Toro 74239, 74244 Operator's Manual

Form No. 3351–973

Z500 and Z553

Z Master with 52in or 60in TURBO FORCE Side Discharge Mower

Model No. 74239–250000001 & Up Model No. 74244–250000001 & Up

Operator’s Manual

Original Instructions (EN)

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 this engine on any forest–covered, brush–covered or grass–covered land. Other states or federal areas may have similar laws.

This spark ignition system complies with Canadian ICES-002.

Ce système d’allumage par étincelle de véhicule est conforme à la norme NMB-002 du Canada.

The enclosed Engine Owner ’s Manual is supplied for information regarding The U.S. Environmental Protection Agency (EPA) and the California Emission Control Regulation of emission systems, maintenance and warranty.

Keep this engine Owner ’s Manual with your unit. Should this engine Owner’s Manual become damaged or illegible, replace immediately. Replacements may be ordered through the engine manufacturer.

Contents

Page

Introduction 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safe Operating Practices 3. . . . . . . . . . . . . . . . . . .

Slope Chart 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety and Instruction Decals 9. . . . . . . . . . . . . . .

Gasoline and Oil 15. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Gasoline 15. . . . . . . . . . . . . . . . . . .

Using Stabilizer/Conditioner 15. . . . . . . . . . . . . . . .

Filling the Fuel Tank 15. . . . . . . . . . . . . . . . . . . . . .

Check Engine Oil Level 15. . . . . . . . . . . . . . . . . . . .

Operation 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using the Rollover Protection System (ROPS) 16. .

Think Safety First 17. . . . . . . . . . . . . . . . . . . . . . . .

Controls 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating the Parking Brake 18. . . . . . . . . . . . . . . .

Operating in Cool Weather 19. . . . . . . . . . . . . . . . .

Starting and Stopping the Engine 19. . . . . . . . . . . .

 2004 by The Toro Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196

Operating the Power Take Off (PTO) 20. . . . . . . . .

The Safety Interlock System 20. . . . . . . . . . . . . . . .

Driving Forward or Backward 21. . . . . . . . . . . . . . .

Stopping the Machine 21. . . . . . . . . . . . . . . . . . . . .

Adjusting the Height-of-Cut 21. . . . . . . . . . . . . . . .

Using the Lift Assist Lever 22. . . . . . . . . . . . . . . . .

Adjusting the Anti-Scalp Rollers 22. . . . . . . . . . . . .

Adjusting the Flow Baffle 23. . . . . . . . . . . . . . . . . .

Positioning the Flow Baffle 23. . . . . . . . . . . . . . . . .

Positioning the Seat 24. . . . . . . . . . . . . . . . . . . . . . .

Unlatching the Seat 24. . . . . . . . . . . . . . . . . . . . . . .

Pushing the Machine by Hand 24. . . . . . . . . . . . . . .

Using the Side Discharge 25. . . . . . . . . . . . . . . . . . .

Breaking in a New Machine 25. . . . . . . . . . . . . . . .

Transporting Machines 25. . . . . . . . . . . . . . . . . . . .

Loading Machines 25. . . . . . . . . . . . . . . . . . . . . . . .

Tips for Mowing Grass 26. . . . . . . . . . . . . . . . . . . .

Maintenance 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Maintenance Schedule 28. . . . . . . .

Servicing the Cutting Blades 29. . . . . . . . . . . . . . . .

Servicing the Air Cleaner 31. . . . . . . . . . . . . . . . . .

Servicing the Engine Oil 32. . . . . . . . . . . . . . . . . . .

Servicing the Spark Plug 33. . . . . . . . . . . . . . . . . . .

Servicing the Fuel Filter 34. . . . . . . . . . . . . . . . . . .

Servicing the Fuel Tank 34. . . . . . . . . . . . . . . . . . . .

Greasing and Lubrication 35. . . . . . . . . . . . . . . . . . .

Greasing the Spindles 36. . . . . . . . . . . . . . . . . . . . .

Cleaning the Cooling Systems 36. . . . . . . . . . . . . . .

Checking the Tire Pressure 37. . . . . . . . . . . . . . . . .

Checking the Wheel Hub Slotted Nut 37. . . . . . . . .

Adjusting the Caster Pivot Bearing 37. . . . . . . . . . .

Servicing the Hydraulic System 38. . . . . . . . . . . . .

Adjusting the Handle Neutral 40. . . . . . . . . . . . . . .

