Form No. 3351–402 Z597–D Z Master with 60in or 72in TURBO FORCE Side Discharge Mower Model No. 74268—240000001 & Up Model No. 74269—240000001 & Up Operator’s Manual Register your product at www.Toro.
Warning Starting and Stopping the Engine . . . . . . . . . . . . Operating the Power Take Off (PTO) . . . . . . . . . The Safety Interlock System . . . . . . . . . . . . . . . . Driving Forward or Backward . . . . . . . . . . . . . . . Stopping the Machine . . . . . . . . . . . . . . . . . . . . . Adjusting the Height-of-Cut . . . . . . . . . . . . . . . . Using the Lift Assist Lever . . . . . . . . . . . . . . . . . Adjusting the Anti-Scalp Rollers . . . . . . . . . . . . . Adjusting the Flow Baffle . . .
Waste Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Storage . . . . . . . . . . . . . . . . . . . . . . Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Toro Total Coverage Guarantee . . . . . . . . . . . . . Page 56 56 57 58 60 Caution signals a hazard that may cause minor or moderate injury if you do not follow the recommended precautions.
• The owner/user can prevent and is responsible for accidents or injuries occurring to himself or herself, other people or property. • Stop equipment and inspect blades after striking objects or if an abnormal vibration occurs. Make necessary repairs before resuming operations. • Keep hands and feet away from the cutting units. Preparation • Never carry passengers and keep pets and bystanders away.
• Follow the manufacturer’s recommendations for wheel weights or counterweights to improve stability. • Charge batteries in an open well ventilated area, away from spark and flames. Unplug charger before connecting or disconnecting from battery. Wear protective clothing and use insulated tools. • Use extreme care with grass catchers or other attachments. These can change the stability of the machine and cause loss of control. • Keep all parts in good working condition and all hardware tightened.
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 1-523552 CAUTION 65-2690 ROTATING BLADES! STOP ENGINE BEFORE REACHING UNDERNEATH. E643253 1-643253 66-1340 43-8480 68-8340 98-4387 54-9220 1. Warning—wear hearing protection.
98-5954 103-5881 103-1636 104-8569 104-7759 103-3276 105-7798 10
107-1613 107-1857 107-1864 107-9863 107-2102 11
107-9864 107-1860 1. Read the Operator’s Manual.
107-7705 107-7701 107-9866 13
106-9989 106-7492 14
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 Unlatch the seat and lift it up to view the hour meter (Fig. 8). Become familiar with all the controls before you start the engine and operate the machine (Figures 7 and 8). Using the Glow Plug Light (Orange Light) The glow plug indicator light turns on when the ignition switch is turned to the On position. When the indicator light turns off, the engine is ready to be started (Fig. 8).
Pulsing Audible Alarm Warning The pulsing audible alarm alerts the user to low oil pressure or the alternator is not charging. Refer to Checking the Engine Oil on page 37 and check the alternator belt. 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 Switching the Fuel Tanks Important Do not run the machine out of fuel.
7. After the glow plug indicator light goes out, turn the key to the start position. When the engine starts, release the key. 1 1 2 Important Use starting cycles of no more than 30 seconds per minute to avoid overheating the starter motor. 3 2 8. If the engine does not start immediately, move the throttle control to fast and turn the key to the start position.
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 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. 1 1. Raise the height-of-cut lever to the transport position (also the 5 inch (127 mm) cutting height position) (Fig. 16). m–5028 Figure 17 2. To adjust, remove the clevis pin from the height-of-cut bracket (Fig. 16). 1. Lift assist lever 3.
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 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.
2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. machine, use genuine Toro replacement blades. Replacement blades made by other manufacturers may result in non-conformance with safety standards. 3. Rotate the blades until the ends face forward and backward (Fig. 34). Measure from a level surface to the cutting edge of the blades (Fig. 35). Note this dimension. Warning Contact with sharp blade can cause serious injury.
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–7412 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.
Servicing the Primary Filter Servicing the Engine Oil Blow compressed air from the inside to the outside of the primary filter. Service Interval/Specification Change oil after the first 50 operating hours and then every 150 operating hours thereafter. 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. Oil Type: High–quality detergent oil classified “API Service CF or CF–4” or higher for diesel engines.
