. PTO—on 2. 1. PTO—off Throttle—fast 2. Throttle—slow 6. Turn the ignition key to Start (Figure 14). When the engines starts, release the key. 4. Move the choke control to the on position before starting a cold engine (Figure 12). Important: Do not engage starter for more than 10 seconds at a time. If engine fails to start allow 30 second cool-down period between attempts.
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. Refer to Fuel System Maintenance, page 35. Important: Make sure that the fuel shut off valve is closed before transporting or storing the machine, as fuel leakage may occur. Set the parking brake before transporting. Make sure to remove the key as the fuel pump may run and cause the battery to lose charge. Figure 15 1.
engaged or if you rise from the seat when the PTO is engaged. Machine can spin very rapidly. Operator may lose control of machine and cause personal injury or damage to machine. Testing the Safety Interlock System 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. • Use caution when making turns. • Slow the machine down before making sharp turns. 1.
Set the parking brake when you leave the machine; refer to Setting the Parking Brake. Remember to remove the key from the ignition switch. 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 Control Lever Resistance The top damper mounting bolt can be adjusted to obtain a desired motion control lever resistance.
Figure 18 1. Height of cut lever 2. Clevis Pin Figure 19 2. To adjust, remove the clevis pin from the height-of-cut bracket (Figure 18). 1. 2. 3. 3. Select a hole in the height-of-cut bracket corresponding to the height-of-cut desired and, insert the clevis pin (Figure 18). Outer roller Spacer Bushing 4. 5. Bolt Nut 4. Move the lever to the selected height. 4. Select a hole so that the outer roller is positioned to the nearest corresponding height-of-cut desired (Figure 19).
the cam lock. Adjust the cam lock until the desired locking pressure is achieved. Figure 21 Figure 20 1. Outer roller 2. Spacer 3. Bushing 4. 5. 1. Cam lock 3. 2. Lever 4. Rotate cam to increase or decrease locking pressure Slot Bolt Nut Positioning the Flow Bafe 4. Select a hole so that the center rollers are positioned to the nearest corresponding height-of-cut desired (Figure 20). The following figures are only recommendations for use.
Figure 22 Position B Use this position when bagging. Figure 24 Using the Lift Assist Lever 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. 1. Place your foot onto lift assist lever. 2. Press on the lift assist lever while pulling up on the height-of-cut lever (Figure 25). Figure 23 Position C This is the full open position. The suggested use for this position is as follows. Figure 25 1.
by-pass the pump enabling the wheels to turn (Figure 28). Important: Do not rotate by-pass valves more than 1 turn. This prevents valves from coming out of the body and causing fluid to run out. Figure 26 1. Adjustment lever Unlatching the Seat Push the seat latch rearward to unlatch the seat. This will allow access to the machine under the seat (Figure 27). Figure 28 1. By-pass valve 2. Hydraulic tank 3. Disengage parking brake before pushing. Changing to Machine Operation Figure 27 1. Seat latch 2.
Important: Do not use the motion control levers as anchors for tieing the machine down. Without the grass deflector, discharge cover, or complete grass catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris. Contact with rotating mower blade(s) and thrown debris will cause injury or death. • Secure a trailer to the towing vehicle with safety chains.
Operating Tips Fast Throttle Setting Loading a unit onto a trailer or truck increases the possibility of backward tip-over and could cause serious injury or death. For best mowing and maximum air circulation, operate the engine at the fast throttle position. Air is required to thoroughly cut grass clippings, so do not set the height-of-cut so low as to totally surround the mower by uncut grass. Always try to have one side of the mower free from uncut grass, which allows air to be drawn into the mower.
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 rst 8 operating hours • Check the hydraulic uid level. After the rst 25 operating hours Before each use or daily • Change the hydraulic lter and oil. • • • • Check the safety interlock system. Check the engine oil level. Check the mower blades. Clean the mower deck. Every 25 hours • Check the hydraulic uid level. Every 50 hours • Grease the mower bearings. • Check the tire pressure.
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. Clean the grease fittings with a rag. Make sure to scrape any paint off the front of the fitting(s). 4. Connect a grease gun to the fitting. Pump grease into the fittings until grease begins to ooze out of the bearings. 5. Wipe up any excess grease.
Figure 32 1. Air cleaner body 2. Primary lter 3. Latch Figure 31 4. 5. Air cleaner cover Safety lter 4. Clean the inside of the air cleaner cover with compressed air. 5. Gently slide the primary filter out of the air cleaner body (Figure 32). 4. Grease the idler pulley pivot (Fig. 38). Engine Maintenance Note: Avoid knocking the filter into the side of the body. 6. Remove the safety filter only if you intend to replace it.
