Form No. 3367-196 Rev B Z500 Z Master® With 52in, 60in and 72in TURBO FORCE® Side Discharge Mower Model No. 74295—Serial No. 311000001 and Up Model No. 74296—Serial No. 311000001 and Up Model No. 74297—Serial No. 311000001 and Up g012081 To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com.
This rotary-blade, riding lawn mower is intended to be used by residential homeowners or professional, hired operators. It is designed primarily for cutting grass on well-maintained lawns on residential or commercial properties. It is not designed for cutting brush or for agricultural uses. You may contact Toro directly at www.Toro.com for product and accessory information, help finding a dealer, or to register your product.
Contents Adjusting the Caster Pivot Bearing ...................... 40 Cooling System Maintenance .................................. 41 Cleaning the Engine Screen and the Oil Cooler ............................................................ 41 Cleaning the Engine Fins .................................... 41 Brake Maintenance ................................................. 41 Adjusting the Parking Brake................................ 41 Belt Maintenance...................................................
Safety • Use extra care when handling gasoline and other fuels. They are flammable and vapors are explosive. 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.
• Be aware there is no rollover protection when the roll bar is down. • Check the area to be mowed and never fold the ROPS in areas where there are slopes, drop offs or water. • Lower the rollbar only when absolutely necessary. Do not wear the seat belt with the roll bar folded down. • Check carefully for overhead clearances (i.e. branches, doorways, electrical wires) before driving under any objects and do not contact them. • Be aware of the mower discharge direction and do not point it at anyone.
Slope Indicator G011841 Figure 3 This page may be copied for personal use. 1. The maximum slope you can safely operate the machine on is 15 degrees. Use the slope chart to determine the degree of slope of hills before operating. Do not operate this machine on a slope greater than 15 degrees. Fold along the appropriate line to match the recommended slope. 2. Align this edge with a vertical surface, a tree, building, fence pole, etc. 3. Example of how to compare slope with folded edge.
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. 66-1340 1-403005 68-8340 1-633462 98-4387 1. Warning—wear hearing protection.
103-5881 107-1860 105-7797 105-7798 107-1861 107-1857 107-1864 8
110-2067 110-2068 1. Read the Operator's Manual. 107-2102 112-8651 1. Interval 2. Power Take-off (PTO) 3. Parking brake 4. Neutral 5. Operator presence switch 6.
115-4212 1. Hydraulic oil level 3. Warning—do not touch the hot surface. 2. Read the Operator's Manual. 117-0905 1. Fast 2. Continuous variable setting 117–2718 3. Slow Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 6. Keep bystandersa safe distance from the battery. 2. No fire, open flame, or smoking. 7. Wear eye protection; explosive gases can cause blindness and other injuries 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 8.
107-9309 1. Warning—read the Operator's Manual for information on charging the battery; contains lead; do not discard. 2. Read the Operator's Manual.
107-8076 1. Fast 3. Neutral 2. Slow Product Overview 4. Reverse Controls Become familiar with all the controls before you start the engine and operate the machine (Figure 4 and Figure 5). 4 5 6 7 8 9 123 10 Figure 5 g012082 11 Figure 4 1. Side discharge 7. Fuel cap (both sides) 2. Lift assist lever 3. Height-of-cut lever 8. Controls 9. Parking brake lever 4. Motion control lever 5. Seat belt 6. Rollbar 1. Ignition switch 4. Power take off (PTO) 2. Choke 3. Throttle 5.
Attachments/Accessories The battery light turns on when the ignition is turned on and when the charge is below the correct operating level (Figure 6). A selection of Toro approved attachments and accessories are available for use with the machine to enhance and expand its capabilities. Contact your Authorized Service Dealer or Distributor or go to www.Toro.com for a list of all approved attachments and accessories. Figure 6 1. Safety interlock symbols 3. Battery light 2.
Operation DANGER 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. • Always place gasoline containers on the ground away from your vehicle before filling.
Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline. To minimize the chance of varnish deposits in the fuel system, use fuel stabilizer at all times. 1 2 Filling the Fuel Tank Important: Do not over fill the fuel tank. Fill the fuel tank to the bottom of the filler neck. The empty space in the tank allows the fuel to expand. Overfilling may result in fuel leakage or damage to the engine or emission system. 3 1. Shut the engine off and set the parking brake. 2.
WARNING There is no rollover protection when the roll bar is in the down position. 1 2 • 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. 3 4 Important: Lower the roll bar only when absolutely necessary.
Setting the Parking Brake 1. Move the motion control levers (Figure 20) out to the neutral lock position. 2. Pull up and back on the parking brake lever to set the parking brake (Figure 13). The parking brake lever should stay firmly in the engaged position. WARNING 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 11 1.
