Form No. 3358-197 Rev B Z593-D Z Master® with a 52 TURBO FORCE® Rear Discharge Mower Model No. 74279TE—Serial No. 270000001 and Up Register at www.Toro.com.
This spark ignition system complies with Canadian ICES-002. Figure 2 1. Safety alert symbol Introduction Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage. You are responsible for operating the product properly and safely. This manual uses 2 other words to highlight information. Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention.
Safety Servicing the Air Cleaner .................................... 30 Servicing the Engine Oil ..................................... 31 Fuel System Maintenance ....................................... 35 Servicing the Fuel Filters .................................... 35 Servicing the Fuel Tank ...................................... 35 Electrical System Maintenance................................ 35 Servicing the Battery........................................... 35 Servicing the Fuses ...................
Preparation • While mowing, always wear substantial footwear and long trousers. Do not operate the equipment when barefoot or wearing open sandals. • Thoroughly inspect the area where the equipment is to be used and remove all objects which may be thrown by the machine. • Warning–Fuel is highly flammable. – Store fuel in containers specifically designed for this purpose. – Refuel outdoors only and do not smoke while refuelling. – Add fuel before starting the engine.
• Do not make sudden turns or rapid speed changes. • Allow the engine to cool before storing in any enclosure. • To reduce the fire hazard, keep the engine, silencer, battery compartment and fuel storage area free of grass, leaves, or excessive grease. • Check the grass catcher frequently for wear or deterioration. • Replace worn or damaged parts for safety. • If the fuel tank has to be drained, this should be done outdoors.
Slope Chart 6
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. 98-1977 1. Entanglement hazard, belt—stay away from moving parts. 58-6520 1. Grease 98-4387 1. Warning—wear hearing protection. 93-7010 1. Thrown object hazard— 2. Thrown object hazard, mower—keep the deflector in place. 3. Cutting/dismemberment of hand or foot—stay away from moving parts. 103-1636 93-7818 1.
107-1866 1. Sliding and loss of control hazard and tipping hazard, drop-offs—do not operate the machine near drop-offs, slopes greater than 15 degrees, or water; keep a safe distance from drop-offs; do not turn sharply while traveling fast, instead, slow down and turn gradually; if the roll bar is raised, wear the seat belt; if the roll bar is lowered, do not wear the seat belt. 107-3069 1. Warning–there is no rollover protection when the roll bar is down. 2.
107-3968 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. 107-3961 1. Height of cut in millimeters 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.
8-5957 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 108-5981 1. Cutting/dismemberment hazard, fan and entanglement hazard, belt. 110-0806 2. Remove the ignition key and read the instructions before servicing or performing maintenance.
2-2389 1. Push to engage 2. Engine—preheat 3. Read the Operator’s Manual. 4. Engine—stop 5. Engine—run 6. Engine—start 7. Fast 8. Continuous variable setting 9. Slow 10. PTO (Power take off) 114-1826 1. Remove the ignition key. 2. Read the instructions before servicing or performing maintenance. Manufacturer’s Mark 1. Indicates the blade is identified as a part from the original machine manufacturer. 112-3858 1. Read the Operator’s Manual. 2.
Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 2. No fire, open flame, or smoking. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 5. Read the Operator’s Manual. 6. Keep bystanders a safe distance from the battery. 7. Wear eye protection; explosive gases can cause blindness and other injuries 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. 10. Contains lead; do not discard.
107-3963 1. Cutting/dismemberment hazard, mower blade—do not carry passengers and keep bystanders away. 3. Thrown object hazard—keep bystanders a safe distance from the machine and keep the deflector in place. 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. 4.
110-0820 1. Fast 2. Slow 5. Warning—read the Operator’s Manual. 6. Poison and caustic liquid/chemical burn hazard—keep children a safe distance from the battery. 7. Explosion hazard—no fire, open flames, or smoking; avoid sparks. 8. To unlock the traction drive, turn the by-pass valve 1 complete revolution counterclockwise using a 5/8 inch or 16 mm wrench. 3. Neutral 4. Reverse Product Overview Figure 4 1. 2. 3. 4. 5.
Temperature Light Operation The temperature light comes on when the engine is over heating (Figure 4). Note: Determine the left and right sides of the machine from the normal operating position. Audible Alarm Adding Fuel This machine has an audible alarm that alerts the user to turn off the engine or engine damage can occur from over heating. Refer to Servicing the Cooling System in Cooling System Maintenance , page 40. The engine runs on clean, fresh diesel fuel with a minimum octane rating of 40.
the filler neck. This space in the tank allows the fuel to expand. Do not fill the fuel tanks completely full. 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. 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.