Setting the Hydraulic Pump Neutral 40. . . . . . . . . .

Adjusting the Tracking 41. . . . . . . . . . . . . . . . . . . .

Replacing the Pump Drive Belt 42. . . . . . . . . . . . . .

Adjusting the Parking Brake 42. . . . . . . . . . . . . . . .

Servicing the Fuse 43. . . . . . . . . . . . . . . . . . . . . . . .

Servicing the Battery 43. . . . . . . . . . . . . . . . . . . . . .

Leveling the Mower at Three Positions 45. . . . . . . .

Cleaning Under the Mower 47. . . . . . . . . . . . . . . . .

Inspecting the Belts 47. . . . . . . . . . . . . . . . . . . . . . .

Replacing the Mower Belt 47. . . . . . . . . . . . . . . . . .

Adjusting the Mower Belt Tension 48. . . . . . . . . . .

Replacing the Grass Deflector 49. . . . . . . . . . . . . . .

Wiring Diagram 51. . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning and Storage 52. . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The Toro Total Coverage Guarantee 56. . . . . . . . . . . . .

Printed in the USA

Page

Introduction

Safety

Read this manual carefully to learn how to operate and maintain your product properly. The information in this manual can help you and others avoid injury and product damage. Although Toro designs and produces safe products, you are responsible for operating the product properly and safely.

Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready. Figure 1 illustrates the location of the model and serial numbers on the product.

Figure 1

1. Location o f the model and serial numbers

Write the product model and serial numbers in the space below:

Model No.

Serial No.

This manual identifies potential hazards and has special safety messages that help you and others avoid personal injury and even death. Danger, Warning, and Caution are signal words used to identify the level of hazard. However, regardless of the hazard, be extremely careful.

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.

This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death.

This product is designed for cutting and recycling grass or, when equipped with a grass bagger, for catching cut grass. Any use for purposes other than these could prove dangerous to user and bystanders.

Safe Operating Practices

The following instructions are from ANSI standard B71.4—2004.

Training

• Read the Operator ’s Manual and other training

material. If the operator(s) or mechanic(s) can not read English it is the owner’s responsibility to explain this material to them.

• Become familiar with the safe operation of the

equipment, operator controls, and safety signs.

• All operators and mechanics should be trained. The

owner is responsible for training the users.

• Never let children or untrained people operate or

service the equipment. Local regulations may restrict the age of the operator.

• The owner/user can prevent and is responsible for

accidents or injuries occurring to himself or herself, other people or property.

Danger signals an extreme hazard that will cause serious injury or death if you do not follow the recommended precautions.

Warning signals a hazard that may cause serious injury or death if you do not follow the recommended precautions.

Caution signals a hazard that may cause minor or moderate injury if you do not follow the recommended precautions.

This manual uses two other words to highlight information. Important calls attention to special mechanical information and Note: emphasizes general information worthy of special attention.

Preparation

• Evaluate the terrain to determine what accessories and

attachments are needed to properly and safely perform the job. Only use accessories and attachments approved by the manufacturer.

• Wear appropriate clothing including hard hat, safety

glasses and hearing protection. Long hair, loose clothing or jewelry may get tangled in moving parts.

• Inspect the area where the equipment is to be used and

remove all objects such as rocks, toys and wire which can be thrown by the machine.

• Use extra care when handling gasoline and other fuels.

They are flammable and vapors are explosive.

• Use extreme care when loading or unloading the

machine into a trailer or truck.

• Use only an approved container

• Never remove gas cap or add fuel with engine

running. Allow engine to cool before refueling. Do not smoke.

• Never refuel or drain the machine indoors.

• Check that operator ’s presence controls, safety

switches and shields are attached and functioning properly. Do not operate unless they are functioning properly.

Operation

• Never run an engine in an enclosed area.

• Only operate in good light, keeping away from holes

and hidden hazards.

• Be sure all drives are in neutral and parking brake is

engaged before starting engine. Start the engine only from the operator’s position.

• Never raise mower with the blades running.

• Never operate without the PTO shield, or other guards

securely in place. Be sure all interlocks are functioning properly.

• Never operate with the discharge deflector raised,

removed or altered, unless using a grass catcher.

• Do not change the engine governor setting or

overspeed the engine.

• Stop on level ground, lower implements, disengage

drives, engage parking brake, shut off engine before leaving the operator ’s position for any reason including emptying the catchers or unclogging the chute.