1 3 2 1 Figure 41 1. Drain plug 2. Oil filter 3. Dip stick 2 m–7506 7. Install the drain plug and tighten it to 25–1/2 ft–lb (35 N m). Figure 43 1. Oil filler cap 2. Air cleaner Note: Dispose of the used oil at a certified recycling center. 3. Add oil slowly, checking the level with the dipstick frequently until the level reaches the upper hole on the dipstick. (Refer to Engine Oil, page 35, for the correct oil type and viscosity to use in different temperature conditions). Adding Engine Oil 1.
Changing the Engine Oil Filter 5. Slide the oil dipstick fully into the tube. Pull the dipstick out and look at the metal end (Fig. 46). If the oil level is low, slowly pour only enough oil into the filler tube to raise the level to the full mark. Service Interval/Specification Replace the oil filter after the first 50 operating hours and then every 300 operating hours thereafter. Important Do not overfill the crankcase with oil because the engine may be damaged.
1 Danger Rotating shaft and fan can cause personal injury. • Do not operate the machine without the covers in place. • Keep fingers, hands and clothing clear of rotating fan and drive shaft. • Shut off the engine and remove the ignition key before performing maintenance. Caution 1 Swallowing engine coolant can cause poisoning. 2 • Do not swallow engine coolant. • Keep out of reach from children and pets. m–7402 Figure 47 Checking the Radiator Coolant 1. Antifreeze overflow bottle 2.
Servicing the Fuel Filter 11. Open fuel shut-off valve (Fig. 48). 12. Start the engine and check for leaks. Draining Water from the Fuel Filter 5 If the water in fuel light comes on stop the engine and drain the water from the fuel filter. 4 1 3 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 1 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3.
Priming the Fuel System 4. Wipe up any excess grease. The primer pump is the gold metal button on top of the fuel filter Fig. 49. Where to Add Grease Lubricate the grease fittings as shown on the Check Service Reference Aid decal (Fig. 50). 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. 2 1 m–7403 Figure 49 1. Fuel filter 2.
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. Grease the three spindle bearings under the pulleys until grease comes out the lower seals (Fig. 51). 5. Grease the idler arm on the mower deck (Fig. 51). 6. Grease the fittings on the push arms (Fig. 51). m–7416 Figure 52 1. Left adjustable pulley 2.
Checking the Tire Pressure 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 on page 19. Maintain the air pressure in the front and rear tires as specified. Uneven tire pressure can cause uneven cut. Check the pressure at the valve stem after every 50 operating hours or monthly, whichever occurs first (Fig. 54). Check the tires when they are cold to get the most accurate pressure reading. 6.
Replacing the Pimary Hydraulic Filter Change the primary hydraulic filter: 1 3 • After the first 250 operating hours and then yearly after that. 2 Use summer filter above 32°F (0°C) Use winter filter below 32°F (0°C) 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. m–1256 Figure 57 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 1. Hydraulic filter 2. Gasket 3.
Bleeding the Hydraulic System Adjusting the Handle Neutral 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 motion control levers do not align, or move easily into the console notch, adjustment is required. Adjust each lever, spring and rod separately. 1. Raise rear of the machine so wheels are off the ground and support with jack stands. Note: Motion control levers must be installed correctly.
9 2 1 1. Raise the frame and block up the machine so drive wheels can rotate freely. 6 7 2. Disconnect the electrical connector from the seat safety switch. Temporarily install a jumper wire across terminals in the wiring harness connector. 3 3. Unlatch the seat, slide seat forward, disconnect the seat rod and tilt the seat fully forward. Setting the Left–hand Hydraulic Pump Neutral 11 10 4 12 5 10 1. Start the engine, open throttle 1/2 way and release parking brake.
2 6 1 5 6 2. Check if the machine pulls to one side. If it does, stop the machine and set the parking brake. 4 5 3. Unlatch the seat and tilt the seat forward to access the tracking knob. Note: Determine the left and right sides of the machine from the normal operating position. 4. To make the machine go right, turn the knob towards the rightside of the machine. Refer to figure 62. 5. To make the machine go left, turn the knob towards the leftside of the machine. Refer to figure 62. 6.
4 Important Make sure that the spring washers are installed correctly as shown in Figure 63. 1 2 3 3 2 m–4638 1 Figure 64 1. Slotted nut 2. Two threads or less showing 3. Hole in threaded rod 4. Washer (if needed) M–4640 Figure 63 1. Spring washers 2. Locknut 3. Dust cap Leveling the Mower at Three Positions Important There are only three measuring positions needed to level the mower. Checking the Wheel Hub Slotted Nut Setting Up the Machine Check after every 500 operating hours. 1.
