Form No. 3351–410 Z597–D Z Master with 152cm TURBO FORCE Side Discharge Mower Model No. 74268TE–240000001 & Up Operator’s Manual Register your product at www.Toro.
Keep this engine Owner’s Manual with your unit. Should this engine Owner’s Manual become damaged or illegible, replace immediately. Replacements may be ordered through the engine manufacturer. Changing the Engine Oil Filter . . . . . . . . . . . . . . Servicing the Cooling System . . . . . . . . . . . . . . . Servicing the Fuel Filter . . . . . . . . . . . . . . . . . . . Servicing the Fuel Tank . . . . . . . . . . . . . . . . . . . . Greasing and Lubrication . . . . . . . . . . . . . . . . . . .
Introduction Safety Read this manual carefully to learn how to operate and maintain your product properly. The information in this manual can help you and others avoid injury and product damage. Although Toro designs and produces safe products, you are responsible for operating the product properly and safely. Safe Operation Practices for Ride-on (riding) Rotary Lawnmower Machines This machine meets or exceeds European Standards in effect at the time of production.
• lack of awareness of the effect of ground conditions, especially slopes; – use slow speeds on slopes and during tight turns; – stay alert for humps and hollows and other hidden hazards; • incorrect hitching and load distribution. • Use care when pulling loads or using heavy equipment. Preparation • While mowing, always wear substantial footwear and long trousers. Do not operate the equipment when barefoot or wearing open sandals. – Use only approved drawbar hitch points.
• Reduce the throttle setting during engine run-out and, if the engine is provided with a shut-off valve, turn the fuel off at the conclusion of mowing. Slope Operation • Do not mow slopes greater than 15 degrees. • Do not mow near drop–offs, ditches, steep banks or water. Wheels dropping over edges can cause rollovers, which may result in serious injury, death or drowning. Maintenance and Storage • Keep all nuts, bolts and screws tight to be sure the equipment is in safe working condition.
Sound Pressure This unit has a maximum sound pressure level at the operator ’s ear of 94 dBA, based on measurements of identical machines per Directive 98/37/EC. Sound Power This unit has a guaranteed sound power level of 105 dBA, based on measurements of identical machines per Directive 2000/14/EC. Vibration This unit does not exceed a hand/arm vibration level of 1.26 m/s2, based on measurements of identical machines per Directive 98/37/EC. This unit does not exceed a whole body vibration level of 0.
Slope Chart 7
Safety and Instruction Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. 58-6520 1. Grease 93-7010 1. Thrown object hazard—stay a safe distance from the machine. 2. Thrown object hazard, mower—keep the deflector in place. 3. Cutting/dismemberment of hand or foot—stay away from moving parts. 99-8939 1. Read the Operator’s Manual. 2. Height of cut 3.
93-7828 103-1636 1. Thrown object hazard, mower—do not operate the mower with the deflector up or removed; keep the deflector in place. 2. Cutting/dismemberment hazard of hand or foot, mower blade—stay away from moving parts. 93-8069 1. Hot surface/burn hazard—stay a safe distance from the hot surface. 104-2449 Battery Symbols Some or all of these symbols are on your battery. 1. Explosion hazard 2. No fire, open flames, or smoking. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 5.
107-2114 107-7700 1. 2. 3. 4. 5. 6. Engine—stop Engine—run Engine—start Power take-off (PTO) Fast Continuous variable setting 7. 8. 9. 10. 11. Slow Temperature Power (Volts) Engine—preheat Water in fuel warning 107-3069 1. Warning—there is no rollover protection when the roll bar is down. 2. To avoid injury or death from a rollover accident, keep the roll bar in the raised and locked position and wear the seat belt.
107-2131 1. Hydraulic oil level 2. Warning—do not touch the hot surface. 107-3962 1. Height of cut in millimeters 107-3961 107-3968 1. Height of cut in millimeters 1. Disengage 2. Engage 3. Parking brake 107-3969 1. Warning—read the Operator’s Manual. 2. Crushing hazard, mower—engage the parking brake, stop the engine, and remove the ignition key before working under the mower.
107-3978 1. Cutting/dismemberment hazard, fan and entanglement hazard, belt—stay away from moving parts. 2. Before starting the engine, clean grass and debris from the mower belt and pulleys, insert the ignition key, and start the engine. 107-7673 1. Cutting blade 107-3982 1. Operator’s Manual location 107-7705 107-7706 1. Read the Operator’s Manual. 2. Pulsing tone indicates low oil pressure or alternator not charging. 107-3993 1. Short, sparse grass and dry conditions. 2. Bagging 3.