• Stop equipment and inspect blades after striking

objects or if an abnormal vibration occurs. Make necessary repairs before resuming operations.

• Use care when approaching blind corners, shrubs,

trees, or other objects that may obscure vision.

Slope Operation

• Do not mow slopes greater than 15 degrees.

• Do not mow near drop–offs, ditches, steep banks or

water. Wheels dropping over edges can cause

rollovers, which may result in serious injury, death or

drowning.

• Do not mow slopes when grass is wet. Slippery

conditions reduce traction and could cause sliding and

loss of control.

• Do not make sudden turns or rapid speed changes.

• Use a walk behind mower and/or a hand trimmer near

drop–offs, ditches, steep banks or water.

• Reduce speed and use extreme caution on slopes.

• Remove or mark obstacles such as rocks, tree limbs,

etc. from the mowing area. Tall grass can hide

obstacles.

• Watch for ditches, holes, rocks, dips, and rises that

change the operating angle, as rough terrain could

overturn the machine.

• Avoid sudden starts when mowing uphill because the

mower may tip backwards.

• Be aware that loss of traction may occur going

downhill. Weight transfer to the front wheels may

cause drive wheels to slip and cause loss of braking

and steering.

• Always avoid sudden starting or stopping on a slope. If

tires lose traction, disengage the blades and proceed

slowly off the slope.

• Follow the manufacturer ’s recommendations for wheel

weights or counterweights to improve stability.

• 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.

• Use extreme care with grass catchers or other

attachments. These can change the stability of the

machine and cause loss of control.

Using the Rollover Protection System (ROPS)

• Keep the roll bar in the raised and locked position and

use the seat belt when operating the machine.

• Be certain that the seat belt can be released quickly in

the event of an emergency.

• 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.

Maintenance and storage

• Disengage drives, lower implement, set parking brake,

stop engine and remove key or disconnect spark plug wire. Wait for all movement to stop before adjusting, cleaning or repairing.

• Clean grass and debris from cutting units, drives,

mufflers, and engine to help prevent fires. Clean up oil or fuel spillage.

• Let engine cool before storing and do not store near

flame.

• Shut off fuel while storing or transporting. Do not store

fuel near flames or drain indoors.

• Park machine on level ground. Never allow untrained

personnel to service machine.

• Use jack stands to support components when required.

• 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.

• Charge batteries in an open well ventilated area, away

from spark and flames. Unplug charger before connecting or disconnecting from battery. Wear protective clothing and use insulated tools.

• Keep all parts in good working condition and all

hardware tightened. Replace all worn or damaged decals.

• Use only Toro-approved attachments. Warranty may

be voided if used with unapproved attachments.

Slope Chart

Example: Compare

slope with folded

edge.

Fold along appropriate line

Align this edge with a vertical surface (Tree, Building, Fence post, pole, etc.)

Safety and Instruction Decals

Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost.

1-633462

1-643339

54-9220

1-523552

43-8480

58-6520

1. Grease

66-1340

68-8340

98-4387

1. Warning—wear hearing protection.

98-5954

103-5881

105-7797

105-7798

1. Explosion hazard

2. No fire, open flames, or smoking.

3. Caustic liquid/chemical burn hazard

104-4163

4. Wear eye protection

5. Read the

6. Keep bystanders a safe

104-8569

Manual.

Operator’s

distance from the battery.

106-9969

107-1613

107-1864

107-1622

107-2102

107-1621

107-2112

107-1860

107-1857

107-1861

107-8076

106-9989

106-7492

1. Contains lead; do not discard.

2. Recycle

104-4164

3. Wear eye protection; explosive gases can cause blindness and other injuries

4. No sparks, flame, or smoking

5. Sulfuric acid can cause blindness or severe burns.

6. Flush eyes immediately with water and get medical help fast.

7. Maximum fill line

8. Minimum fill line

9. Instructions for activating the battery

Gasoline and Oil

Warning

Recommended Gasoline

Use UNLEADED Regular Gasoline suitable for automotive use (85 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available.

Important Never use methanol, gasoline containing

methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged. Do not mix oil with gasoline.

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.

• Fill the fuel tank outdoors, in an open area,

when the engine is cold. Wipe up any gasoline that spills.

• Never fill the fuel tank inside an enclosed

trailer.

