Form No. 3357-693 Rev A Z558 Z Master, with 52in, 60in or 72in TURBO FORCE® Side Discharge Mower Model No. 74271—Serial No. 270000001 and Up Model No. 74272—Serial No. 270000001 and Up Model No. 74273—Serial No. 270000001 and Up Register your product at www.Toro.
Warning CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Important: This engine is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate the engine on any forest-covered, brush-covered, or grass-covered land. Other states or federal areas may have similar laws. Figure 1 1.
Using the Rollover Protection System (ROPS).................. 16 Think Safety First .............................. 17 Operating the Parking Brake .............. 18 Starting and Stopping the Engine .............................. 18 Operating the Power Take Off (PTO) ............................... 20 The Safety Interlock System............... 20 Driving Forward or Backward ............ 21 Stopping the Machine ........................ 22 Adjusting the Control Lever Resistance .........................
Safety hair, loose clothing or jewelry may get tangled in moving parts. Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means CAUTION, WARNING, or DANGER-“personal safety instruction." Failure to comply with the instruction may result in personal injury or death.
• Keep hands and feet away from the cutting units. • Never carry passengers and keep pets and bystanders away. • Be alert, slow down and use caution when making turns. Look behind and to the side before changing directions. • Slow down and use caution when crossing roads and sidewalks. Stop blades if not mowing. • Be aware of the mower discharge direction and do not point it at anyone. • Do not operate the mower under the influence of alcohol or drugs.
• Carefully release pressure from components with stored energy. • Disconnect battery or remove spark plug wire before making any repairs. Disconnect the negative terminal first and the positive last. Reconnect positive first and negative last. • Use care when checking blades. Wrap the blade(s) or wear gloves, and use caution when servicing them. Only replace blades. Never straighten or weld them. • Keep hands and feet away from moving parts. If possible, do not make adjustments with the engine running.
Slope Chart 7
Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. 1-403005 54-9220 1-523552 58-6520 1.
8-4387 1. Warning—wear hearing protection.
7-1857 107-1861 107-2112 107-1864 107-1613 107-1860 10
Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 6. 2. No re, open ame, or smoking. 7. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 8. 5. Read the Operator’s Manual. 9. 10. Keep bystanders a safe distance from the battery. Wear eye protection; explosive gases can cause blindness and other injuries Battery acid can cause blindness or severe burns. Flush eyes immediately with water and get medical help fast. Contains lead; do not discard.
110-5731 1. 2. 3. 4. Engine—stop Engine—run Engine—start Fast 5. 6. 7.
106-9989 107-8076 1. Fast 2. Slow 3. Neutral 13 4.
Product Overview Controls Become familiar with all the controls before you start the engine and operate the machine (Figure 3 and Figure 4). Figure 4 Figure 3 1. 2. 3. 4. Motion control lever Parking brake lever Height-of-cut lever Fuel cap (both sides) 5. 6. 7. 1. Gas cap 2. Choke 3. Ignition switch Controls Seat belt Roll bar 4. 5. 6. Throttle Power take off (PTO) Hour meter Hour Meter The hour meter records the number of hours the engine has operated. It operates when the engine is running.
Operation In certain conditions during fueling, static electricity can be released causing a spark which can ignite the gasoline vapors. A fire or explosion from gasoline can burn you and others and can damage property. Note: Determine the left and right sides of the machine from the normal operating position. Adding Fuel • Always place gasoline containers on the ground away from your vehicle before filling. Use unleaded regular gasoline suitable for automotive use (85 pump octane minimum).
• Cleans the engine while it runs • Eliminates gum-like varnish buildup in the fuel system, which causes hard starting There is no rollover protection when the roll bar is in the down position. Important: Do not use fuel additives containing methanol or ethanol. • Lower the roll bar only when absolutely necessary. Add the correct amount of gas stabilizer/conditioner to the gas. • Do not wear the seat belt when the roll bar is in the down position.