107-7719 1. Cutting/dismemberment hazard, fan and entanglement hazard, belt—stay away from moving parts. 2. Before starting the engine, clean grass and debris from the mower belt and pulleys, insert the ignition key, and start the engine. 107-9864 1. Read the Operator’s Manual. 107-9862 1. Read the instructions before servicing or performing maintenance. 2. Hourly interval 3. 4. 5. 6.
107-3963 1. Cutting/dismemberment hazard, mower blade—do not carry passengers and keep bystanders away. 2. Cutting/dismemberment hazard of hand or foot, mower blade— remove the ignition key and read the instructions before servicing or performing maintenance; stay away from moving parts. 15 3. Thrown object hazard—keep bystanders a safe distance from the machine and keep the deflector in place. 4.
107-3964 1. Warning—do not use drugs or alcohol. 2. Warning—read the Operator’s Manual and receive training. 3. Warning—engage the parking brake, stop the engine, and remove the ignition key before leaving the machine. 1. 2. 3. 4. 5. 6. Poison and caustic liquid/chemical burn hazard—keep children a safe distance from the battery. 4. Warning—wear hearing protection. 5. Read the Operator’s Manual. 107-3967 Fast Slow Neutral Reverse Warning—read the Operator’s Manual. 16 7.
Operation 2 Note: Determine the left and right sides of the machine from the normal operating position. 1 Using the Rollover Protection System (ROPS) m–7447 Figure 2 Warning 1. Full down position To avoid injury or death from rollover: keep the roll bar in the raised locked position and use the seat belt. Important Always use the seat belt with the roll bar in the raised position. Ensure that the rear part of the seat is secured with the seat latch.
7. Tighten the front handles against the center roll bar ends (Fig. 3). 2 1 1 m–6897 Figure 4 1. Front handle 3 Think Safety First m–6478 Figure 5 Please read all safety instructions and symbols in the safety section. Knowing this information could help you or bystanders avoid injury. 1. Safe Zone—use the Z Master here on slopes less than 15 degrees or flat areas. 2. Use walk behind mower and/or hand trimmer near drop–offs and water. 3.
Adding Fuel Danger The engine runs on clean, fresh diesel fuel with a minimum octane rating of 40. Purchase fuel in quantities that can be used within 30 days to ensure fuel freshness. 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. Use summer grade diesel fuel (No. 2–D) at temperatures above 20° F (–7° C) and winter grade diesel fuel (No. 1–D or No. 1–D/2–D blend) below 20° F (–7° C).
Controls Using the Hour Meter Become familiar with all the controls before you start the engine and operate the machine (Figures 7 and 8). 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. Unlatch the seat and lift it up to view the hour meter (Fig. 8).
Continuous Audible Alarm Setting the Parking Brake The continuous audible alarm alerts the user that the engine is over heating. Refer to Servicing the Cooling System on page 39. 1. Move the motion control levers (Fig. 7) out to the neutral lock position. 2. Pull back and up on the parking brake lever to set the parking brake (Fig. 10). The parking brake lever should stay firmly in the Engaged position.
4. Move the PTO (power take off) switch to the off position (Fig. 11). 1 1 5. Move the throttle lever to slow (Fig. 8). 2 6. Turn the ignition key clockwise to the run position (Fig. 13). The glow plug indicator light will come on. 3 2 7. After the glow plug indicator light goes out, turn the key to the start position. 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.
Understanding the Safety Interlock System Operating the Power Take Off (PTO) The safety interlock system is designed to prevent the engine from starting unless: The power take off (PTO) switch engages and disengages power to the electric clutch. • You are sitting on the seat. • The parking brake is engaged. Engaging the PTO • The power take off (PTO) is disengaged. 1. While seated in the seat, release the pressure on the traction control levers and place in neutral.
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. 2 3 1 4 Caution m–2715 Machine can spin very rapidly. Operator may lose control of machine and cause personal injury or damage to machine. Figure 15 1. Motion control lever—neutral lock position • Use caution when making turns.
Adjusting the Height-of-Cut Using the Lift Assist Lever 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 clevis pin into different hole locations. The lift assist lever is used along with the height-of-cut lever for raising the deck. This allows for easier raising of the deck. 1. Raise the height-of-cut lever to the transport position (also the 5 inch (127 mm) cutting height position) (Fig. 16). 1. Place your foot onto the lift assist lever.