• Do not fill the fuel tank completely full. Add

gasoline to the fuel tank until the level is 1/4 to 1/2 inch (6 to 13 mm) below the bottom of the filler neck. This empty space in the tank allows gasoline to expand.

• Never smoke when handling gasoline, and stay

away from an open flame or where gasoline fumes may be ignited by a spark.

• Store gasoline in an approved container and

keep it out of the reach of children. Never buy more than a 30-day supply of gasoline.

• Always place gasoline containers on the ground

away from your vehicle before filling.

• Do not fill gasoline containers inside a vehicle

or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge.

• When practical, remove gas–powered

equipment from the truck or trailer and refuel the equipment with its wheels on the ground.

• If this is not possible, then refuel such

equipment on a truck or trailer from a portable container, rather than from a gasoline dispenser nozzle.

• If a gasoline dispenser nozzle must be used,

keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete.

• Do not operate without entire exhaust system in

place and in proper working condition.

Gasoline is harmful or fatal if swallowed. Long–term exposure to vapors can cause serious injury and illness.

• Avoid prolonged breathing of vapors.

• Keep face away from nozzle and gas tank or

conditioner opening.

• Keep gas away from eyes and skin.

Using Stabilizer/Conditioner

Use a fuel stabilizer/conditioner in the machine to provide the following benefits:

• Keeps gasoline fresh during storage of 90 days or less.

For longer storage it is recommended that the fuel tank be drained.

• Cleans the engine while it runs

• Eliminates gum-like varnish buildup in the fuel

system, which causes hard starting

Important Do not use fuel additives containing

methanol or ethanol. Add the correct amount of gas stabilizer/conditioner to the

gas. 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.

Filling the Fuel Tank

1. Shut the engine off and set the parking brake.

2. Clean around each fuel tank cap and remove the cap.

Add unleaded regular gasoline to both fuel tanks, until the level is 1/4 to 1/2 inch (6 mm to 13 mm) below the bottom of the filler neck. This space in the tank allows gasoline to expand. Do not fill the fuel tanks completely full.

3. Install fuel tank caps securely. Wipe up any gasoline

that may have spilled.

Check Engine Oil Level

Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking Oil Level, page 32.

Operation

Note: Determine the left and right sides of the machine from the normal operating position.

Using the Rollover Protection

System (ROPS)

Warning

To avoid injury or death from rollover: keep the roll bar in the raised locked position and use the seat belt.

Ensure that the rear part of the seat is secured with the seat latch.

Warning

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.

m–7447

Figure 2

1. Full down position 2. Down position with bagger installed

Important Always use the seat belt with the roll bar in

the raised position.

Important Ensure that the rear part of the seat is

secured with the seat latch.

5. To raise the roll bar, remove the hairpin cotter pins and

remove the two pins (Fig. 3).

6. Raise the roll bar to the upright position and install the

two pins and secure them with the hairpin cotter pins (Fig. 3).

Important Lower the roll bar only when absolutely

necessary.

1. To lower the roll bar, loosen the front handles (Fig. 4).

2. Remove the hairpin cotter pins and remove the two

pins (Fig. 3).

3. Lower the the roll bar to the down position. There are

two down positions. See Figure 2 for the positions.

4. Install the two pins and secure them with the hairpin

cotter pins (Fig. 3).

1. Roll bar

2. Raised position

m–7431

Figure 3

3. Pin

4. Hairpin cotter pin

7. Tighten the front handles against the center roll bar

ends (Fig. 3).

m–6897

Figure 4

1. Front handle

Think Safety First

Please read all safety instructions and symbols in the safety section. Knowing this information could help you or bystanders avoid injury.

Danger

Operating on wet grass or steep slopes can cause sliding and loss of control.

Wheels dropping over edges can cause rollovers, which may result in serious injury, death or drowning.

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.

To avoid loss of control and possibility of rollover:

• Do not operate near drop–offs or near water.

• Do not operate on slopes greater than

15 degrees.

• Reduce speed and use extreme caution on

slopes.

• Avoid sudden turns or rapid speed changes.

m–6478

Figure 5

1. Safe Zone—use the Z Master here on slopes less than 15 degrees or flat areas.

2. Use walk behind mower and/or hand trimmer near drop–offs and water.

3. Water

The use of protective equipment for eyes, ears, feet, and head is recommended.

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.

Wear hearing protection when operating this machine.

Figure 6

1. Warning—wear hearing protection.

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