Figure 14 1. PTO—on 2. PTO—off Figure 16 1. Throttle—fast 4. Move the choke control to the on position before starting a cold engine (Figure 15). 2. Throttle—slow 6. Turn the ignition key to Start (Figure 17). When the engines starts, release the key. Note: A warm or hot engine may not require choking. After engine starts, move the choke control to the off position. Important: Do not engage starter for more than 10 seconds at a time.
4. Turn the ignition key to the off position and remove the key (Figure 17). 5. Close the fuel shut off valve before transporting or storing the machine. Refer to Fuel System Maintenance (page 36). 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 18 CAUTION 1.
the throttle control in the fast position for best performance. Always operate in the full throttle position when mowing. CAUTION Machine can spin very rapidly. Operator may lose control of machine and cause personal injury or damage to machine. • Use caution when making turns. Figure 19 • Slow the machine down before making sharp turns. 1. Triangles light up when the interlock components are in the correct position Driving Forward Testing the Safety Interlock System 1.
CAUTION 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. Refer to Figure 21 for the mounting options. Torque the bolt to 200 in-lb (22.6 N⋅m). Figure 20 1.
Figure 22 1. Height of cut lever 2. Pin Figure 23 2. To adjust, remove the pin from the height-of-cut bracket (Figure 22). 1. Outer roller 2. Spacer 3. Select a hole in the height-of-cut bracket corresponding to the height-of-cut desired and, insert the pin (Figure 22). 4. Bolt 5. Nut 3. Bushing 4. Select a hole so that the outer roller is positioned to the nearest corresponding height-of-cut desired (Figure 23). 4. Move the lever to the selected height. Adjusting the Anti-Scalp Rollers 5.
1 2 g0121 19 Figure 25 2. Nut 1. Slot Figure 24 1. Outer roller 2. Spacer 4. Bolt 5. Nut Positioning the Flow Baffle 3. Bushing The following figures are only recommendations for use. Adjustments will vary by grass type, moisture content, and height of grass. 4. Select a hole so that the center rollers are positioned to the nearest corresponding height-of-cut desired (Figure 24). Note: If the engine power draws down and the mower ground speed is the same, open up the baffle.
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 29). Figure 29 G012121 Figure 27 Positioning the Seat Position C The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable. This is the full open position. The suggested use for this position is as follows. To adjust, move the lever sideways to unlock seat (Figure 30).
Figure 31 1. Seat latch 2. Fuel cap 3. Seat Pushing the Machine by Hand Figure 32 1. By-pass valve 2. Controls Important: Always push the machine by hand. Never tow the machine because hydraulic damage may occur. 3. Disengage parking brake before pushing. Pushing the Machine Changing to Machine Operation 1. Disengage the power take off (PTO) and turn the ignition key to off. Move the levers to neutral locked position and apply parking brake. Remove the key.
DANGER WARNING 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. 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. Do not drive machine on a public street or roadway.
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. WARNING Loading a unit onto a trailer or truck increases the possibility of backward tip-over and could cause serious injury or death. Cutting a Lawn for the First Time • Use extreme caution when operating a unit on a ramp. Cut grass slightly longer than normal to ensure the cutting height of the mower does not scalp any uneven ground.
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. Keep the Underside of the Mower Clean Clean clippings and dirt from the underside of the mower after each use. If grass and dirt build up inside the mower, cutting quality will eventually become unsatisfactory.
Maintenance Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 8 hours • Check the hydraulic fluid. After the first 25 hours • Change the hydraulic filter. After the first 100 hours • Check the wheel hub slotted nut. • Check the wheel lug nuts. Before each use or daily • • • • • Check the safety interlock system. Check the engine oil level. Clean the engine screen and the oil cooler. Check the mower blades. Clean the mower deck.
Lubrication Greasing and Lubrication Lubricate the machine when shown on the Check Service Reference Aid decal (Figure 35). Grease more frequently when operating conditions are extremely dusty or sandy. Grease Type: General-purpose grease. Figure 34 How to Grease 1. Seal guard 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2. Spacer nut with wrench flats 2. Remove the caster wheel from the caster forks. 2.
13. Torque the nut to 75-80 in-lb (8-9 N-m), loosen, then re-torque to 20-25 in-lb (2-3 N-m). Make sure axle does not extend beyond either nut. • Brake handle pivot. • Brake rod bushings. • Motion control bronze bushings. 14. Reinstall the seal guards over the wheel hub and insert wheel into caster fork. Reinstall caster bolt and tighten nut fully. Greasing the Bearings Service Interval: Every 25 hours Important: To prevent seal and bearing damage, check the bearing adjustment often.