1 4 2 2 5 1 3 5 Figure 20 Figure 18 1. Anti–scalp roller 2. Spacer 3. Bushing 1 3 m–6844 m–6821 1. Anti–scalp roller 2. Spacer 3. Bushing 4. Flange Nut 5. Bolt 4. Flange Nut 5. Bolt Adjusting the Flow Baffle The mower discharge flow can be adjusted for different types of mowing conditions. Position the cam locks and baffle to give the best quality of cut. 1. To adjust the cam locks, swing the lever up to loosen the cam lock (Fig. 21). 3 2.
Positioning the Flow Baffle Position C The following figures are only recommendations for use. Adjustments will vary by grass type, moisture content, and height of grass. This is the full open position. The suggested use for this position is as follows. Note: If the engine power draws down and the mower ground speed is the same, open up the baffle. • Use in wet conditions. Position A • Allows increased ground speed in heavy conditions. This is the full rear position.
Unlatching the Seat Push the seat latch downward to unlatch the seat. This will allow access to the machine under the seat. 3 1 2 2 m–6861 Figure 25 1. Seat suspension knob 2. Seat position adjustment 1 Changing the Back Position m–7505 Figure 27 The back of the seat can be adjusted to provide a comfortable ride. Position the back of the seat where it is most comfortable. 1. Seat latch 2. Right side of machine 1.
Transporting the Machine Note: The machine will not drive unless the by-pass valves are turned in. Use a heavy-duty trailer or truck to transport the machine. Ensure that the trailer or truck has all necessary lighting and marking as required by law. Please carefully read all the safety instructions. Knowing this information could help you, your family, pets, or bystanders avoid injury.
Warning Warning Loading a unit onto a trailer or truck increases the possibility of backward tip–over and could cause serious injury or death. Unit could fall onto someone and cause serious injury or death. • Use extreme caution when operating unit on Z Stand. • Use only for cleaning mower and removing blades. • Do not keep unit on Z Stand for extended periods of time. • Always turn the engine off, set the parking brake and remove the key before performing any maintenance to mower.
Warning Parking brake may not hold machine parked on Z Stand and could cause personal injury or property damage. Do not park on Z Stand unless wheels are chocked or blocked. 8. Perform maintenance. 9. Remove chocks or blocks. 1 3 2 m–5600 Figure 31 1. Z Stand (Positioned in slot) 2. Crack in side walk or turf 3. Latch resting on pivot tab Driving off the Z Stand 1. Raise latch to unlocked position (Fig. 32). 2. Start engine and place at half throttle. Disengage parking brake. 3.
Tips for Mowing Grass Long Grass Fast Throttle Setting If the grass is ever allowed to grow slightly longer than normal, or if it contains a high degree of moisture, raise the cutting height higher than usual and cut the grass at this setting. Then cut the grass again using the lower, normal setting. For best mowing and maximum air circulation, operate the engine at fast.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position.
Maintenance Service Interval Before Storage Service • • • • • • Primary hydraulic filter—change Cooling Fan hydraulic filter—change Battery–charge, Disconnect cables fuel—drain Chipped Surfaces—paint Perform all maintenance procedures listed above before storage • Change engine coolant Every 4 years 1More often Maintenance Procedure in dusty, dirty conditions Important Refer to your engine operator’s manual for additional maintenance procedures.
Checking for Bent Blades Removing the Blades 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. The 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. 2.
1 1 m–1854 Figure 37 1. Sharpen at original angle 2 2. Check the balance of the blade by putting it on a blade balancer (Fig. 38). If the blade stays in a horizontal position, the blade is balanced and can be used. If the blade is not balanced, file some metal off of the end of the sail area only (Fig. 36). Repeat this procedure until the blade is balanced. m–7507 Figure 39 1. Front engine panel 4. Release the latches on the air cleaner and pull the air cleaner cover off of the air cleaner body (Fig.
USE THESE SAE VISCOSITY OILS Servicing the Primary Filter Blow compressed air from the inside to the outside of the primary filter. Important Do not exceed 100 psi and keep the hose at least 2 inches from the filter. Replace air filters if they are damaged or cannot be cleaned. Servicing the Safety Filter Do not clean the safety filter. Replace it after 600 operating hours. Draining the Engine Oil Important Never attempt to clean the safety filter.
