Form No. 3355-163 Rev A Z500 Z Master, With 152cm Turbo Force® Side Discharge Mower Model No. 74262TE—Serial No. 260000001 and Up Register your product at www.Toro.
This spark ignition system complies with Canadian ICES-002 Figure 2 Introduction 1. Safety alert symbol Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage. You are responsible for operating the product properly and safely. This manual uses 2 other words to highlight information. Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention.
Loading Machines ............................. 27 Using the Z Stand® ........................... 28 Operating Tips .................................. 29 Maintenance...................................................... 31 Recommended Maintenance Schedule(s) ............................... 31 Lubrication................................................ 31 Greasing and Lubrication................... 31 Engine Maintenance.................................. 33 Servicing the Air Cleaner ...................
Safety ◊ the type of machine is unsuitable for its task; ◊ lack of awareness of the effect of ground conditions, especially slopes; This machine meets or exceeds European Standards in effect at the time of production. However, 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.
• Mow only in daylight or in good artificial light. • Before attempting to start the engine, disengage all blade attachment clutches and shift into neutral. • Do not use on slopes greater than 15 degrees. • Remember there is no such thing as a safe slope. Travel on grass slopes requires particular care.
information that you must know that is not included in the CEN standard. • Watch for ditches, holes, rocks, dips, and rises that change the operating angle, as rough terrain could overturn the machine. • Engine exhaust contains carbon monoxide, which is an odorless, deadly poison that can kill you. Do not run engine indoors or in an enclosed area. • Avoid sudden starts when mowing uphill because the mower may tip backwards. • Be aware that loss of traction may occur going downhill.
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. 1-643339 93-7824 1. Thrown object hazard—stay a safe distance from the machine. 2. Thrown object hazard, mower—keep the deector in place. 3. Cutting/dismemberment of hand or foot—stay away from moving parts. 58-6520 98-1977 1. Grease 1. Entanglement hazard, belt—stay away from moving parts. 98-4387 1.
107-2131 1. Hydraulic oil level 2. Warning—do not touch the hot surface. 99-8939 1. Read the Operator’s Manual. 2. Height of cut 3. Remove the ignition key and read the instructions before servicing or performing maintenance. 105-7797 107-3069 1. 2. 107-1866 1.
7-3962 1. Height of cut in millimeters 107-3961 1. Height of cut in millimeters 107-3963 1. Cutting/dismemberment hazard, mower blade—do not carry passengers and keep bystanders away. 2. Cutting/dismemberment 3. Thrown object hazard—keep 4. Before starting the engine, hazard of hand or foot, bystanders a safe distance clean grass and debris from mower blade—remove the from the machine and keep the mower belt and pulleys, ignition key and read the the deector in place.
107-3964 1. Warning—do not use drugs or alcohol. 3. 2. Warning—read the Operator’s Manual and receive training. 4. Warning—engage the parking brake, 5. Read the Operator’s Manual. stop the engine, and remove the ignition key before leaving the machine. Warning—wear hearing protection. 107-3978 1. 2. 107-3968 1. Disengage 2. Engage 3. Cutting/dismemberment hazard, fan and entanglement hazard, belt—stay away from moving parts.
107-3996 1. Engine 107-3984 1. Read the instructions before 4. servicing or performing maintenance. 5. 2. Hourly interval 3. Engine 6. 2. Cutting blade Battery Symbols Grease Some or all of these symbols are on your battery Tire pressure Hydraulic oil level 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.
110-5721 1. 2. 3. 4. Engine—stop Engine—run Engine—start Power take-off (PTO) 5. 6. 7. 8. Fast Continuous variable setting Slow Choke 107-8077 1. Fast 3. Neutral 5. Warning-read— the Operator’s Manual. 2. Slow 4. Reverse 6. Poison and caustic liquid/chemical burn hazard—keep children a safe distance from the battery. 13 7. Explosion hazard—no re, open ames, or smoking; avoid sparks. 8.