Engine Maintenance Servicing the Air Cleaner Note: Check the filters more frequently if the operating conditions are extremely dusty or sandy. Removing the Filters 1 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. Release the latches on the air cleaner and pull the air cleaner cover off the air cleaner body (Figure 38).
Servicing the Primary Filter Service Interval: Every 200 hours • If the primary filter is dirty, bent, or damaged, replace it. • Do not clean the primary filter. Servicing the Safety Filter Service Interval: Every 600 hours Important: Never attempt to clean the safety filter. If the safety filter is dirty, then the primary filter is damaged. Replace both filters.
Changing the Oil Service Interval: Every 100 hours 1. Start the engine and let it run five minutes. This warms the oil so it drains better. 2. Park the machine so that the drain side is slightly lower than the opposite side to ensure the oil drains completely. 3. Disengage the PTO and set the parking brake. Figure 42 4. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 1. Oil filter 3. Adapter 2. Adapter gasket 5. Place a pan below the drain.
Installing the Spark Plugs 1. Install the spark plugs and the metal washer. Ensure that the air gap is set correctly. 2. Tighten the spark plugs to 18 to 22 ft-lb (24.4 to 29.8 N⋅m). 3. Connect the wires to the spark plugs (Figure 44). Figure 43 1. Center electrode insulator 3. Air gap (not to scale) 2. Side electrode Important: Always replace the spark plugs when it has a black coating, worn electrodes, an oily film, or cracks. 2. Check the gap between the center and side electrodes (Figure 43).
Draining the Fuel Tank Fuel System Maintenance DANGER In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property. Replacing the Fuel Filter Service Interval: Every 200 hours or yearly, whichever occurs first. Never install a dirty filter if it is removed from the fuel line. • Drain gasoline from the fuel tank when the engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills. 1.
Electrical System Maintenance 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. Unlatch the seat and tilt the seat up. 4. First disconnect the negative battery cable and ground wire from the negative (-) battery terminal (Figure 47). 5. Slide the red terminal boot off the positive (red) battery terminal.
5. Slide the red terminal boot onto the positive (red) battery post. 6. Secure battery with J-bolts, hold down clamp and 2 washers (1/4 inch), and 2 wing nuts (1/4 inch) (Figure 47). 1. Unlatch the seat and raise the seat to gain access to fuse holder (Figure 49). Charging the Battery WARNING Charging the battery produces gasses that can explode. Never smoke near the battery and keep sparks and flames away from battery. Important: Always keep the battery fully charged (1.265 specific gravity).
Drive System Maintenance Checking the Tire Pressure Adjusting the Tracking Maintain the air pressure in the front and 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 (Figure 51). Service Interval: Every 25 hours/Monthly (whichever comes first) Note: Determine the left and right sides of the machine from the normal operating position.
Figure 52 1. Slotted Nut 2. Two threads or less showing 3. Hole in threaded shaft 4. 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 52). Figure 53 1. Spring Washers 6. If more than two threads are showing remove nut and install washer between hub and nut. 3. Dust Cap 2. Lock Nut 7. Torque the slotted nut to 125 ft-lb. (170 N⋅m) (Figure 52). 4.
Cooling System Maintenance Brake Maintenance Cleaning the Engine Screen and the Oil Cooler Service Interval: Every 200 hours Service Interval: Before each use or daily 1. Disengage brake lever (lever down). Before each use, check and clean the engine screen and oil cooler. Remove any build-up of grass, dirt or other debris from the oil cooler screen and engine screen (Figure 54 and Figure 55). 2. Measure the length of the spring.
Belt Maintenance Inspecting the Belts Service Interval: Every 100 hours Check the belts for cracks, frayed edges, burn marks or any other damage. Replace damaged belts. 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. 1.
Figure 58 1. Center bolt 3. Left support plate 2. Alignment hole 4. Spring loaded idler Figure 60 1. Spring loaded idler pulley 5. If adjustment is required, loosen the idler plate to adjust it (Figure 59). 6. Insert a ratchet or breaker bar into the square hole in the idler plate to adjust the tension (Figure 59). 4. Idler pulley arm 2. Top alignment hole 5. Belt 3. 0 to 1/4 inch gap (0 to 6 mm) 6. Rubber bumper 10.
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. Figure 62 3. Install new belt around engine and hydro pump pulleys (Figure 62). Note: Motion control levers must be installed correctly. See Installing the Motion Control Levers in the set up instructions. 4. Pull spring loaded idler down and align below traction belt.
Hydraulic 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 64). Servicing the Hydraulic System 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. 10. Tighten the nut and jam nut (Figure 64).