Adding Engine Oil 1 1. Tilt the seat forward and remove the front engine panel (Fig. 42). 1 m–5152 Figure 44 1. Note the clearance left in the filler opening. 4. Start the engine and run it at idle for 5 minutes. 2 5. Shut off the engine. 6. Wait 3 minutes and check the oil level. m–7507 7. Add oil, if required, to bring the level to the upper hole on the dipstick. Figure 42 1. Front engine panel 2. Nut 8. Replace the dipstick and filler cap as needed and close the hood. 2.
1 3 1 2 3 m–1256 Figure 45 1. Oil filter 2. Gasket 2 3. Adapter 1 Checking the Engine Oil Level Note: Check the oil when the engine is cold. m–7400 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. Figure 46 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.
Cleaning the Cooling System Caution Clean the cooling system daily before each use. Swallowing engine coolant can cause poisoning. 1. Position the machine on a level surface, stop the engine, and set the parking brake. • Do not swallow engine coolant. • Keep out of reach from children and pets. Important Before starting the engine, clean grass from the pump drive belt compartment. Check more often in dry conditions. Checking the Radiator Coolant 2.
7. Tighten the drain plug when fuel begins to flow. Priming the Fuel System 8. Bleed the air from the fuel line by priming the fuel system. Refer to Priming the Fuel System on page 41. The primer pump is the gold metal button on top of the fuel filter Fig. 49. Changing the Fuel Filter To bleed air from the fuel system, push down on the primer pump until resistance becomes firm. This should take about 10–15 pushes on the primer pump.
Where to Add Grease Greasing the Spindles Lubricate the grease fittings as shown on the Check Service Reference Aid decal (Fig. 50). The cutting unit 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.
8. Grease the drive belt idler arms (Fig. 52). 1 m–1872 Figure 54 1. Valve stem Servicing the Hydraulic System m–7416 Checking the Hydraulic Fluid Figure 52 1. Left adjustable pulley 2. Back of the machine Check the hydraulic fluid level: • Before the engine is first started. 9. Grease the pump belt idler arm. • After the first 8 operating hours. • After every 25 operating hours. Fluid Type: Mobil 1 15W-50 synthetic motor oil or equivalent synthetic oil. Important Use oil specified or equivalent.
3. Place drain pan under filter, remove the old filter and wipe the filter adapter gasket surface clean (Fig. 57). 1 2 4 3 1 M–4763 m–5615 Figure 56 Figure 55 1. Cap 2. Baffle 1. Primary hydraulic filter 3. Cold fluid level—full 4. Hot fluid level—full 4. Apply a thin coat hydro fluid to the rubber gasket on the replacement filter (Fig. 57). 5. Install the replacement primary hydraulic filter onto the filter adapter. Do not tighten. Warning 6.
Replacing the Cooling Fan Hydraulic Filter Checking the Hydraulic Lines After every 100 operating hours, check hydraulic lines and hoses for leaks, loose fittings, kinked lines, loose mounting supports, wear, weather and chemical deterioration. Make necessary repairs before operating. Change the cooling fan hydraulic filter: • After the first 250 operating hours and then yearly after that. Note: Keep areas around hydraulic system clean from grass and debris build up. 1.
Setting the Hydraulic Pump Neutral 7. Check where the control lever is relative to notch in console (Fig. 59). It should be centered allowing lever to pivot outward to the neutral lock position. Note: Adjust handle neutral first. That has to be correct before the following adjustment can be made. 2 3 Danger Mechanical or hydraulic jacks may fail to support machine and cause a serious injury. 1 • Use jack stand when supporting machine. • Do not use hydraulic jacks. m–6282 Figure 59 1.
Setting the Right–hand Hydraulic Pump Neutral 2 6 1. Loosen the locknuts at the ball joints on pump control rod (Fig. 60). 1 5 6 4 5 2. Start the engine, open throttle 1/2 way and release parking brake. Refer to Starting and Stopping the Engine, page 21. Note: Motion control lever must be in neutral while making any adjustments. Note: The front nut on the pump rod has left–hand threads. 3.
Checking the Wheel Hub Slotted Nut 2 Check after every 500 operating hours. 3 The slotted nut needs to be torqued to 125 ft-lb (170 N⋅m). 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. 1 3. Remove the cotter pin. m–6280 4. Torque the slotted nut to 125 ft.-lb. (170 N⋅m) (Fig. 64). Figure 62 1. Pump rod 2.
3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. m–2539 4. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE Figure 66 5. Check tire pressure of all four tires. If needed, adjust to 13 psi (90 kPa) 7. If the measurements at positions B or C are not correct, loosen the bolt attaching the rear chain to the rear support arm (Fig. ). 6.