Think Safety First 5. To raise the roll bar, remove the hairpin cotter pins and remove the two pins (Figure 6). 6. Raise the roll bar to the upright position and install the two pins and secure them with the hairpin cotter pins (Figure 6). Please read all safety instructions and symbols in the safety section. Knowing this information could help you or bystanders avoid injury. Important: Always use the seat belt with the roll bar in the raised position.
Setting the Parking Brake 1. Move the motion control levers (Figure 16) out to the neutral lock position. 2. Pull up and back on the parking brake lever to set the parking brake (Figure 10). The parking brake lever should stay firmly in the engaged position. Parking brake may not hold machine parked on a slope and could cause personal injury or property damage. Do not park on slopes unless wheels are chocked or blocked Figure 8 1. Safe Zone-use the Z Master 3.
3. Move the PTO (power take off) switch to the Off position (Figure 11). Figure 13 Figure 11 1. PTO—on 2. 1. PTO—off Throttle—fast 2. Throttle—slow 6. Turn the ignition key to Start (Figure 14). When the engines starts, release the key. 4. Move the choke control to the on position before starting a cold engine (Figure 12). Important: Do not engage starter for more than 10 seconds at a time. If engine fails to start, allow 30 second cool-down period between attempts.
4. Turn the ignition key to the off position and remove the key (Figure 14). 5. Close the fuel shut off valve before transporting or storing the machine. Refer to Fuel System Maintenance, page 35. Important: Make sure that the fuel shut off valve is closed before transporting or storing the machine, as fuel leakage may occur. Set the parking brake before transporting. Make sure to remove the key as the fuel pump may run and cause the battery to lose charge. Figure 15 1.
engaged or if you rise from the seat when the PTO is engaged. Machine can spin very rapidly. Operator may lose control of machine and cause personal injury or damage to machine. Testing the Safety Interlock System Test the safety interlock system before you use the machine each time. If the safety system does not operate as described below, have an Authorized Service Dealer repair the safety system immediately. • Use caution when making turns. • Slow the machine down before making sharp turns. 1.
Set the parking brake when you leave the machine; refer to Setting the Parking Brake. Remember to remove the key from the ignition switch. Children or bystanders may be injured if they move or attempt to operate the tractor while it is unattended. Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes. Adjusting the Control Lever Resistance The top damper mounting bolt can be adjusted to obtain a desired motion control lever resistance.
Figure 18 1. Height of cut lever 2. Clevis Pin Figure 19 2. To adjust, remove the clevis pin from the height-of-cut bracket (Figure 18). 1. 2. 3. 3. Select a hole in the height-of-cut bracket corresponding to the height-of-cut desired and, insert the clevis pin (Figure 18). Outer roller Spacer Bushing 4. 5. Bolt Nut 4. Move the lever to the selected height. 4. Select a hole so that the outer roller is positioned to the nearest corresponding height-of-cut desired (Figure 19).
the cam lock. Adjust the cam lock until the desired locking pressure is achieved. Figure 21 Figure 20 1. Outer roller 2. Spacer 3. Bushing 4. 5. 1. Cam lock 3. 2. Lever 4. Rotate cam to increase or decrease locking pressure Slot Bolt Nut Positioning the Flow Bafe 4. Select a hole so that the center rollers are positioned to the nearest corresponding height-of-cut desired (Figure 20). The following figures are only recommendations for use.
Figure 22 Position B Use this position when bagging. Figure 24 Using the Lift Assist Lever The lift assist lever is used along with the height-of-cut lever for raising the mower. This allows for easier raising of the mower. 1. Place your foot onto lift assist lever. 2. Press on the lift assist lever while pulling up on the height-of-cut lever (Figure 25). Figure 23 Position C This is the full open position. The suggested use for this position is as follows. Figure 25 1.
by-pass the pump enabling the wheels to turn (Figure 28). Important: Do not rotate by-pass valves more than 1 turn. This prevents valves from coming out of the body and causing fluid to run out. Figure 26 1. Adjustment lever Unlatching the Seat Push the seat latch rearward to unlatch the seat. This will allow access to the machine under the seat (Figure 27). Figure 28 1. By-pass valve 2. Hydraulic tank 3. Disengage parking brake before pushing. Changing to Machine Operation Figure 27 1. Seat latch 2.