7. If required, add fluid to the hydraulic tank. Note: The fluid level should be to the top of the hot level of the baffle, when the fluid is hot (Figure 65). 8. Install cap on filler neck. WARNING 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.
Bleeding the Hydraulic System DANGER 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. 1. Raise rear of the machine so wheels are off the ground and support with jack stands. 2. Start the engine and run at low idle speed. Engage the lever and traction on one side and spin the wheel by hand. 3. When the wheel begins to spin on its own, keep it engaged until wheel drives smoothly. (minimum 2 minutes) 4.
Figure 69 1. Clevis pin in slot Figure 68 1. Pump rod 4. Ball joint 2. Double nuts 3. Lock nut 5. Yoke 6. Adjustment bolt 7. Spring 2. Nut against yoke 8. Pivot shaft 3. Adjustment bolt 9. Yoke 4. Pump rod 10. Locknut 5. Double nuts 11. Ball joint 6. Jam nut 4. Move the motion control lever forward and reverse, then back to neutral. The wheel must stop turning or slightly creep in reverse. 2. Start the engine, open throttle 1/2 way, and release parking brake.
Mower Deck Maintenance 8. Remove the jumper wire from the wire harness connector and plug the connector into the seat switch. 9. Install the seat rod and lower the seat into position. Leveling the Mower at Three Positions 10. Remove the jack stands. Important: There are only three measuring positions needed to level the mower. Setting Up the Machine 1. Position mower on a flat surface. 2. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 3.
8. Loosen the jam nut under the rear support arm and adjust the adjustment bolt to get a measurement of 3-1/8 to 3-1/4 inches (80 to 83 mm) (Figure 71). Note: It is recommended that both sides of the mower are adjusted the same distance. 9. Tighten the jam nut under the rear support arm and tighten the bolt securing the chain to the rear support arm. 10. Adjust the opposite side if needed. Adjusting the Front-to-Rear Mower Pitch Figure 70 1. Measure here from blade to hard surface 1.
Servicing the Cutting Blades 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 (Figure 71). Maintain sharp blades throughout the cutting season because sharp blades cut cleanly without tearing or shredding the grass blades. Tearing and shredding turns grass brown at the edges, which slows growth and increases the chance of disease. 9.
Checking for Bent Blades 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. 1. Disengage the blade control switch (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 77 1. Sharpen at original angle 2. Check the balance of the blade by putting it on a blade balancer (Figure 78). 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 the end of the sail area only (Figure 79). Repeat this procedure until the blade is balanced. Figure 79 1. Sail Area of Blade 2. Blade 3. Spring Disk 4. Blade Bolt 5. Cone Towards Bolt Head Figure 78 1. Blade 2.
Cleaning Cleaning Under the Mower Service Interval: Before each use or daily 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. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Figure 80 1. Bolt 3. Raise the mower to the transport position. 5. Spring installed 2. Spacer 6. Grass Deflector 3. Locknut 7.
Storage C. Stop engine, allow to cool and drain the fuel tank; refer to Servicing the Fuel Tank in Fuel System Maintenance (page 36). 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. 2. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine and hydraulic system. Clean dirt and chaff from the outside of the engine's cylinder head fins and blower housing. 3. 4. 5. 6.
Troubleshooting Problem Starter does not crank Engine will not start, starts hard, or fails to keep running. Possible Cause 1. Blade control (PTO) is engaged. 1. Move blade contro (PTO) to disengaged. 2. 3. 4. 5. Parking brake is not on. Operator is not seated. Battery is dead. Electrical connections are corroded or loose. 6. Fuse is blown. 7. Relay or switch is defective. 2. 3. 4. 5. 1. Fuel tank is empty. 1. Fill fuel tank with fuel. 2. Air cleaner is dirty. 2.
Problem Uneven cutting height. Blades do not rotate. Possible Cause Corrective Action 1. Blade(s) not sharp. 1. Sharpen the blade(s). 2. Cutting blade(s) is/are bent. 3. Mower is not level. 4. Underside of mower is dirty. 5. Tire pressure is not correct. 6. Blade spindle bent. 2. Install new cutting blade(s). 3. Level mower 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. 1.
Schematics Wire Diagram (Rev.
Notes: 59
The Toro Total Coverage Warranty A Limited Warranty (see warranty periods below) Conditions and Products Covered 3. The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to the original purchaser to repair the Toro Products listed below if defective in materials or workmanship. Warranty Period •Engine •Battery See engine manufacturer's warranty1 90 days Parts and Labor 1 year Parts only •Belts and Tires 90 days •Attachments 1 year 21 in.