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 (Fig. 68). If it is not correct, proceed to the following steps. 8 1 8 Front 4 A 6 B 2 m–1078 7 5 Front 3 m–6831 Figure 68 Figure 70 1. 11–1/2 inch (29.2 cm) between the large washers 2. Front nut 3. Spring jam nut MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE m–2539 4. 5. 6. 7. 8.
Check belts for cracks, frayed edges, burn marks, or any other damage. Replace damaged belts. 2 Replacing the Mower Belt 3 Squealing when the belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks and cracks are signs of a worn mower belt. Replace the mower belt if any of these conditions are evident. 1 3 1 Note: Remove the drive belts first if the mower belt needs to be replaced. Refer to Replacing the Drive Belts on page 51. m–7418 1.
6. Install the new drive belt around the clutch pulley, the adjustable idler pulleys, the spring loaded idler pulley, and the front three stacked pulleys (Fig. 74). 2 1 2 4 6 m–7408 4 1 5 Figure 76 3 1. Right adjustable pulley 3 Replacing the Pump Drive Belt m–7404 Check pump drive belt for wear after every 50 hours of operation. Figure 74 1. Drive belt 2. Clutch 3. Spring loaded idler pulley 2. Right side of mower 4. Adjustable idler pulley 5. Three stacked pulleys 6. Mower belt—top 1.
Tensioning the Alternator Belt 2. Pull the spring loaded idler down and remove the fan drive belt from the engine and the pump pulley (Fig. 78). 1. Place a handle between the alternator and cylinder block (Fig. 79). 3. Install the new belt around the engine and hydro pump pulley (Fig. 78). 2. Adjust the alternator to the outside until there is 3/8 to 1/2 inch (10 to 13 mm) deflections in the belt between the engine and the alternator (Fig. 79). 4. Pull the spring loaded idler down and align the belt.
7. If an adjustment is necessary, loosen the jam nut directly above the trunion roller. Turn the lock nut below the trunion roller until the correct measurement is obtained (Fig. 80). 2. To replace a fuse, pull out on the fuse to remove it (Fig. 81). 2 8. Tighten the jam nut directly above the trunion roller (Fig. 80). Note: If the 1/4–5/16 inch (5–8 mm) can not be achieved, remove a pin from either yoke at the ends of the brake rod.
8 6 2. Unlatch the seat and tilt the seat up. 5 3 3. First disconnect the negative battery cable and ground wire from the negative (–) battery terminal (Fig. 82). 4 2 4. Slide the red terminal boot off the positive (red) battery terminal. Then remove positive (red) battery cable (Fig. 82). 5. Remove both wing nuts (1/4 inch) securing the battery clamp (Fig. 82). 6. Remove the battery. 7 Charging the Battery 1 m–7509 Warning Figure 82 1. 2. 3. 4.
Waste Disposal Note: Do not run the machine with the battery disconnected, electrical damage may occur. Engine oil, hydraulic oil, and engine coolant are pollutants to the environment. Dispose of these according to your state and local regulations. Replacing the Grass Deflector Warning 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.
Wiring Diagram 57
Cleaning and Storage Important Do not store stabilizer/conditioned fuel over 90 days. 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to Off. Remove the key. 12. Check and tighten all bolts, nuts, and screws. Repair or replace any part that is damaged. 13. Paint all scratched or bare metal surfaces. Paint is available from your Authorized Service Dealer. 2.
Troubleshooting Problem Starter does not crank Engine g will not start,, starts hard,, or f il tto kkeep running. fails i Engine g loses power. Engine g overheats. Possible Causes Corrective Action 1. Blade control (PTO) is engaged. 1. Move blade control (PTO) to disengaged. 2. Parking brake is not on. 2. Set parking brake. 3. Operator is not seated. 3. Sit on the seat. 4. Battery is dead. 4. Charge the battery. 5. Electrical connections are corroded or loose. 5.
Problem Machine does not drive. Abnormal vibration. Uneven cutting g height. g Blades do not rotate. Possible Causes Corrective Action 1. Traction belt is worn, loose or broken. 1. Contact Authorized Service Dealer. 2. Traction belt is off pulley. 2. Contact Authorized Service Dealer. 3. Hydro fluid level low. 3. Add hydro fluid to reservoir. 1. Cutting blade(s) is/are bent or unbalanced. 1. Install new cutting blade(s). 2. Blade mounting bolt is loose. 2. Tighten blade mounting bolt. 3.
