Toro 74242 Z500 Z Master Operator'S Manual Download Page 51 | Manualshive

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51

Wiring Diagram

A

Y

T

I

Y

Y

OR

OR

VIO

I

A

R

OR

KEY SW

B

S

X

1

2

GN

BU

BN

BK

BLUE

BROWN

T

R

TA

N

RED

PINK

GND

BK

BK

GY

DK.GN

SHOWN WITH

LEVER IN

NEUTRAL

POSITION

L

T

.BU

DK.GN

BK

P1–B

P1–C

P2–C

BN

T

BK

K

1

(KILL

RELA

Y)

DK.BU

HOUR

METER

R

OR

R

SW1

W

F2

20A

DK.BU

4

OR

W

VIO

3

OR

GY

OR/BK

ORANGE

GREY

GREEN

Y

W

YELLOW

WHITE

VIOLET

SHOWN WITH

LEVER IN

NEUTRAL

POSITION

GY

X

S

–

+

Y

B

BLACK

GY

OR/BK

DK.GN/W

(IGNITION)

L

T

.GN

BK/R

L

T

.BU

LIGHT BLUE

DK.BU

DARK BLUE

OR/BK

ORANGE/BLACK

PK/BK

PINK/BLACK

VIO

PK

WIRE COLOR CODES

(NEUTRAL)

SW5

L

T

.BU

(BRAKE)

SW3

SHOWN WITH

P

ARK BRAKE

DISENGAGED

P1–A

PK/BK

DK.GN

S

W

6

(SEA

T SW)

F1

20A

–

+

BA

TTERY

GND

DK.GN/W

DARK GREEN/WHITE

DARK

GREEN

DK.GN

L

T

.GN

DELA

Y MODULE

100–6186

SHOWN IN

OFF POSITION

2

3

5

4

1

S

W

7

(TIL

T SW)

SHOWN WITH

OPERA

TOR

IN SEA

T

ST

B

ST

ARTER

LIGHT GREEN

BLACK/RED

SW4

(NEUTRAL)

(PTO)

SW2

REG

MAG

FUEL

OIL

AC

FUEL

SOLINIOD

OIL

SWITCH

SP

ARK PLUG

SP

ARK PLUG

IGNITION

MODULES

AC

PTO

CLUTCH

SWITCH OPENS

WHEN TIL

TED

P

AST 60 DEGREES

FROM VERTICAL

TERMINAL

VIEW FROM

BACK OF SWITCH

OFF NO CONNECTION

ON B I

A

AND

X

Y

ST

ART B I S

KEY SWITCH PN 88–9830

2

3

5

4

1

(ST

ART RELA

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K2

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Summary of Contents for 74242 Z500 Z Master

Page 1: ...Operator s Manual Original Instructions EN Register your product at www Toro com Form No 3329 714 Z500 Z Master with 52in TURBO FORCE Side Discharge Mower Model No 74242 240000001 Up ...

Page 2: ...ver Protection System ROPS 16 Think Safety First 17 Controls 18 Operating the Parking Brake 18 Starting and Stopping the Engine 19 Operating the Power Take Off PTO 20 The Safety Interlock System 20 Driving Forward or Backward 21 Page 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...

Page 3: ...educe 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...

Page 4: ...ion 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...

Page 5: ...ndoors 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 b...

Page 6: ...6 ...

Page 7: ...7 Slope Chart ...

Page 8: ...8 ...

Page 9: ...d 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 1 523552 1 643401 98 4387 1 Warning wearhearing protection 98 5954 43 8480 54 9220 66 1340 ...

Page 10: ... 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 105 7797 104 7759 104 8569 105 7798 107 1864 ...

Page 11: ...11 107 2102 107 1622 107 1621 106 9969 ...

Page 12: ...12 107 2112 107 1857 107 1860 107 1861 103 2433 ...

Page 13: ...13 106 9989 106 7492 ...

Page 14: ...xplosive 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 ...

Page 15: ...sible 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 Gasoline is harmful or fatal if swallowed Long term exposure to vapors can cause serious injury and illness Avoid...

Page 16: ... and do not contact them Warning 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 m 6836 ...

Page 17: ...nd 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 3 1 m 6478 Figure 5 1 Safe Zone use the Z Master here on slopes less than 15 degrees or flat areas 2 Us...

Page 18: ...gular maintenance 1 m 3077 Figure 9 1 Hour meter Operating the Parking Brake Always set the parking brake when you stop the machine or leave it unattended Setting the Parking Brake 1 Move the motion control levers Fig 7 out to the neutral lock position 2 Pull back and up on the parking brake lever to set the parking brake Fig 10 The parking brake lever should stay firmly in the engaged position Pa...