Important: Do not use the motion control levers as anchors for tieing the machine down. Without the grass deflector, discharge cover, or complete grass catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris. Contact with rotating mower blade(s) and thrown debris will cause injury or death. • Secure a trailer to the towing vehicle with safety chains.
Operating Tips Fast Throttle Setting Loading a unit onto a trailer or truck increases the possibility of backward tip-over and could cause serious injury or death. For best mowing and maximum air circulation, operate the engine at the fast throttle position. Air is required to thoroughly cut grass clippings, so do not set the height-of-cut so low as to totally surround the mower by uncut grass. Always try to have one side of the mower free from uncut grass, which allows air to be drawn into the mower.
Long Grass If the grass is ever allowed to grow slightly longer than normal, or if it contains a high degree of moisture, raise the cutting height higher than usual and cut the grass at this setting. Then cut the grass again using the lower, normal setting. When Stopping If the machine’s forward motion must be stopped while mowing, a clump of grass clippings may drop onto your lawn. To avoid this, move onto a previously cut area with the blades engaged.
Maintenance Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the rst 8 operating hours • Change the engine oil. • 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. Check the mower blades. Clean the mower deck. Every 25 hours • Check the hydraulic uid level. Every 50 hours • Grease the mower bearings.
Lubrication Greasing and Lubrication Lubricate the machine when shown on the Check Service Reference Aid decal (Figure 30). Grease more frequently when operating conditions are extremely dusty or sandy. Grease Type: General-purpose grease. 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. Figure 30 3.
5. Gently slide the primary filter out of the air cleaner body (Figure 32). Avoid knocking the filter into the side of the body. 6. Remove the safety filter only if you intend to replace it. Never attempt to clean the safety filter. If the safety filter is dirty, then the primary filter is damaged and you should replace both filters. 7. Inspect the primary filter for damage by looking into the filter while shining a bright light on the outside of the filter. Holes in the filter will appear as bright spots.
2. If the safety filter is being replaced, carefully slide it into the filter body (Figure 32). 3. Carefully slide the primary filter over the safety filter (Figure 32). Ensure that it is fully seated by pushing on the outer rim of the filter while installing it. 3. Clean around the oil dipstick (Figure 34) so dirt cannot fall into engine. Note: Do not press on the soft inside area of the filter. 4. Install the air cleaner cover with the side indicated as UP facing up and secure the latches (Figure 32).
7. When oil has drained completely, close the drain valve. 8. Remove the drain hose (Figure 35). Note: Dispose of the used oil at a recycling center. Figure 36 1. Engine oil lter 3. Pour new oil of the proper type into the center hole in the new oil filter. Stop pouring when the oil reaches the bottom of the threads. Allow a minute or two for the oil to be absorbed by filter material. 4. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Figure 37). 5.
tool/feeler gauge to check and adjust the air gap. Install a new spark plug(s) if necessary. • Type: NGK® BPR4ES or equivalent • Air Gap: 0.030 inch (0.75 mm) Removing the Spark Plug 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. Figure 39 1. 2. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Canter electrode insulator Side electrode 3. Air gap (not to scale) 2.
4. Loosen the hose clamp at the fuel filter and slide it up the fuel line away from the fuel filter (Figure 40). 5. Disconnect the fuel line from the fuel filter (Figure 40). 6. Open the fuel shutoff valve. Note: Allow gasoline to drain into a fuel container can or drain pan (Figure 40). 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 40).
