Form No. 3353-652 Rev D Z593-D Z Master® with 52in or 60in TURBO FORCE® Side Discharge Mower Model No. 74264—Serial No. 250000001 and Up Model No. 74265—Serial No. 250000001 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.
Switching the Fuel Tanks ................... 16 Using the Rollover Protection System (ROPS).................. 16 Think Safety First .............................. 18 Operating the Parking Brake .............. 18 Starting and Stopping the Engine .............................. 19 Operating the Power Take Off (PTO) ............................... 21 The Safety Interlock System............... 21 Driving Forward or Backward ............ 22 Stopping the Machine ........................
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. 1-523552 54-9220 1-643253 58-6520 1.
103-1636 68-8340 98-4387 1. Warning—wear hearing protection.
6-9989 107-1613 107-1857 107-1622 10
107-1864 107-1860 107-2102 107-1861 11
108-5957 107-2112 108-5981 110-0305 107-2449 108-5955 110-0306 12
110-3852 1. Remove the ignition key and read the instructions before servicing or performing maintenance. 2. Continuous tone signals the user that engine is overheating. 110-3853 110-3851 1. 1. Remove the ignition key and read the instructions before servicing or performing maintenance. Cutting/dismemberment hazard, fan and entanglement hazard, belt. 2. Remove the ignition key and read the instructions before servicing or performing maintenance. Manufacturer’s Mark 1.
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). Glow Plug Light The glow plug indicator light turns on when the glow plug button is engaged (Figure 4). Glow Plug Switch This switch activates the glow plugs and is indicated by the glow plug light. Hold down the glow plug switch for 10 seconds prior to starting.
Operation In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel 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 • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any fuel that spills. The engine runs on clean, fresh diesel fuel with a minimum octane rating of 40.
2. Clean around each fuel tank cap and remove the cap. Add fuel to both fuel tanks, until the level is 1/4 to 1/2 inch (6 to 13 mm) below the bottom of the filler neck. This space in the tank allows the fuel to expand. Do not fill the fuel tanks completely full. 3. Install fuel tank caps securely. Wipe up any fuel that may have spilled. 4. If possible, fill the fuel tank after each use. This will minimize possible buildup of condensation inside the fuel tank.
5. To raise the roll bar, remove the hairpin cotter pins and remove the two pins (Figure 7). 6. Raise the roll bar to the upright position and install the two pins and secure them with the hairpin cotter pins (Figure 7). There is no rollover protection when the roll bar is in the down position. • Lower the roll bar only when absolutely necessary. Important: Always use the seat belt with the roll bar in the raised position. • Do not wear the seat belt when the roll bar is in the down position.
Think Safety First Please read all safety instructions and symbols in the safety section. Knowing this information could help you or bystanders avoid injury. 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. Figure 9 1. Safe Zone-use the Z Master 3. here on slopes less than 15 degrees or at areas. 2.
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 11). The parking brake lever should stay firmly in the engaged position. 3. Set the parking brake; refer to Setting the Parking Brake. 4. Move the PTO (power take off) switch to the off position (Figure 12). 5. Move the throttle lever to the middle position (Figure 14). 6.
Note: Additional starting cycles may be required when starting the engine for the first time after the fuel system has been completely without fuel. 4. Release the switch after 10 to 15 seconds. The light will turn off. 5. Turn the key to the start position and the glow plug indicator light will come back on. When the engine starts, release the key. Important: Use starting cycles of no more than 30 seconds per minute to avoid overheating the starter motor. Note: Do not use fuel left over from the summer.
The Safety Interlock System Operating the Power Take Off (PTO) The power take off (PTO) switch starts and stops the mower blades and any powered attachments. Engaging the PTO If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. 1. If the engine is cold, allow the engine to warm up 5 to 10 minutes before engaging the PTO. • Do not tamper with the interlock switches. 2.
PTO and rise slightly from the seat; the engine should stop. 4. Sitting on the seat, engage the parking brake, move the PTO switch to off and move the motion control levers to neutral lock position. Now start the engine. While the engine is running, center either motion control and move (forward or reverse); the engine should stop. Repeat for other motion control. 5. Sitting on the seat, disengage the parking brake, move the PTO switch to off and move the motion control levers to neutral lock position.