There is no rollover protection when the roll bar is in the down position. • Lower the roll bar only when absolutely necessary. • Do not wear the seat belt when the roll bar is in the down position. • Drive slowly and carefully. • Raise the roll bar as soon as clearance permits. • Check carefully for overhead clearances (i.e. branches, doorways, electrical wires) before driving under any objects and do not contact them. Important: Lower the roll bar only when absolutely necessary. Figure 5 1.
Important: Always use the seat belt with the roll bar in the raised position. Operating on wet grass or steep slopes can cause sliding and loss of control. 1 Wheels dropping over edges can cause rollovers, which may result in serious injury, death or drowning. 2 There is no rollover protection when the roll bar is down. Always keep the roll bar in the raised and locked position and use the seat belt. Read and follow the rollover protection instructions and warnings.
This machine produces sound levels in excess of 85 dBA at the operators ear and can cause hearing loss through extended periods of exposure. Wear hearing protection when operating this machine. Wear protective equipment for your eyes, ears, feet, and head when using this machine. Figure 10 1. Parking brake-ON 2. Parking brake-OFF Figure 9 3. Brake Stop Starting and Stopping the Engine 1. Warning— wear hearing protection Starting the Engine in Normal Weather Operating the Parking Brake 1.
Figure 11 1. 2. 3. 4. 5. Hour meter Ignition switch Glow plug switch Glow plug light Engine Temperature light 6. 7. 8. 9. Throttle control PTO Switch Audible alarm Fuel selector valve Figure 13 1. Throttle—fast 2. Throttle—slow Starting the Engine in Cold Weather (Below 23°F or -5°C) 9. Turn the key to the start position and the glow plug indicator light will come back on. When the engine starts, release the key (Figure 12). Note: Use the correct engine oil for the starting temperature.
4. Turn the ignition key to the off position (Figure 12). Wait for all moving parts to stop before leaving the operating position. 5. Remove the key to prevent possibility of someone accidentally starting the machine before transporting or storing machine. 6. Close the fuel selector valve before transporting or storing the machine. Important: Make sure that the fuel selector valve is closed before transporting or storing the machine, as fuel leakage may occur. Set the parking brake before transporting.
Testing the Safety Interlock System 2. Move the levers to the center, un-locked position. 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. 1. Sitting on the seat, engage the parking brake and move the PTO to on. Try starting the engine; the engine should not crank. 2. Sitting on the seat, engage the parking brake and move the PTO to off.
To turn, release pressure on the motion control lever toward the direction you want to turn (Figure 15). To stop, push the motion control levers to the neutral position. Stopping the Machine To stop the machine, move the traction control levers to neutral and move to locked position, disengage the power take off (PTO), and turn the ignition key to off. Set the parking brake when you leave the machine; refer to Setting the Parking Brake in Operation , page 15.
Positioning the Seat Changing the Seat Position The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable. 1. To adjust, move the lever sideways to unlock seat (Figure 19). 2. Slide the seat to the desired position and release the lever to lock it in position. Changing the Seat Suspension The seat can be adjusted to provide a smooth and comfortable ride. Position the seat where you are most comfortable.
2. Rotate the by-pass valves counterclockwise 1 turn to push. This allows hydraulic fluid to by-pass the pump enabling the wheels to turn (Figure 22). 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. 3. Disengage parking brake before pushing. Changing to Machine Operation Rotate the by-pass valves clockwise 1 turn to operate machine (Figure 22). Note: Do not over tighten the by-pass valves.
Driving on the street or roadway without turn signals, lights, reflective markings, or a slow moving vehicle emblem is dangerous and can lead to accidents causing personal injury. Loading a unit onto a trailer or truck increases the possibility of backward tip-over and could cause serious injury or death. • Use extreme caution when operating a unit on a ramp. Do not drive machine on a public street or roadway. • Use only a single, full width ramp; Do Not use individual ramps for each side of the unit.
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. 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 first 8 hours • Check the hydraulic fluid level. After the first 25 hours • Change the hydraulic filter and oil. After the first 50 hours • Change the engine oil. • Change the engine oil filter. After the first 100 hours • Change gear box oil. Before each use or daily • • • • • Check the engine oil. Check the engine coolant level. Clean the engine oil cooler. Check the mower blades.
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 Greasing and Lubrication Lubricate the machine when shown on the Check Service Reference Aid decal (Figure 24).
Engine Maintenance 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. Servicing the Air Cleaner 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Air Filter: Check and/or replace after every 250 operating hours or more often in dusty conditions. 3. Remove the belt covers. Note: Check the filters more frequently if operating conditions are extremely dusty or sandy. 4.
Figure 27 1. Air filter body 2. Air filter Figure 28 3. Air cleaner cover 4. Latches 1. Air filter body 2. Air filter Installing the Air Filter 3. Air cleaner cover 4. Latches Servicing the Engine Oil 1. If installing a new filter, check the filter for shipping damage. Do not use a damaged filter. Change the engine oil as follows: • After the first 50 operating hours. 2. Carefully slide the filter into the filter body (Figure 28).