Removing the Battery Battery terminals or metal tools could short against metal machine components causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. • When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine. • Do not allow metal tools to short between the battery terminals and metal parts of the machine. Figure 41 1. 2. 3. 4. 5. 6.
Charging the Battery The fuses are as follows: • Main F1-30 amp, blade-type • Alternator F2-25 amp, blade-type Charging the battery produces gasses that can explode. 1. Unlatch the seat and raise the seat to gain access to fuse holder (Figure 43). Never smoke near the battery and keep sparks and flames away from battery. Important: Always keep the battery fully charged (1.265 specific gravity). This is especially important to prevent battery damage when the temperature is below 32°F (0°C). 1.
Drive System Maintenance Checking the Tire Pressure Check the pressure at the valve stem after every 50 operating hours or monthly, whichever occurs first (Figure 45). Adjusting the Tracking Maintain the air pressure in the rear tires at 13 psi (90 kPa). Uneven tire pressure can cause uneven cut. Check the tires when they are cold to get the most accurate pressure reading. Note: Determine the left and right sides of the machine from the normal operating position.
Figure 46 1. Slotted Nut 2. Two threads or less showing 3. 4. Hole in threaded shaft Washer (if needed) 5. Check the distance from bottom of slot in nut to inside edge of hole. Two threads or less should be showing (Figure 46). Figure 47 6. If more than two threads are showing remove nut and install washer between hub and nut. 1. Spring Washers 2. Lock Nut 7. Torque the slotted nut to 125 ft-lb. (170 N⋅m) (Figure 46). 3. Dust Cap 4.
Figure 48 Figure 50 1. Oil cooler 1. 2. 3. Cleaning the Engine Fins Brake lever Spring (2-3/4 inches/70 mm) Adjusting nuts 4. 5. Collar on brake rod 3/16–1/4 inch (5–7 mm) 6. Jam nut and yoke 3. If adjustment is necessary, loosen the jam nut below the spring and tighten the nut directly below the yoke (Figure 50). Turn the nut until the correct measurement is obtained. Tighten the two nuts together and repeat on opposite side of unit. 4.
the mower belt if any of these conditions are evident. 1. Disengage the PTO, move the motion control levers to the neutral locked position, and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the belt covers. 4. Loosen the nut securing the idler plate and move the idler plate to relieve the belt tension on the idler pulley (Figure 51). 5. Remove the nut, washer and belt guide from the rear leftside pulley. 6.
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. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Raise the mower to the transport position. Important: Check the amount of twist in the belt between the pulleys. Make sure it is only what is specified in Figure 51.
Controls System Maintenance Adjusting the Control Handle Neutral Position If motion control levers do not align, or move easily into the console notch, adjustment is required. Adjust each lever, spring and rod separately. Note: Motion control levers must be installed correctly. See Installing the Motion Control Levers in the set up instructions. 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2.
centered allowing lever to pivot outward to the neutral lock position. 8. If adjustment is needed, loosen the nut and jam nut against the yoke (Figure 59). 9. Apply slight rearward pressure on the motion control lever, turn the head of the adjustment bolt in the appropriate direction until the control lever is centered in the neutral lock position (Figure 59). • Before the engine is first started. • After the first 8 operating hours. • After every 25 operating hours.
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 61 1. Hydraulic lter • Keep body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid. 4. Apply a thin coat hydro fluid to the rubber gasket on the replacement filter (Figure 62).
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 64). 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 66). Figure 67 1. Measure here from blade to hard surface Figure 66 1. 2. 3. 4. Rear chain Rear support arm Bolt Jam Nut 5. 6. 7. Adjustment bolt Front swivel Front support arm 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 67). 3. Record this measurement. 8.
Adjusting the Compression Spring Check the cutter blades daily for sharpness, and for any wear or damage. File down any nicks and sharpen the blades as necessary. If a blade is damaged or worn, replace it immediately with a genuine Toro replacement blade. For convenient sharpening and replacement, you may want to keep extra blades on hand. 1. Raise the mower lift lever to the transport position. 2. Check the distance between the two large washers, it needs to be 11-1/8 inches (28.
