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

Register your product at www.Toro.com

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

Page

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

2004 by The Toro Company		Contact us at www.Toro.com
8111 Lyndale Avenue South		All Rights Reserved
Bloomington, MN 55420-1196	2	Printed in the USA

Introduction

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.

1

Figure 1

1. Location of 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.

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.

Safety

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 DANGERЪpersonal safety instruction.º 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 B71.4Ð2004.

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.

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.

3

•Use extra care when handling gasoline and other fuels. They are flammable and vapors are explosive.

•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.

•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 when loading or unloading the machine into a trailer or truck.

•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.

•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.

4

•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.

5

6

Slope Chart

			appropriate along Fold
.edge	folded with slope	Compare Example:
			line

Align this edge with a vertical surface

(Tree, Building, Fence post, pole, etc.)

7

8

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

54-9220

1-643339

58-6520

1. Grease

1-523552

66-1340

43-8480

68-8340

9

98-4387

1. WarningÐwear hearing protection.

105-7797

98-5954

105-7798

103-5881

104-4163

1.Explosion hazard

2.No fire, open flames, 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.

106-9969

104-8569

107-1613

10

107-1864

107-1622

107-2102

107-1621

11

107-2112

107-1860

107-1857	107-1861

107-8076

12

106-9989

106-7492

13

			104-4164
1.	Contains lead; do not	3.	Wear eye protection;	5.	Sulfuric acid can cause
	discard.		explosive gases can cause		blindness or severe burns.
2.	Recycle		blindness and other injuries	6.	Flush eyes immediately with
		4.	No sparks, flame, or smoking		water and get medical help
					fast.

7.Maximum fill line

8.Minimum fill line

9.Instructions for activating the battery

14

Gasoline and Oil

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.

Warning

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.

15

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.

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).

2

1

	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).

1

2

3

4

m±7431

Figure 3

1.	Roll bar	3.	Pin
2.	Raised position	4.	Hairpin cotter pin

16

7.Tighten the front handles against the center roll bar ends (Fig. 3).

1

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.

2 1

3

		m±6478
	Figure 5
1. Safe ZoneÐuse the	2.	Use walk behind mower
Z Master here on slopes		and/or hand trimmer near
less than 15 degrees or		drop±offs and water.
flat areas.	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. WarningÐwear hearing protection.

17