Form No. 3364-220 Rev A Z500 Z Master®, With 52in, 60in or 72in TURBO FORCE® Side Discharge Mower Model No. 74295—Serial No. 310000001 and Up Model No. 74296—Serial No. 310000001 and Up Model No. 74297—Serial No. 310000001 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. 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. Figure 1 1.
Using the Rollover Protection System (ROPS) .......................................................... 15 Think Safety First ............................................... 16 Operating the Parking Brake ............................... 17 Starting and Stopping the Engine ........................ 17 Operating the Power Take Off (PTO) ................. 18 The Safety Interlock System................................ 19 Driving Forward or Backward............................. 20 Stopping the Machine.............
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. 2. 3. 4. 5. 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 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.
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 1. Ignition switch 2. Choke 3. Throttle Figure 4 1. 2. 3. 4. 5. 6. Side discharge Lift assist lever Height-of-cut lever Motion control lever Seat belt Rollbar 7. 8. 9. 10. 11. Fuel cap (both sides) Controls Parking brake lever Mower deck Front caster wheel 4.
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 2. Hour meter 3.
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. Important: Lower the roll bar only when absolutely necessary. Filling the Fuel Tank 2. Lower the roll bar to the down position. There are two down positions. See Figure 7 for the positions. 1. Remove the hairpin cotter pins and remove the two pins (Figure 8). 1. Shut the engine off and set the parking brake. 3.
1 2 3 Figure 9 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. 4 G004955 Figure 8 1. Roll bar 2. Raised position 3. Water 3. Pin 4. Hairpin cotter pin CAUTION This machine produces sound levels in excess of 85 dBA at the operators ear and can cause hearing loss through extended periods of exposure. Think Safety First Please read all safety instructions and symbols in the safety section.
Figure 10 1. Warning— wear hearing protection Operating the Parking Brake Always set the parking brake when you stop the machine or leave it unattended. Figure 11 1. Parking brake-ON 2. Parking brake-OFF 3. Brake Stop Setting the Parking Brake 1. Move the motion control levers (Figure 18) out to the neutral lock position. Starting and Stopping the Engine 2. Pull up and back on the parking brake lever to set the parking brake (Figure 11).
Figure 15 1. Off 2. Run 7. After the engine starts, move the choke to off (Figure 13). If the engine stalls or hesitates, move the choke back to on for a few seconds, then move the throttle lever to desired setting. Repeat this as required. Figure 13 1. Choke—on 3. Start 2. Choke—off 5. Move the throttle control to the Fast position before starting a cold engine (Figure 14). Stopping the Engine 1. Push the PTO to the off position (Figure 12). 2.
Engaging the PTO • The power take off (PTO) is disengaged. • The motion control levers are in the neutral locked position 1. If the engine is cold, allow the engine to warm up 5 to 10 minutes before engaging the PTO. 2. While seated in the seat, release the pressure on the traction control levers and place in neutral. 3. Place the throttle in the fast position.
control and move (forward or reverse); the engine should stop. Repeat for other motion control. 5. Sitting on the seat, disengage the parking brake, move the PTO switch to off and move the motion control levers to neutral lock position. Try starting the engine; the engine should not crank. 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.
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 Figure 20 The top damper mounting bolt can be adjusted to obtain a desired motion control lever resistance. Refer to Figure 19 for the mounting options. 1. Height of cut lever 2. Pin 2.
Figure 22 1. Outer roller 2. Spacer 3. Bushing Figure 21 1. Outer roller 2. Spacer 3. Bushing 4. Bolt 5. Nut 4. Bolt 5. Nut 4. Select a hole so that the center rollers are positioned to the nearest corresponding height-of-cut desired (Figure 22). 4. Select a hole so that the outer roller is positioned to the nearest corresponding height-of-cut desired (Figure 21). Note: Do not adjust the rollers to support the mower housing. 5. Install the outer roller, bushing, spacer, bolt, and nut (Figure 21). 5.
1 2 g0121 19 Figure 23 G012121 2. Nut 1. Slot Figure 25 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. • Use in tall, dense grass mowing conditions. Note: If the engine power draws down and the mower ground speed is the same, open up the baffle. • Use in wet conditions.
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 27). Figure 29 Figure 27 1. Seat latch 2. Fuel cap Positioning the Seat 3. Seat Pushing the Machine by Hand The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable. Important: Always push the machine by hand. Never tow the machine because hydraulic damage may occur.
DANGER 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. • Never remove the grass deflector from the mower because the grass deflector routes material down toward the turf. If the grass deflector is ever damaged, replace it immediately. • Never put your hands or feet under the mower.
WARNING WARNING 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. • Use only a single, full width ramp; Do Not use individual ramps for each side of the unit.
When Stopping mower free from uncut grass, which allows air to be drawn into the mower. 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. Cutting a Lawn for the First Time Cut grass slightly longer than normal to ensure the cutting height of the mower does not scalp any uneven ground. However, the cutting height used in the past is generally the best one to use.
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 33). Grease more frequently when operating conditions are extremely dusty or sandy. Grease Type: General-purpose grease. Figure 32 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 Primary Filter Service Interval: Every 200 hours Servicing the Air Cleaner • If the primary filter is dirty, bent, or damaged, replace it. Note: Check the filters more frequently if the operating conditions are extremely dusty or sandy. • Do not clean the primary filter. Removing the Filters Servicing the Safety Filter 1. Disengage the PTO, move the motion control levers to the neutral locked position, and set the parking brake. 2.
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. 4. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Figure 36 5. Place a pan below the drain.