2. Rotate the opposite ends of the blades forward. 3. Measure from a level surface to the cutting edge of the blades at the same position as in step 1 above. The difference between the dimensions obtained in steps 1 and 2 must not exceed 1/8 inch (3 mm). If this dimension exceeds 1/8 inch (3 mm), the blade is bent and must be replaced; refer to Removing the Blades and Installing the Blades. Figure 69 1. Cutting Edge 2. Curved Area 3.
Sharpening the Blades When sharpening blade, pieces of blade could be thrown and cause serious injury. Wear proper eye protection when sharpening blade. 1. Use a file to sharpen the cutting edge at both ends of the blade (Figure 71). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges. Figure 73 1. 2. 3. Sail Area of Blade Blade Spring Disk 4. 5. Blade Bolt Cone Towards Bolt Head 3.
Important: The grass deflector must be able to lower down into position. Lift the deflector up to test that it lowers into the full down position. Figure 74 1. Bolt 2. Spacer 3. Locknut 5. 6. 7. 4. Spring 8. Spring installed Grass Deector L end of spring, place behind deck edge before installing bolt J hook end of spring Cleaning Cleaning Under the Mower Remove the grass buildup under the mower daily. 1.
Storage stabilizer manufacture. Do not use an alcohol based stabilizer (ethanol or methanol). 1. Disengage the power take off (PTO), set the parking brake and turn the ignition key to off. Remove spark plug wire. Remove the key. Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline and used at all times. 2. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine and hydraulic system.
Troubleshooting Problem Starter does not crank Possible Cause Corrective Action 1. Blade control (PTO) is engaged. 2. Parking brake is not on. 3. Operator is not seated. 4. Battery is dead. 5. Electrical connections are corroded or loose. 1. Move blade contro (PTO) to disengaged. 2. Set the parking brake. 3. Sit on the seat. 4. Charge the battery. 5. Check the electrical connections for good contact. 6. Replace fuse. 7. Contact an Authorized Service Dealer. 6. Fuse is blown. 7.
Problem Machine does not drive. Abnormal vibration. Possible Cause 1. By pass valve is not closed tight. 2. Drive or pump belt is worn, loose or broken. 3. Drive or pump belt is off a pulley. 4. Broken or missing idler spring. 5. Hydraulic uid level is low or too hot. 1. Tighten the by pass valve. 2. Change the belt. 1. Cutting blade(s) is/are bent or unbalanced. 2. Blade mounting bolt is loose. 3. Engine mounting bolts are loose. 4. Loose engine pulley, idler pulley, or blade pulley. 5.
Problem Blades do not rotate. Possible Cause 1. Drive belt is worn, loose or broken. 2. Drive belt is off pulley. 3. Deck belt is worn, loose or broken. 4. Deck belt is off pulley. 5. Broken or missing idler spring. 58 Corrective Action 1. Check the belt tension. 2. Install drive belt and check adjusting shafts and belt guides for correct position. 3. Install new deck belt. 4. Install deck pulley and check the idler pulley, idler arm and spring for correct position and function. 5. Replace the spring.
Schematics Wire Diagram (Rev.
Evaporative Emission Control Warranty Statement California Evaporative Emission Control Warranty Statement Your Warranty Rights and Obligations Introduction The California Air Resources Board and The Toro® Company are pleased to explain the evaporative emission control system’s warranty on your 2006 model year equipment. In California, new equipment that use small off-road engines must be designed, built, and equipped to meet the State’s stringent anti-smog standards.
LCE The Toro Total Coverage Guarantee A Limited Warranty Conditions and Products Covered Items and Conditions Not Covered The Toro® Company and its afliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair the listed Toro Products if defective in materials or workmanship.