Figure 29 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 30 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 33 1. Engine Figure 31 3. To add oil to the engine, locate and use a hose and funnel for adding oil (Figure 34). 2. Drain plug 1. Back of machine 2. Oil fill cap 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 30, ). Adding Engine Oil 1.
Figure 35 1. Note the clearance left in the filler opening. 5. Replace the dipstick and install the front engine panel. 6. Start the engine and run it at idle for 5 minutes. 7. Shut off the engine. 8. Wait 3 minutes and check the oil level. Figure 36 9. Add oil, if required, to bring the level to the upper hole on the dipstick. 1. Oil filter 2. Right side of machine 10. Replace the dipstick and , filler cap, and the front engine panel. 11. Check for leaks.
Fuel System Maintenance Electrical System Maintenance Servicing the Fuel Filters Servicing the Battery Replace the fuel filters after every 400 operating hours or yearly, whichever occurs first, and replace them more frequently under extremely dusty or dirty conditions. Warning CALIFORNIA Proposition 65 Warning Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.
Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. • Always Disconnect the negative (black) battery cable before disconnecting the positive (red) cable. • Always Reconnect the positive (red) battery cable before reconnecting the negative (black) cable. 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2.
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. Make sure the filler caps are installed in battery. Charge battery for 10 to 15 minutes at 25 to 30 amps or 30 minutes at 10 amps. 2. When the battery is fully charged, unplug the charger from the electrical outlet, then disconnect the charger leads from the battery posts (Figure 40). 3.
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 46 and Adjusting the Hydraulic Pump Neutral in Hydraulic System Maintenance , page 47. 1. Push both control levers forward the same distance. 2. Check if the machine pulls to one side.
Checking the Wheel Hub Slotted Nut 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the dust cap from caster and tighten lock nut (Figure 45). 4. Tighten the locknut until the spring washers are flat and then back off a 1/4 turn to properly set the pre-load on the bearings (Figure 45). Check after every 500 operating hours. The slotted nut needs to be torqued to 125 ft-lb (170 N•m). 1.
Cooling System Maintenance Servicing the Cooling System Discharge of hot pressurized coolant or touching hot radiator and surrounding parts can cause severe burns. • Do not remove the radiator cap when the engine is hot. Always allow the engine to cool at least 15 minutes or until the radiator cap is cool enough to touch without burning your hand before removing the radiator cap. • Do not touch radiator and surrounding parts that are hot. Figure 46 1. Gear box 2. Side plug 3. Rear plug 4.
1. Position the machine on a level surface, stop the engine, and set the parking brake. 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 47). 4. If the coolant level is low, add a 50/50 mix of extended life antifreeze/Dex-Cool® and water to the overflow bottle (Figure 47). 5.
Brake Maintenance Belt Maintenance Adjusting the Parking Brake Inspecting the Belts 1. Engage the parking brake, lever up. Inspect all belts every 100 hours. 2. Measure the length of the spring. Measurement should be 2-1/2 inch (64 mm) between the washers (Figure 49). Check belts for cracks, frayed edges, burn marks, or any other damage. Replace damaged belts. Replacing the Mower Belt 3.
Replacing the PTO Drive Belt Squealing when the belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks, and cracks are signs of a worn PTO belt. Replace the mower belt if any of these conditions are evident. 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3.
Figure 55 1. Pump drive belt 2. Clutch Figure 54 1. PTO Drive belt 2. Clutch 3. Spring 4. Spring loaded idler pulley 5. Gear box 6. Clutch stop bracket 3. Spring loaded idler pulley 4. Spring Replacing and Tensioning the Alternator Belt Replacing the Pump Drive Belt Check the alternator belt for wear after every 50 hours of operation. Check pump drive belt for wear after every 50 hours of operation.
12. Install the oil cooler shield and engine straps to the rear frame with the 4 bolts previously removed (Figure 56). 13. Install the engine straps to the side of the machine (Figure 56). 14. Tighten the bottom bolt and install the upper bolt holding the alternator and cover (Figure 58). Tensioning the Alternator Belt 1. Place a handle between the alternator and cylinder block. 2.
Controls System Maintenance 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 60). Adjusting the Control Handle Neutral Position Note: Keeping rearward pressure on the lever will keep the pin at the end of the slot and allow the adjustment bolt to move the lever to the appropriate position.