Installing the Filters 2. Disengage the PTO, turn the ignition key to off, and remove the key. 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 32). 3. Carefully slide the primary filter over the safety filter (Figure 32). 3.
6. When oil has drained completely, close the drain valve. Note: Dispose of the used oil at a recycling center. Figure 36 1. Oil lter 2. Adapter gasket 2. Adapter 3. Pour new oil in through the center hole of the filter. Fill it up to the bottom of the threads inside. Figure 35 1. Oil drain valve 3. Oil drain hose 4. Allow the filter material to absorb the new oil for 1 to 2 minutes. 7. Slowly pour approximately 80% of the specified oil into the filler tube (Figure 34). 5.
Checking the Spark Plugs 1. Look at the center of the spark plugs (Figure 37). If you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means that the air cleaner is dirty. Figure 38 1. 4. Clean around the spark plugs to prevent dirt from falling into the engine and potentially causing damage. Figure 37 1. Center electrode insulator 2. Side electrode 3. Spark-plug wire/spark plug 5. Remove the spark plugs and the metal washers.
4. Loosen the hose clamp at the fuel filter and slide it up the fuel line away from the fuel filter (Figure 39). 5. Disconnect the fuel line from the fuel filter (Figure 39). 6. Open the fuel shutoff valve. Note: Allow gasoline to drain into a fuel container can or drain pan (Figure 39). Note: Now is the best time to install a new fuel filter because the fuel tank is empty. 7. Install the fuel line onto the fuel filter. Slide the hose clamp close to the fuel filter to secure the fuel line (Figure 39).
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 40 1. 2. 3. 4. 5. 6.
Charging the Battery The fuses are as follows: • Main F1-30 amp, blade-type • Alternator F2-25 amp, blade-type Charging the battery produces gasses that can explode. 1. Unlatch the seat and raise the seat to gain access to fuse holder (Figure 42). 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.
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 44). Adjusting the Tracking Maintain the air pressure in the 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 45 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 45). Figure 46 6. If more than two threads are showing remove nut and install washer between hub and nut. 1. Spring Washers 2. Lock Nut 7. Torque the slotted nut to 125 ft-lb. (170 N⋅m) (Figure 45). 3. Dust Cap 4.
Figure 47 1. Engine screen 2. Oil cooler Figure 49 Cleaning the Engine Fins 1. 2. Every 100 hours clean the engine cylinder and cylinder head cooling fins. Also clean around carburetor, 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. 3. 2. Clean the engine cooling fins. 3. Install the engine shroud. Collar on brake rod 3/16–1/4 inch (5–7 mm) 6.
the mower belt if any of these conditions are evident. 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 belt covers. 4. Loosen the nut securing the idler plate and move the idler plate to relieve the belt tension on the idler pulley (Figure 50). 5. Remove the nut, washer and belt guide from the rear leftside pulley. 6.
Figure 52 1. 2. Figure 51 1. Belt cover 2. Latch 3. Center bolt Alignment hole 3. 4. Left support plate Spring loaded idler 5. If adjustment is required, loosen the mower idler plate and adjust it (Figure 53). Insert slot into the tab 6. Insert a ratchet or breaker bar into the square hole in the mower idler plate to adjust the tension (Figure 53). Adjusting the Mower Belt Tension 7. To increase belt tension, rotate the mower idler plate until resistance is felt and rotation stops.
pulleys (Figure 56). Remove belt between pulleys. Figure 56 Figure 54 1. Spring loaded idler pulley 2. Top alignment hole 3. 0 to 1/4 inch gap (0 to 6 mm) 4. 5. 6. Idler pulley arm Belt Rubber bumper 2. Install new belt around engine and hydro pump pulleys (Figure 56). 3. Pull spring loaded idler down and align below traction belt. Release the pressure on the spring loaded idler (Figure 56). 10. Adjust the belt tension and the idler plate, if necessary, and tighten all hardware securely (Figure 53).
Figure 57 1. Neutral locked position 2. Control lever 3. Neutral position 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 57). Figure 58 1. 2. 3. 4. 5. 6. 7. Check where the control lever is relative to notch in console (Figure 57). It should be centered allowing lever to pivot outward to the neutral lock position.
2. Clean the area around filler neck of hydraulic tank (Figure 59). 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. • Keep body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid. Figure 59 1. Cap 2. Bafe 3. 4. • Use cardboard or paper to find hydraulic leaks.