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 1. Ignition switch 2. Throttle 3. Choke Figure 3 1. 2. 3. 4. Motion control lever Parking brake lever Height-of-cut lever Fuel cap (both sides) 5. 6. 7. Controls Seat belt Roll bar 4. 5. 6. Power take off (PTO) Hour meter Gas cap 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 36. 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.
Driving Backward 1. Move the levers to the center, un-locked position. 2. To go backward, slowly pull the motion control levers rearward (Figure 16). To go straight, apply equal pressure to both motion control levers (Figure 16). To turn, release pressure on the motion control lever toward the direction you want to turn (Figure 16). To stop, push the motion control levers to the neutral position. Figure 17 1. Height of cut lever 2. Clevis Pin Stopping the Machine 2.
5. Install the flange nut bushing, spacer, and bolt. Torque to 40-45 ft-lb (54-61 N•m) (Figure 18 , Figure 19 and Figure 20 ). 6. Repeat this adjustment on the other anti-scalp rollers. Figure 20 1. 2. 3. 4. 5. 4. 5. Flange Nut Bolt Adjusting the Flow Bafe Figure 18 1. Anti-scalp roller 2. Spacer 3. Bushing Anti-scalp roller Spacer Bushing Flange Nut Bolt The mower discharge flow can be adjusted for different types of mowing conditions.
Figure 21 1. Cam lock 3. 2. Lever 4. Rotate cam to increase or decrease locking pressure Slot Figure 23 Positioning the Flow Bafe The following figures are only recommendations for use. Adjustments will vary by grass type, moisture content, and height of grass. Position C 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 tall, dense grass mowing conditions.
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 27 1. 2. Seat latch Fuel cap 3. Seat Pushing the Machine by Hand Figure 25 1. Lift Assist Lever Important: Always push the machine by hand. Never tow the machine because hydraulic damage may occur.
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. • Never remove the grass deflector from the mower because the grass deflector routes material down toward the turf. If the grass deflector is ever damaged, replace it immediately. • Never put your hands or feet under the mower.
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 31 1. Z Stand (Positioned in slot) 3. 2. Crack in side walk or turf • Use extreme caution when operating the machine on the Z Stand®. • Use only for cleaning the mower and removing the blades. Latch resting on pivot tab 4. Set the foot of stand on the ground and rest the latch on the pivot tab (Figure 31).
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 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 35 1. 2. 3. Figure 34 Air cleaner body Primary lter Latch 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 35). 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 35). 3. Carefully slide the primary filter over the safety filter (Figure 35). 3.
6. When oil has drained completely, close the drain valve. Note: Dispose of the used oil at a recycling center. Figure 39 1. 2. 2. 3. Adapter 3. Pour new oil in through the center hole of the filter. Fill it up to the bottom of the threads inside. Figure 38 1. Oil drain valve Oil lter Adapter gasket 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 37). 5.
Checking the Spark Plugs 1. Look at the center of the spark plugs (Figure 40). 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 41 1. Spark-plug wire/spark plug 4. Clean around the spark plugs to prevent dirt from falling into the engine and potentially causing damage. Figure 40 1. Center electrode insulator 2. Side electrode 3. 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 42). 5. Disconnect the fuel line from the fuel filter (Figure 42). 6. Open the fuel shutoff valve. Note: Allow gasoline to drain into a fuel container can or drain pan (Figure 42). 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 42).
6. Remove both wing nuts (1/4 inch) securing the battery clamp (Figure 43). Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. 7. Remove the battery. Installing the Battery 1. Position battery in the tray with the terminal posts toward the engine (Figure 43). • Always Disconnect the negative (black) battery cable before disconnecting the positive (red) cable. 2.