Hydraulic System Maintenance Servicing the Hydraulic System Checking the Hydraulic Fluid Level Fluid Type: Mobil 1 15W-50 synthetic motor oil or equivalent synthetic oil. Figure 61 Important: Use oil specified or equivalent. Other fluids could cause system damage. 1. Hot fluid level-full 2. Cold fluid level-full Hydraulic System Oil Capacity: 132 ounces (3.9 l) Check the hydraulic fluid level: Hydraulic fluid escaping under pressure can penetrate skin and cause injury.
clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 1/2 turn (Figure 64). 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 10. Clean up any spilled fluid. Important: Do not substitute automotive oil filter or severe hydraulic system damage may result. 11. Add fluid to the cold level of the baffle in the hydraulic tank. 3.
Checking the Hydraulic Hoses After every 100 operating hours, check the hydraulic hoses for leaks, loose fittings, kinked lines, loose mounting supports, wear, weather and chemical deterioration. Make necessary repairs before operating. Engine must be running so motion control adjustment can be performed. Contact with moving parts or hot surfaces may cause personal injury. Note: Keep areas around the hydraulic system clean from grass and debris build up.
Figure 66 Figure 65 1. Tracking knob 2. Hydraulic tank 3. Hydraulic pumps 1. Double nuts 2. Pump rod 3. Adjustment bolt 4. Turn this way to track right 5. Turn this way to track left Setting the Left-hand Hydraulic Pump Neutral Position 4. Locknut 5. Ball joint 6. Pumps Electrical system will not perform proper safety shut off with jumper wire installed. 1. Loosen the locknuts at the ball joints on the pump control rod (Figure 66).
Mower Deck Maintenance Leveling the Mower at Three Positions Important: There are only three measuring positions needed to level the mower. Setting Up the Machine 1. Position the mower on a flat surface. 2. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. Figure 67 3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 1. Measure here from blade to hard surface 2. Measure at B and C 7.
Adjusting the Front-to-Rear Mower Pitch Adjusting the Compression Spring 1. Position the right blade front-to-rear (Figure 69). 2. Check the distance between the two large washers, it needs to be 11-1/2 inches (29.2 cm) (Figure 70). 1. Raise the mower lift lever to the transport position. 2. Measure the right blade at the A location, from a level surface to the cutting edge of the blade tip (Figure 69). 3.
A worn or damaged blade can break, and a piece of the blade could be thrown into the operator’s or bystander’s area, resulting in serious personal injury or death. • Inspect the blade periodically for wear or damage. • Replace a worn or damaged blade. Inspect and check the blades every 8 hours. 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.
Contact with a sharp blade can cause serious injury. Wear gloves or wrap sharp edges of the blade with a rag. 1. Hold the blade end using a rag or thickly-padded glove. 2. Remove the blade bolt, spring disk and blade from the spindle shaft (Figure 75). Sharpening the Blades Figure 72 1. Measure here from blade to hard surface When sharpening blade, pieces of blade could be thrown and cause serious injury. 2. Position A Wear proper eye protection when sharpening blade. 4.
Installing the Blades Cleaning 1. Install the blade onto the spindle shaft (Figure 75). Cleaning Under the Mower Important: The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting. Remove the grass buildup under the mower daily. 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2. Install the spring disk and blade bolt.
Storage Note: A fuel stabilizer/conditioner is most effective when mixed with fresh fuel and used at all times. Cleaning and Storage B. Run the engine to distribute conditioned fuel through the fuel system (5 minutes). 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to Off. Remove the key. C. Stop the engine, allow it to cool, and drain the fuel tank; refer to Servicing the Fuel Tank in Fuel System Maintenance , page 35. 2.
Troubleshooting Problem The starter does not crank. The engine will not start, starts hard, or fails to keep running. Possible Cause 1. The blade control (PTO) is engaged. 1. Move the blade control (PTO) to the disengaged position. 2. 3. 4. 5. The parking brake is not on. The operator is not seated. The battery is dead. The electrical connections are corroded or loose. 6. The fuse is blown. 7. The relay or switch is defective. 2. 3. 4. 5. 1. The fuel tank is empty. 1. Fill the fuel tank with fuel.
Problem Uneven cutting height. Possible Cause 1. The cutting blade(s) is/are not sharp. 1. Sharpen the blade(s). 2. The cutting blade(s) is/are bent. 3. The mower deck is not level. 2. Install new cutting blade(s). 3. Level the mower deck from side-to-side and front-to-rear. 4. Clean the underside of the mower. 5. Adjust the tire pressure. 6. Contact an Authorized Service Dealer. 4. The underside of mower is dirty. 5. The tire pressure is not correct. 6. The blade spindle is bent.
Schematics Wire Diagram (Rev.
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The Toro Warranty Conditions and Products Covered Instructions for Obtaining Warranty Service The Toro® Company and its afliate, Toro Warranty Company, pursuant to an agreement between them, jointly promises to the original purchaser* to repair any Toro Product used for normal residential purposes* if defective in materials or workmanship.