1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. Children or bystanders may be injured if they move or attempt to operate the tractor while it is unattended. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes. 3.
5. Swing the lever back over to tighten the baffle and cam locks (Figure 21). 6. If the cams do not lock the baffle into place or it is too tight, loosen the lever and then rotate the cam lock. Adjust the cam lock until the desired locking pressure is achieved. Figure 19 1. Anti-scalp roller 2. Bushing 3. 4. Flange Nut Bolt Figure 21 1. Cam lock 3. 2. Lever 4. Rotate cam to increase or decrease locking pressure Slot Positioning the Flow Bafe The following figures are only recommendations for use.
Figure 22 Position B Use this position when bagging. Figure 24 Positioning the Seat The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable. Important: To adjust, move the lever sideways to unlock seat (Figure 25). Slide the seat to the desired position and release lever to lock in position. Figure 23 Position C This is the full open position. The suggested use for this position is as follows.
Unlatching the Seat The machine will not drive unless by-pass valves are turned in. Push the seat latch rearward to unlatch the seat. This will allow access to the machine under the seat (Figure 26). Figure 26 1. Seat latch 2. Fuel cap 3. Figure 27 Seat 1. Side console controls 2. By-pass valve 3. Hydraulic pumps Pushing the Machine by Hand Using the Side Discharge Important: Always push the machine by hand. Never tow the machine because hydraulic damage may occur.
Loading Machines Use extreme caution when loading units on trailers or trucks. One full width ramp that is wide enough to extend beyond the rear tires is recommended instead of individual ramps for each side of the unit (Figure 28). The lower rear section of the tractor frame extends back between the rear wheels and serves as a stop for tipping backward. Having a full width ramp provides a surface for the frame members to contact if the unit starts to tip backward.
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 cooling system level. • Check the hydraulic uid. After the rst 25 operating hours • Change the hydraulic lter and oil. After the rst 50 operating hours • Change the engine oil. • Change the engine oil lter. After the rst 100 operating hours • Change gear box oil. Before each use or daily • • • • • • Check the safety system. Check the engine oil.
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. Lubrication Where to Add Grease Greasing and Lubrication Lubricate the grease fittings as shown on the Check Service Reference Aid decal (Figure 29).
Greasing the Mower Deck and Belt Idlers 7. Grease the PTO drive belt idler arm (Figure 31). 8. Grease the pump belt idler arm (Figure 31). The mower deck must be lubricated weekly or every 25 hours. Grease with No. 2 general purpose lithium base or molybdenum base grease. Important: Make sure cutting unit spindles are full of grease weekly. 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2.
appear as bright spots. If the filter is damaged discard it. Figure 33 1. 2. Figure 32 1. Air lter body 2. Air lter 3. 4. Air lter body Air lter 3. 4. Air cleaner cover Latches Air cleaner cover Latches Servicing the Engine Oil Installing the Air Filter Change engine oil: 1. If installing a new filter, check the filter for shipping damage. Do not use a damaged filter. • Change the engine oil after the first 50 operating hours. 2. Carefully slide the filter into the filter body (Figure 33).
Figure 34 Checking the Engine Oil Level Note: Check the oil when the engine is cold. 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. Figure 35 1. Oil dipstick 2. Metal end 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Rear left side of machine Changing the Engine Oil 3.
Figure 38 1. Figure 36 1. Back of machine 2. Engine 2. Oil ll cap 3. To add oil to the engine, locate and use a hose and funnel for adding oil (Figure 39). Drain plug 4. Add oil slowly, checking the level with the dipstick frequently until the level reaches the upper hole on the dipstick. For the correct oil type and viscosity to use in different temperature conditions, refer to Servicing the Engine Oil in Engine Maintenance, page 32, ). Adding Engine Oil 1.
Important: Add the oil very slowly and do not block the opening of the filler hole (Figure 40). If you add oil too fast or block the hole, the oil could back up and foul the air intakes, causing engine damage. filter on by hand until the gasket contacts the oil filter adapter. Tighten 1/2 to 3/4 turn more. 4. Add oil; refer to Adding Engine Oil. Figure 40 1. Note the clearance left in the ller opening. 5. Replace the dipstick and install the front engine panel. 6.
them more frequently under extremely dusty or dirty conditions. Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns. Replacing the Fuel Filter Ensure that an Authorized Service Dealer replaces the fuel filter and any components for the fuel system. Do not drink electrolyte and avoid contact with skin, eyes or clothing. Wear safety glasses to shield your eyes and rubber gloves to protect your hands.