Bleeding the Hydraulic System 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. Figure 60 2. Start the engine and run at low idle speed. Engage the lever and traction on one side and spin the wheel by hand. 1. Hydraulic lter 4. Apply a thin coat hydro fluid to the rubber gasket on the replacement filter (Figure 61). 3.
This adjustment must be made with drive wheels turning. Hydraulic fluid escaping under pressure can penetrate skin and cause injury. 1. Raise the frame and use jack stands to hold up the machine so drive wheels can rotate freely. • 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. 2.
Figure 62 1. Tracking knob 2. Pump rod 3. 4. Adjustment bolt Yoke Figure 63 1. 2. 3. 4. 5. 6. 3. Move the motion control lever forward and reverse, then back to neutral. The wheel must stop turning or slightly creep in reverse. 4. Open the throttle to fast. Make sure wheel remains stopped or slightly creeps in reverse, adjust if necessary. Clevis pin in slot Nut against yoke Adjustment bolt Pump rod Double nuts Jam nut 7. 8. 9. 10. 11. Spring Pivot shaft Yoke Locknut Ball joint 2.
Electrical system will not perform proper safety shut off with jumper wire installed. • If one rear chain is loose, lower (loosen) the front support arm on the same side. Refer to Adjusting the Front-to-Rear Mower Pitch. • Remove jumper wire from wire harness connector and plug connector into seat switch when adjustment is completed. • If one front chain is loose, raise (tighten) the front support arm for that chain. Refer to Adjusting the Front-to-Rear Mower Pitch.
Figure 65 1. 2. 3. 4. Rear chain Rear support arm Bolt Jam Nut 5. 6. 7. Figure 66 Adjustment bolt Front swivel Front support arm 1. 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 (Figure 65). Measure here from blade to hard surface 2. Measure at A and B 2. Measure the right blade at the A location, from a level surface to the cutting edge of the blade tip (Figure 66). 3. Record this measurement.
Adjusting the Compression Spring 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. For convenient sharpening and replacement, you may want to keep extra blades on hand. 1. Raise the mower lift lever to the transport position. 2. Check the distance between the two large washers, it needs to be 11-1/8 inches (28.
2. Rotate the opposite ends of the blades forward. 3. Measure from a level surface to the cutting edge of the blades at the same position as in step 1 above. The difference between the dimensions obtained in steps 1 and 2 must not exceed 1/8 inch (3 mm). If this dimension exceeds 1/8 inch (3 mm), the blade is bent and must be replaced; refer to Removing the Blades and Installing the Blades. Figure 68 1. Cutting Edge 2. Curved Area 3.
Sharpening the Blades When sharpening blade, pieces of blade could be thrown and cause serious injury. Wear proper eye protection when sharpening blade. 1. Use a file to sharpen the cutting edge at both ends of the blade (Figure 70). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges. Figure 72 1. Sail Area of Blade 2. Blade 3. Spring Disk 4. 5. Blade Bolt Cone Towards Bolt Head 3.
Important: The grass deflector must be able to lower down into position. Lift the deflector up to test that it lowers into the full down position. Figure 73 1. Bolt 2. Spacer 3. Locknut 5. 6. 7. 4. Spring 8. Spring installed Grass Deector L end of spring, place behind deck edge before installing bolt J hook end of spring Cleaning Cleaning Under the Mower Remove the grass buildup under the mower daily. 1.
Storage stabilizer manufacture. Do not use an alcohol based stabilizer (ethanol or methanol). 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: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline and used at all times. 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 Possible Cause Corrective Action 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. 1. Move blade contro (PTO) to disengaged. 2. Set the parking brake. 3. Sit on the seat. 4. Charge the battery. 5. Check the electrical connections for good contact. 6. Replace fuse. 7. Contact an Authorized Service Dealer. 6. Fuse is blown. 7.
Problem Machine does not drive. Abnormal vibration. Possible Cause 1. By pass valve is not closed tight. 2. Drive or pump belt is worn, loose or broken. 3. Drive or pump belt is off a pulley. 4. Broken or missing idler spring. 5. Hydraulic uid level is low or too hot. 1. Tighten the by pass valve. 2. Change the belt. 1. Cutting blade(s) is/are bent or unbalanced. 2. Blade mounting bolt is loose. 3. Engine mounting bolts are loose. 4. Loose engine pulley, idler pulley, or blade 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. 59 Corrective Action 1. Check the belt tension. 2. Install drive belt and check adjusting shafts and belt guides for correct position. 3. Install new deck belt. 4. Install deck pulley and check the idler pulley, idler arm and spring for correct position and function. 5. Replace the spring.
Schematics Wire 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.