Page 19: ...ese instructions can burn out starter motor 7 After the engine starts move the choke to off Fig 12 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 11 1 PTO On 2 PTO Off Figure 12 1 Choke On 2 Choke Off 1 m 2719 2 1 2 m 4201 Figure 13 1 Throttle Fast 2 Throttle Slow Figure 14 1 Off 2 Run 3 S...

Page 20: ...e seat The parking brake is engaged The power take off PTO is disengaged The motion control levers are in neutral locked position The safety interlock system also is designed to stop the engine when the traction controls are moved from the locked position with the parking brake engaged or if you rise from the seat when the PTO is on engaged Testing the Safety Interlock System Test the safety inter...

Page 21: ...tral in the direction you want to turn Fig 16 The farther you move the traction control levers in either direction the faster the machine will move in that direction To stop pull the motion control levers to the neutral position Driving Backward 1 Move the levers to the center un locked position 2 To go backward slowly pull the motion control levers rearward Fig 16 To go straight apply equal press...

Page 22: ...r you change the height of cut it is recommended to adjust the height of the anti scalp rollers 1 Disengage the power take off PTO and turn the ignition key to off Move the levers to the neutral locked position and apply the parking brake Remove the key 2 After adjusting the height of cut adjust the rollers by removing the flange nut bushing spacer and bolt Fig 19 Note The two middle rollers will ...

Page 23: ...best quality of cut 1 To adjust the cam locks swing the lever up to loosen the cam lock Fig 26 2 Adjust the baffle and cam locks in the slots to the desired discharge flow 3 Swing the lever back over to tighten the baffle and cam locks 4 If the cams do not lock the baffle into place or it is too tight loosen the lever and then rotate the cam lock Adjust the cam lock until the desired locking press...

Page 24: ...Use this position when bagging Middle Position m 6880 Figure 24 Position C This is the full open position The suggested use for this position is as follows Use in tall dense grass mowing conditions Use in wet conditions Lowers the engine power consumption Allows increased ground speed in heavy conditions This position is similar to the benefits of the Toro SFS mower Full Forward Position m 6879 Fi...

Page 25: ... 1 Rotate the by pass valves clockwise 1 turn to operate machine Fig 28 Note Do not over tighten the by pass valves Note The machine will not drive unless the by pass valves are turned in m 6124 1 Figure 28 1 By pass valve Using the Side Discharge The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf Danger Without the grass deflector discharge cover ...

Page 26: ... full width continuous ramp The ramp should be long enough so that the angles do not exceed 15 degrees Fig 29 A steeper angle may cause mower deck components to get caught as the unit moves from ramp to trailer or truck Steeper angles may also cause the unit to tip backward If loading on or near a slope position the trailer or truck so it is on the down side of the slope and the ramp extends up th...

Page 27: ...quently If you cannot mow for an extended period first mow at a high cutting height then mow again two days later at a lower height setting Cutting Speed To improve cut quality use a slower ground speed in certain conditions Avoid Cutting Too Low If the cutting width of the mower is wider than the mower you previously used raise the cutting height to ensure that uneven turf is not cut too short Lo...

Page 28: ... adjust tension Belts check for wear cracks Tires check pressure Every 100 Hours Engine Oil change1 Hydraulic lines check Engine Cooling System clean1 Every 200 Hours Oil Filter change 200 hours or every other oil change 1 Hydraulic filter change Spark Plug s check Fuel Filter replace Brake pivot grease Every 250 Hours Replace or clean primary air cleaner filter1 Safety air cleaner1 check Every 50...

Page 29: ...r damage File down any nicks and sharpen the blades as necessary If a blade is damaged or worn replace it immediately with a genuine TORO replacement blade For convenient sharpening and replacement you may want to keep extra blades on hand Danger A worn or damaged blade can break and a piece of the blade could be thrown into the operator s or bystander s area resulting in serious personal injury o...

Page 30: ...r is bent To ensure optimum 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 Contact with sharp blade can cause serious injury Wear gloves or wrap sharp edges of the blade with a rag Warning 1 Hold the blade end using a rag or thickly padded glove Remove...

Page 31: ...it as well 6 Inspect the primary filter for damage by looking into the filter while shining a bright light on the outside of the filter Holes in the filter will appear as bright spots If the filter is damaged discard it Important Never attempt to clean the safety filter If the safety filter is dirty then the primary filter is damaged and you should replace both filters 4 3 5 1 2 1 m 4815 Figure 36...

Page 32: ... is low slowly pour only enough oil into the filler tube to raise the level to the full mark Important Do not overfill the crankcase with oil because the engine may be damaged Do not run engine with oil below the low mark because the engine may be damaged 1 3 2 m 3219 m 4811 Figure 37 1 Oil dipstick 2 Filler tube 3 Metal end Changing the Oil 1 Start the engine and let it run five minutes This warm...