Figure 39 1. Oil filter 2. Adapter gasket Figure 40 3. Adapter 1. Center electrode insulator 2. Side electrode 3. Pour new oil in through the center hole of the filter. Fill it up to the bottom of the threads inside. 3. Air gap (not to scale) Important: Always replace the spark plugs when it has a black coating, worn electrodes, an oily film, or cracks. 4. Allow the filter material to absorb the new oil for 1 to 2 minutes. 2. Check the gap between the center and side electrodes (Figure 40).
Installing the Spark Plugs 1. Install the spark plugs and the metal washer. Ensure that the air gap is set correctly. Fuel System Maintenance 2. Tighten the spark plugs to 18 to 22 ft-lb (24.4 to 29.8 N⋅m). Replacing the Fuel Filter 3. Connect the wires to the spark plugs (Figure 41). Service Interval: Every 200 hours or yearly, whichever occurs first. Never install a dirty filter if it is removed from the fuel line. 1.
Draining the Fuel Tank Electrical 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. Servicing the Battery WARNING • 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. 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 44). 5. Slide the red terminal boot off the positive (red) battery terminal. Then remove the positive (red) battery cable (Figure 44).
Drive System Maintenance 1. Unlatch the seat and raise the seat to gain access to fuse holder (Figure 46). Adjusting the Tracking Note: Determine the left and right sides of the machine from the normal operating position. Note: Adjust the handle neutral and hydraulic pump neutral before adjusting the tracking. Refer to Adjusting the Handle Neutral and Adjusting the Hydraulic Pump Neutral. 1. Push both control levers forward the same distance. 2. Check if the machine pulls to one side.
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 48). Figure 49 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 49). Figure 48 6.
Cooling System Maintenance Cleaning the Engine Screen and the Oil Cooler Service Interval: Before each use or daily 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 51 and Figure 52). Figure 50 1. Spring Washers 2. Lock Nut 3. Dust Cap 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 50).
Brake Maintenance Belt Maintenance Adjusting the Parking Brake Inspecting the Belts Service Interval: Every 200 hours Service Interval: Every 100 hours Check the parking brake for proper adjustment. Check the belts for cracks, frayed edges, burn marks or any other damage. Replace damaged belts. 1. Disengage brake lever (lever down). 2. Measure the length of the spring. Replacing the Mower Belt The measurement should be 2-3/4 inch (70 mm) between washers (Figure 53).
Figure 55 1. Center bolt 2. Alignment hole 3. Left support plate 4. Spring loaded idler 5. If adjustment is required, loosen the idler plate to adjust it (Figure 56). 6. Insert a ratchet or breaker bar into the square hole in the idler plate to adjust the tension (Figure 56). Figure 54 1. 2. 3. 4. 5. Clutch Mower belt 1/4 trun belt twist Belt guide Mower spindle pulley 6. 7. 8. 9. 10. 7.
Figure 59 3. Install new belt around engine and hydro pump pulleys (Figure 59). Figure 57 1. Spring loaded idler pulley 2. Top alignment hole 3. 0 to 1/4 inch gap (0 to 6 mm) 4. Idler pulley arm 5. Belt 6. Rubber bumper 4. Pull spring loaded idler down and align below traction belt. Release the pressure on the spring loaded idler (Figure 59). 10. Adjust the belt tension and the idler plate, if necessary, and tighten all hardware securely (Figure 56). 11.
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 61). 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 Note: The fluid level should be to the top of the hot level of the baffle, when the fluid is hot (Figure 62). 8. Install cap on filler neck. WARNING Servicing the Hydraulic System 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 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.
DANGER Mechanical or hydraulic jacks may fail to support machine and cause a serious injury. • Use jack stand when supporting machine. • Do not use hydraulic jacks. WARNING Engine must be running so motion control adjustment can be performed. Contact with moving parts or hot surfaces may cause personal injury. Keep hands, feet, face, clothing and other body parts away from rotating parts, muffler and other hot surfaces. Figure 65 1. Pump rod 2. Double nuts 3.
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. 10. Remove the jack stands. Figure 66 1. 2. 3. 4. 5. 6. Clevis pin in slot Nut against yoke Adjustment bolt Pump rod Double nuts Jam nut 7. 8. 9. 10. 11. Spring Pivot shaft Yoke Locknut Ball joint 2. Start the engine, open throttle 1/2 way, and release parking brake. Refer to Starting and Stopping the Engine in Operation (page 14).
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 mower on a flat surface. Figure 67 2. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 1. Measure here from blade to hard surface 3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 2. Measure at B and C 2.
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 68). (6 to 10 mm) lower in front at A than in the rear at B (Figure 68). 9. Tighten both swivel jam nuts against the front swivel to lock the height. 10. Check to make sure there is equal tension on the chains and adjust again if needed. Note: It is recommended that both sides of the mower are adjusted the same distance. 9.
Checking for Bent Blades shredding the grass blades. Tearing and shredding turns grass brown at the edges, which slows growth and increases the chance of disease. 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. Rotate the blades until the ends face forward and backward (Figure 72).
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. Hold the blade end using a rag or thickly-padded glove. 2. Remove the blade bolt, curved washer, and blade from the spindle shaft (Figure 73). 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 76).
Replacing the Grass Deflector Cleaning WARNING Cleaning Under the Mower An uncovered discharge opening could allow the lawn mower to throw objects in the operator’s or bystander’s direction and result in serious injury. Also, contact with the blade could occur. Remove the grass buildup under the mower daily. • Never operate the lawn mower unless you install a cover plate, a mulch plate, or a grass chute and catcher. 1.
Storage C. Stop engine, allow to cool and drain the fuel tank; refer to Servicing the Fuel Tank in Fuel System Maintenance (page 34). 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: 57
Notes: 58
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.