Drive System Maintenance Adjusting the Tracking Note: Determine the left and right sides of the machine from the normal operating position. The right hand pump has a knob for adjusting the tracking. Important: Adjust the handle neutral and hydraulic pump neutral before adjusting the tracking. Refer to Adjusting the Handle Neutral and Adjusting the Hydraulic Pump Neutral. Figure 44 1. Push both control levers forward the same distance. 4.
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 cotter pin. 4. Torque the slotted nut to 125 ft-lb (170 N⋅m) (Figure 48). Figure 46 1. Pump rod 2. Turn this way to track left 3. 4. Tracking knob Turn this way to track right 5. Repeat this adjustment until the tracking is correct.
Figure 50 1. 2. Engine screen Oil cooler Cleaning the Engine Fins 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. Figure 49 1. Spring Washers 2. Lock Nut 3. Dust Cap 1. Remove the engine shroud. 2. Clean the engine cooling fins. 3. Install the engine shroud. 4.
and cracks are signs of a worn mower belt. Replace 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 bolts holding the belt covers in place and remove the belt covers. Figure 52 1. Brake lever 2. Spring (2-3/4 inches/70 mm) 3. Adjusting nuts 4. 5.
Figure 54 1. 2. Figure 53 1. Clutch 4. Belt guide 7. 8. Belt guide 10. Rear left installed side pulley Nut 2. Mower belt 5. 3. 1/4 trun belt twist 6. Mower spindle pulley Mower idler pulley 9. Washer Belt cover Latch 3. 4. Insert slot into the tab Bolt Adjusting the Mower Belt Tension 1. Disengage the PTO, move the motion control levers to the neutral locked position, and set the parking brake. 2.
Figure 55 1. Center bolt 2. Alignment hole 3. 4. Left support plate Spring loaded idler Figure 57 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 (Figure 56). 6. Insert a ratchet or breaker bar into the square hole in the mower idler plate to adjust the tension (Figure 56). 11.
pulleys (Figure 59). Remove belt between pulleys. Figure 59 Figure 60 1. 2. 2. Install new belt around engine and hydro pump pulleys (Figure 59). Neutral locked position Control lever 3. Neutral potion 3. Pull spring loaded idler down and align below traction belt. Release the pressure on the spring loaded idler (Figure 59). 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 60).
2. Clean the area around filler neck of hydraulic tank (Figure 62). Figure 62 1. Cap 2. Bafe Clevis pin in slot Nut against yoke Adjustment bolt Pump rod Double nuts Jam nut 7. 8. 9. 10. 11. 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 62). Figure 61 1. 2. 3. 4. 5. 6. 3. 4. 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 63 1. • Keep body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid. Hydraulic lter 4. Apply a thin coat hydro fluid to the rubber gasket on the replacement filter (Figure 64).
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 66). 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.
7. If the measurements at positions B or C are not correct, loosen the bolt attaching the rear chain to the rear support arm (Figure 68). Figure 69 1. Figure 68 1. 2. 3. 4. Rear chain Rear support arm Bolt Jam Nut 5. 6. 7. Adjustment bolt Front swivel Front support arm 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 69). 3. Record this measurement. 8.
Adjusting the Compression Spring 1. Raise the mower lift lever to the transport position. 2. Check the distance between the two large washers, it needs to be 10-1/2 inches (26.7 cm) (Figure 70). 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. • Inspect the blade periodically for wear or damage. • Replace a worn or damaged blade. Inspect and check the blades every 8 hours.
Checking for Bent Blades 1. Rotate the blades until the ends face forward and backward (Figure 72). Measure from a level surface to the cutting edge, position A, of the blades (Figure 72). Note this dimension. 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. Contact with a sharp blade can cause serious injury.
Replacing the Grass Deector Figure 74 1. Blade 2. 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. Balancer Installing the Blades 1. Install the blade onto the spindle shaft (Figure 75). • Never operate the lawn mower unless you install a cover plate, a mulch plate, or a grass chute and catcher.
Figure 76 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. 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.
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.