Page 33: ...orrect before installing the spark plug Use a spark plug wrench for removing and installing the spark plug s and a gapping tool feeler gauge to check and adjust the air gap Install a new spark plug s if necessary Type Champion RC12YC or equivalent Air Gap 0 030 inch 0 76 mm Removing the Spark Plug s 1 Disengage the power take off PTO and turn the ignition key to off Move levers to neutral locked p...

Page 34: ...off valve Servicing the Fuel Tank Draining The Fuel Tank 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 Drain gasoline from the fuel tank when the engine is cold Do this outdoors in an open area Wipe up any gasoline that spills Never smoke when draining gasoline and stay away from a...

Page 35: ...pe up any excess grease Greasing the Front Caster Pivots Lubricate the front caster pivots once a year 1 Remove the dust cap and adjust the caster pivots Keep dust cap off until greasing is done Refer to Adjusting the Caster Pivot Bearing page 37 2 Remove the hex plug Thread a grease zerk into the hole 3 Pump grease into the zerk until it oozes out around the top bearing 4 Remove the grease zerk i...

Page 36: ...he push arms Fig 45 m 6822 Figure 45 Cleaning the Cooling Systems Cleaning the Engine Screen and the Oil Cooler Before each use check and clean engine screen and oil cooler Remove any build up of grass dirt or other debris from the oil cooler and engine air intake screen Fig 46 m 3801 ÓÓÓ ÓÓÓ ÓÓÓ ÓÓÓ ÓÓÓ 1 2 Figure 46 1 Engine screen 2 Oil cooler Cleaning the Engine Fins Every 100 hours clean engi...

Page 37: ...o inside edge of hole Two threads or less should be showing Fig 49 6 If more than two threads are showing remove nut and install washer between hub and nut Fig 49 7 Torque the slotted nut to 125 ft lb 170 N m Fig 49 8 Tighten nut until the next set of slots line up with the hole in the shaft Fig 49 9 Replace cotter pin 3 m 4638 1 2 4 Figure 49 1 Slotted nut 2 Two threads or less showing 3 Hole in ...

Page 38: ... to allow any air to purge out of the system and warm the fluid Refer to Starting and Stopping the Engine on page 19 6 Recheck the fluid level while the fluid is warm The fluid should be between cold and hot 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 Fig 51 8 Install cap on filler neck 3 1 2 m 5615 4 ...

Page 39: ...ulic tank 9 Start the engine and let it run for about two minutes to purge air from the system Stop the engine and check for leaks If one or both wheels will not drive refer Bleeding Hydraulic System page 39 10 Recheck the fluid level while the fluid is warm The fluid should be between cold and hot 11 If required add fluid to the hydraulic tank Do not overfill m 1256 1 2 3 Figure 53 1 Hydraulic fi...

Page 40: ...e 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 forward 4 Begin with either the left or right motion control lever 5 Move the lever to the neutral position but not locked Fig 54 M 6278 1 2 6 7 4 5 10 8 3 9 10 11 11 Figure...

Page 41: ...at fully forward Setting the Right hand Hydraulic Pump Neutral 1 Start the engine open the throttle 1 2 way and release parking brake Refer to Starting and Stopping the Engine page 19 Note The motion control lever must be in neutral while making any adjustments 2 Adjust the pump rod length by rotating the knob in the appropriate direction until the wheel is still or slightly creeping in reverse Fi...

Page 42: ...Adjusting the Hydraulic Pump Neutral on page 41 1 Push both control levers forward the same distance 2 Check if the machine pulls to one side If it does stop the machine and set the parking brake 3 Tip the seat up to access the tracking knob Note Determine the left and right sides of the machine from the normal operating position 4 To make the machine go right turn the knob towards the rightside o...

Page 43: ...ng 2 75 inch 70 mm 3 Adjusting nuts 4 Collar on brake rod 5 3 16 1 4 inch 5 7 mm 6 Jam nut and yoke Servicing the Fuse Service Interval Specification The electrical system is protected by fuses It requires no maintenance however if a fuse blows check component circuit for malfunction or short Fuse Main F1 20 amp blade type Alternator F2 20 amp blade type 1 Raise the seat to gain access to fuse hol...

Page 44: ...ttery terminal 4 Secure the cables with 2 bolts 1 4 x 3 4 inch 2 washers 1 4 inch and 2 locknuts 1 4 inch Fig 62 5 Slide the red terminal boot onto the positive red battery post 6 Secure the battery with J bolts hold down clamp and 2 washers 1 4 inch and 2 wing nuts 1 4 inch Fig 62 1 9 5 2 6 7 10 4 3 8 11 7 m 5598 Figure 62 1 Battery 2 Terminal boot 3 Positive battery cable 4 Negative battery cabl...