5. Slide the red terminal boot off the positive (red) battery terminal. Then remove the positive (red) battery cable (Figure 43). Figure 43 1. Negative Battery Post 2. Positive Battery Post 3. 4. Figure 44 Red (+) cable Black (-) cable 1. Battery 2. Hydraulic tank 3. Bolts 4. 5. Wing nut Right side fuel tank 6. Remove both wing nuts (1/4 inch) securing the battery clamp (Figure 44). Installing the Battery 7. Remove the two bolts holding the hydraulic tank in place (Figure 44). 1.
Charging the Battery Fuse: • Ignition, F1-30 amp, blade-type • Radiator fan, F2-30 amp, blade-type Charging the battery produces gasses that can explode. 1. Unlatch the engine hood and raise the engine hood to gain access to fuse holder (Figure 46). Never smoke near the battery and keep sparks and flames away from battery. 2. To replace the fuses, pull out on the fuse to remove it. Important: Always keep the battery fully charged (1.265 specific gravity).
Drive System Maintenance Adjusting the Tracking The machine has a knob for adjusting the tracking located under the seat. Important: Adjust the handle neutral and hydraulic pump neutral before adjusting the tracking. Refer to Adjusting the Handle Neutral in Controls System Maintenance, page 48 and Adjusting the Hydraulic Pump Neutral in Hydraulic System Maintenance, page 49. 1. Push both control levers forward the same distance. 2. Check if the machine pulls to one side.
Figure 48 Checking the Wheel Hub Slotted Nut Check after every 500 operating hours. The slotted nut needs to be torqued to 125 ft-lb (170 N•m). 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 49). Figure 47 1. Tracking knob 2. Hydraulic tank 3.
Servicing the Gear Box 7. Torque the slotted nut to 125 ft-lb. (170 N•m) (Figure 49). 8. Tighten the nut until the next set of slots line up with the hole in the shaft (Figure 49). 9. Replace the cotter pin. Checking the Gear Box Oil Level Use SAE 75W–90 Synthetic Gear Lube. 1. Park the machine on a level surface. Adjusting the Caster Pivot Bearing 2. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake.
Cooling System Maintenance Note: Do not open the radiator cap. Doing this may induce air into the cooling system. 1. Position the machine on a level surface, stop the engine, and set the parking brake. Servicing the Cooling System 2. Unlatch the seat and tilt the seat up. 3. With the engine cool, check the overflow bottle level. The fluid needs to be up to the bump on the outside of the overflow bottle (Figure 52).
6. If adjustment is necessary, repeat the procedures above. 7. Repeat on the opposite side of machine. Figure 54 1. Brake lever in engaged 3. position 2. Spring 2–1/2 inch (64 mm) Figure 53 1. Hydraulic oil cooler 2. Left rear tire 3. Adjusting nut and jam nut Radiator screen Belt Maintenance Changing the Engine Coolant Inspecting the Belts Change the engine coolant yearly. Inspect all belts every 100 hours. Contact an Authorized Service Dealer for changing the coolant.
Replacing the PTO Drive Belt 5. Remove the existing belt if needed. 6. Install the new belt around the mower pulleys and the gearbox pulley under the engine (Figure 56). 7. Install spring to the idler arm (Figure 56). 8. Install the belt guide on the spring loaded idler at a 45 degree angle as shown in Figure 56. 9. Install the belt covers by sliding the cover into the tab, install the bolts, and close the latches (Figure 55).
Figure 59 1. Pump drive belt 2. Clutch Figure 58 1. PTO Drive belt 2. Clutch 3. Spring 4. 5. 6. Spring loaded idler pulley Gear box Clutch stop bracket 3. 4. Spring loaded idler pulley Spring Replacing and Tensioning the Alternator Belt Replacing the Pump Drive Belt Check the alternator belt for wear after every 50 hours of operation. Replacing the Alternator Belt Check pump drive belt for wear after every 50 hours of operation. 1.