3. Record this measurement. This measurement needs to be 3–1/8 to 3–1/4 inches. Front 2 4. Position the left blade front-to-rear (Fig. 65). 6 5. Measure the left blade at the C location (Fig. 65), from a level surface to the cutting edge of the blade tips (Fig. 66). 6. Record this measurement. This measurement needs to be 3–1/8 to 3–1/4 inches. 2 Front 7 1 3 4 1 5 m–6830 Figure 67 1. 2. 3. 4. B C m–1078 Rear chain Rear support arm Bolt Jam Nut 5. Adjustment bolt 6. Front swivel 7.
8 1 8 MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE 4 m–2539 Figure 69 Note: Both of the front swivels need to be adjusted the same amount to maintain equal chain tension. 6 2 7. Loosen the front swivel jam nuts, at the front of the right and left swivels, approximately a 1/2 inch (13 mm) (Fig. 70). 7 5 Front 3 m–6831 Figure 70 8. Adjust the lift nuts on both the left and the right side of the machine to achieve 1/4 to 3/8 inch (6 to 10 mm) lower in front at A than in the rear at B (Fig. 70). 1.
2 Inspecting the Belts 1 Inspect all belts every 100 hours. Check belts for cracks, frayed edges, burn marks, or any other damage. Replace damaged belts. 1 Replacing the Mower Belt 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. m–7422 Note: Remove the drive belts first if the mower belt needs to be replaced.
7. 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). 6. Position the adjustable pulley lower in the slot and tighten the nut (Fig. 76). 7. Check to make sure the coils of the spring on the spring–loaded idler pulley have the correct measurement (Fig. 75). 8. Adjust the belt tension; refer to Adjusting the Drive Belts, page 51. 8. Repeat as necessary on the opposite side of the machine. 9.
2. Pull the spring loaded idler down and remove the traction belt from the engine and hydro pump pulleys (Fig. 77). Remove the belt between the pulleys. 1 3. Install the new belt around the engine and hydro pump pulleys (Fig. 77). 4. Pull the spring loaded idler down and align it below the traction belt. Release the pressure on the spring loaded idler (Fig. 77). 4 3 2 m–7426 Figure 78 1. Fan belt 2. Idler pulley 1 2 3. Engine pulley 4. Hydro pump pulley m–7405 Figure 77 1.
7. Install a new belt around the pulleys and the alternator (Fig. 80). 3. If an adjustment is necessary, loosen the jam nut below the spring and tighten the nut directly below the yoke (Fig. 81). Turn the nut until the correct measurement is obtained. Tighten the two nuts together and repeat on the opposite side of the unit. Tensioning the Alternator Belt 4. Turn the nuts clockwise to shorten the spring length and counterclockwise to lengthen the spring. 1.
Servicing the Fuses Installing the Battery The electrical system is protected by fuses. It requires no maintenance, however, if a fuse blows, check the component/circuit for a malfunction or short. 1. Position battery in the machine. Fuse: Main/Ignition –20 amp, blade-type Glow plug/Alternator –40 amp, blade-type 3. Then install negative battery cable and ground wire to the negative (–) battery terminal. Secure the cable. 1. To gain access to the main fuse, unlatch the seat and tilt the seat forward.
Removing the 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). Warning 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. 1. Remove the battery from the chassis; refer to Removing the Battery, page 55.
2. Place spacer and spring onto grass deflector. Place the L end of spring behind deck edge. 4. Grease and oil the machine; refer to Greasing and Lubrication, page 40. Note: Make sure the L end of spring is installed behind deck edge before installing the bolt as shown in figure 85. 5. Change the crankcase oil; refer to Servicing the Engine Oil, page 35. 3. Install bolt and nut. Place J hook end of spring around grass deflector (Fig. 85). 6.
Wiring Diagram 57
Troubleshooting Problem Starter does not crank Engine g will not start,, starts hard,, or f il to fails t keep k running. 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.
The Toro Total Coverage Guarantee LCE A Limited Warranty Conditions and Products Covered Owner Responsibilities The Toro Company and its affiliate, 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.