Page 45: ...led water into each battery cell until the level is up to the upper line Fig 61 on the battery case Important Do not overfill the battery because electrolyte sulfuric acid can cause severe corrosion and damage to the chassis 5 Wait five to ten minutes after filling the battery cells Add distilled water if necessary until the electrolyte level is up to the upper line Fig 61 on the battery case 6 Re...

Page 46: ...g the Mower Side to Side 1 Position the right blade front to rear Fig 64 2 Measure the right blade at the B location Fig 64 from a level surface to the cutting edge of the blade tip Fig 65 3 Record this measurement This measurement needs to be 3 1 8 to 3 1 4 inches 4 Position the left blade front to rear Fig 64 5 Measure the left blade at the C location Fig 64 from a level surface to the cutting e...

Page 47: ...ine to achieve 1 4 to 3 8 inch 6 to 10 mm lower in front at A than in the rear at B Fig 69 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 Adjusting the Compression Spring 1 Raise the mower lift lever to the transport position Fig 69 2 Check the distance between the two large washers it...

Page 48: ...amount of twist in the belt between the pulleys Make sure it is only what is specified in Figure 70 2 m 6825 3 3 3 4 4 1 3 6 5 Figure 70 1 Clutch 2 Mower belt 3 1 4 turn belt twist 4 Belt guide 5 Mower spindle pulley 6 Mower idler pulley 6 Adjust the belt tension refer to Adjusting the Mower Belt Tension page 48 7 Install the belt covers and close the latches Fig 71 1 m 6824 1 2 Figure 71 1 Belt c...

Page 49: ...end of the adjustment slot and more belt tension is required a small change to the right side fixed idler can create more belt tension adjustment Fig 75 m 3746 1 2 Figure 75 1 Fixed Idler 2 Adjustment slot Replacing the Grass Deflector 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...

Page 50: ...that they are aware that these switches contain mercury and will apply sound disposal practices when these devices reach their normal end of life or are damaged Disposing the Mercury Tilt Switch Several states have passed laws concerning the disposal of devices containing mercury In all the remaining states it is advisable to follow similar procedures The laws state that these sealed devices conta...

Page 51: ...E OR BK ORANGE BLACK PK BK PINK BLACK VIO PK WIRE COLOR CODES NEUTRAL SW5 LT BU BRAKE SW3 SHOWN WITH PARK BRAKE DISENGAGED P1 A PK BK DK GN SW6 SEAT SW F1 20A BATTERY GND DK GN W DARK GREEN WHITE DARK GREEN DK GN LT GN DELAY MODULE 100 6186 SHOWN IN OFF POSITION 2 3 5 4 1 SW7 TILT SW SHOWN WITH OPERATOR IN SEAT ST B STARTER LIGHT GREEN BLACK RED SW4 NEUTRAL PTO SW2 REG MAG FUEL OIL AC FUEL SOLINIO...

Page 52: ...r storage as follows A Add a petroleum based stabilizer conditioner to fuel in the tank Follow mixing instructions from stabilizer manufacture Do not use an alcohol based stabilizer ethanol or methanol Note A fuel stabilizer conditioner is most effective when mixed with fresh gasoline and used at all times B Run engine to distribute conditioned fuel through the fuel system 5 minutes C Stop engine ...

Page 53: ... plugs are pitted fouled or gap is incorrect 5 Install new correctly gapped spark plugs 6 Dirt in fuel filter 6 Replace fuel filter 7 Dirt water or stale fuel is in fuel system 7 Contact Authorized Service Dealer Engine loses power 1 Engine load is excessive 1 Reduce ground speed g 2 Air cleaner is dirty 2 Clean air cleaner element 3 Oil level in crankcase is low 3 Add oil to crankcase 4 Cooling f...

Page 54: ...pindle bent 6 Contact Authorized Service Dealer Uneven cutting height 1 Blade s not sharp 1 Sharpen blade s g g 2 Cutting blade s is are bent 2 Install new cutting blade s 3 Mower is not level 3 Level mower from side to side and front to rear 4 Anti scalp roller not set correctly 5 Underside of mower is dirty 4 Adjust gage wheel height 5 Clean the underside of the mower 6 Tire pressure is incorrec...

Page 55: ......

Page 56: ...vered There is no other express warranty except for special emission system coverage on some products This express warranty does not cover the following Cost of regular maintenance service or parts such as filters fuel lubricants tune up parts blade sharpening brake and clutch adjustments Any product or part which has been altered or misused or required replacement or repair due to normal wear acc...

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