10. Install the fan and fan plate to the machine with the 2 bolts previously removed (Figure 61). 11. Install the oil cooler with the 4 bolts previously removed (Figure 61). 12. Install the oil cooler shield and engine straps to the rear frame with the 4 bolts previously removed (Figure 60). 13. Install the engine straps to the side of the machine (Figure 60). 14. Tighten the bottom bolt and install the upper bolt holding the alternator and cover (Figure 62). Tensioning the Alternator Belt Figure 60 1.
4. Begin with either the left or right motion control lever. 5. Move the lever to the neutral position but not locked (Figure 63). 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 63). 7. Check where the control lever is relative to notch in console (Figure 63). It should be centered allowing lever to pivot outward to the neutral lock position. Figure 62 1. Alternator 2. Alternator belt 3.
2. Clean the area around filler neck of hydraulic tank (Figure 65). 3. Remove the cap from the filler neck. Look inside to check if there is fluid in the reservoir (Figure 65). 4. If there is no fluid, add fluid to the reservoir until it reaches the cold level of the baffle. 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 in Operation, page 15. 6. Recheck the fluid level while the fluid is warm.
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 66 1. Hydraulic lter • Keep body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid. 4. Remove the righthand hydraulic line that comes into the adapter (Figure 67). 5.
both wheels will not drive, refer to Bleeding Hydraulic System. 13. Recheck the fluid level while the fluid is warm. The fluid should be between cold and hot. Hydraulic fluid escaping under pressure can penetrate skin and cause injury. 14. If required, add fluid to the hydraulic tank. Do not overfill. • 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.
Engine must be running so motion control adjustment can be performed. Contact with moving parts or hot surfaces may cause personal injury. Keep hands, feet, face, clothing and other body parts away from rotating parts, muffler and other hot surfaces. 1. Raise the frame and block up the machine so drive wheels can rotate freely. 2. Disconnect the electrical connector from the seat safety switch. Temporarily install a jumper wire across terminals in the wiring harness connector. 3.
Mower Deck Maintenance 6. Tighten the locknuts at the ball joints (Figure 70). Leveling the Mower at Three Positions Important: There are only three measuring positions needed to level the mower. Setting Up the Machine 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. 3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 4.
Figure 72 Figure 71 1. Measure here from blade to hard surface 2. 1. 2. 3. 4. Measure at B and C 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 72). Rear chain Rear support arm Bolt Jam Nut 5. 6. 7. Adjustment bolt Front swivel Front support arm Adjusting the Front-to-Rear Mower Pitch 8.
4. Measure the right blade at the B location, from a level surface to the cutting edge of the blade tip (Figure 73). 5. Record this measurement. 6. The mower blade should be a 1/4 to 3/8 inch (6 to 10 mm) lower at position A than at position B (Figure 73). If it is not correct, proceed to the following steps. Note: Both of the front swivels need to be adjusted the same amount to maintain equal chain tension. 7.
Before Inspecting or Servicing the Blades Park the machine on a level surface, disengage the blade control (PTO), and set the parking brake. Turn the ignition key to Off. Remove the key. Inspecting the Blades 1. Inspect the cutting edges (Figure 75). If the edges are not sharp or have nicks, remove and sharpen the blades. Refer to Sharpening the Blades. 2. Inspect the blades, especially the curved area (Figure 75).
Contact with a sharp blade can cause serious injury. Figure 78 Wear gloves or wrap sharp edges of the blade with a rag. 1. 1. Hold the blade end using a rag or thickly-padded glove. Blade 2. Balancer Installing the Blades 2. Remove the blade bolt, spring disk and blade from the spindle shaft (Figure 79). 1. Install the blade onto the spindle shaft (Figure 79). Important: The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting.
Replacing the Grass Deector 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. • Never operate the lawn mower unless you install a cover plate, a mulch plate, or a grass chute and catcher. Figure 80 • Make sure the grass deflector is in the down position. 1. Remove the locknut, bolt, spring and spacer holding the deflector to the pivot brackets (Figure 80).
Storage A. Add a petroleum based stabilizer/conditioner to fuel in the tank. Follow mixing instructions from the stabilizer manufacturer. Do not use an alcohol based stabilizer (ethanol or methanol). Cleaning and Storage 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to Off. Remove the key. 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. 62 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.
The Toro Total Coverage Guarantee LCE A Limited Warranty Conditions and Products Covered Owner Responsibilities 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. 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.