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Toro Z Master Z597-D Operator's Manual
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Toro Z Master Z597-D Operator's Manual

With 60in or 72in turbo force side discharge mower
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Form No. 3354-691 Rev A
Z597-D Z Master® with 60in
or 72in TURBO FORCE® Side
Discharge Mower
Model No. 74268TE—Serial No. 260000001 and Up
Model No. 74269TE—Serial No. 260000001 and Up
Register your product at www.Toro.com
Original Instructions (EN)

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Summary of Contents for Toro Z Master Z597-D

  • Page 1 Form No. 3354-691 Rev A Z597-D Z Master® with 60in or 72in TURBO FORCE® Side Discharge Mower Model No. 74268TE—Serial No. 260000001 and Up Model No. 74269TE—Serial No. 260000001 and Up Register your product at www.Toro.com Original Instructions (EN)

  • Page 2: Table Of Contents

    Safety ..............5 Engine Maintenance........37 Safe Operating Practices ...... 5 Servicing the Air Cleaner ....37 Toro Riding Mower Safety ....7 Servicing the Engine Oil ....39 Sound Pressure Level......7 Fuel System Maintenance ......41 Sound Power Level ......8 Servicing the Fuel Filter .....

  • Page 3: Introduction

    Schematics ............67 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 identifies the location of the model and serial numbers on the product.
  • Page 4 This manual uses 2 other words to highlight information. Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention.

  • Page 5: Safety

    Safety ◊ the type of machine is unsuitable for its task; This machine meets or exceeds European ◊ lack of awareness of the effect of Standards in effect at the time of production. ground conditions, especially slopes; However, improper use or maintenance by the ◊...
  • Page 6 • Mow only in daylight or in good artificial light. – before checking, cleaning or working on the lawnmower; • Before attempting to start the engine, disengage all blade attachment clutches and – after striking a foreign object. Inspect shift into neutral. the lawnmower for damage and make repairs before restarting and operating the •...

  • Page 7: Toro Riding Mower Safety

    flames away from battery. • Keep the roll bar in the raised and locked position and use the seat belt when operating • Use only genuine Toro replacement parts to the machine. ensure that original standards are maintained.

  • Page 8: Sound Power Level

    Sound Power Level This unit has a guaranteed sound power level of 105 dBA, based on measurements of identical machines per EN 11094. Vibration Level Hand-Arm This unit does not exceed a hand/arm vibration level of 1.26 m/s2, based on measurements of identical machines per EN 1033.

  • Page 9: Slope Chart

    Slope Chart...

  • Page 10: Decals

    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. 58-6520 1. Grease 93-7824 1. Thrown object hazard—stay a safe distance from the machine.
  • Page 11 107-1866 1. Sliding and loss of control hazard and tipping hazard, drop-offs—do not operate the machine near drop-offs, slopes greater than 15 degrees, or water; keep a safe 99-8939 distance from drop-offs; do not turn sharply while traveling fast, instead, slow down and turn gradually; if the roll bar is 1.
  • Page 12 107-3961 1. Height of cut in millimeters 107-3069 1. Warning—there is no rollover protection when the roll bar is down. 2. To avoid injury or death from a rollover accident, keep the roll bar in the raised and locked position and wear the seat belt.
  • Page 13 107-3963 1. Cutting/dismemberment 2. Cutting/dismemberment 3. Thrown object hazard—keep 4. Before starting the engine, hazard, mower blade—do hazard of hand or foot, bystanders a safe distance clean grass and debris from not carry passengers and mower blade—remove the from the machine and keep the mower belt and pulleys, keep bystanders away.
  • Page 14 107-3968 1. Disengage 3. Parking brake 107-3993 2. Engage 1. Short, sparse grass and dry 3. Long, thick grass and wet conditions. conditions. 2. Bagging 107-3969 1. Warning—read the Operator’s Manual. 2. Crushing hazard, mower—engage the parking brake, stop the engine, and remove the ignition key before working under the mower.
  • Page 15 107-7719 1. Cutting/dismemberment hazard, fan and entanglement hazard, belt—stay away from moving parts. 2. Before starting the engine, clean grass and debris from the mower belt and pulleys, insert the ignition key, and start the engine. 107-7700 1. Water in fuel warning 7.
  • Page 16 Manufacturer’s Mark 1. Indicates the blade is identied as a part from the original machine manufacturer. 107-3967 1. Fast 3. Neutral 5. Warning—read the 7. Explosion hazard—no re, Operator’s Manual. open ames, or smoking; avoid sparks. 4. Reverse 2. Slow 6.

  • Page 17: Product Overview

    Product Overview Hour Meter The hour meter records the number of hours the engine has operated. It operates when the engine is running. Use these times for scheduling regular maintenance (Figure 4). Glow Plug Light (Orange Light) The glow plug indicator light turns on when the ignition switch is turned to the on position.

  • Page 18: Operation

    Operation In certain conditions, fuel is extremely Note: Determine the left and right sides of the flammable and highly explosive. A fire or machine from the normal operating position. explosion from fuel can burn you and others and can damage property. Adding Fuel •...

  • Page 19: Checking The Engine Oil Level

    2. Clean around each fuel tank cap and remove the cap. Add fuel to both fuel tanks, until the level is 1/4 to 1/2 inch (6 to 13 mm) below the bottom of the filler neck. This space in the tank allows the fuel to expand.

  • Page 20: Think Safety First

    2. Remove the hairpin cotter pins and remove the two pins (Figure 7). 3. Lower the the roll bar to the down position. There are two down positions. See Figure 6 for the positions. 4. Install the two pins and secure them with the hairpin cotter pins (Figure 7).

  • Page 21: Understanding The Audible

    Operating on wet grass or steep slopes can This machine produces sound levels in cause sliding and loss of control. excess of 85 dBA at the operators ear and can cause hearing loss through extended Wheels dropping over edges can cause periods of exposure.

  • Page 22: Operating The Parking Brake

    Pulsing Audible Alarm The pulsing audible alarm alerts the user to low oil pressure or the alternator is not charging. Refer to Checking the Engine Oil and check the alternator belt. Operating the Parking Brake Always set the parking brake when you stop the machine or leave it unattended.
  • Page 23 Figure 13 1. Ignition switch 6. Fuel cap 2. Throttle control 7. Volt meter 3. Glow plug light 8. Engine Temperature gauge Figure 15 4. Power take off (PTO) Switch 9. Water in fuel light 5. Hour meter 1. Throttle—fast 2.

  • Page 24: Operating The Power Take Off

    5. Remove the key to prevent possibility of someone accidentally starting the machine before transporting or storing machine. 6. Close the fuel selector valve before transporting or storing the machine. Important: Make sure that the fuel selector valve is closed before transporting or storing the machine, as fuel leakage may occur.

  • Page 25: Driving Forward Or Backward

    engaged or if you rise from the seat when the PTO is engaged. Machine can spin very rapidly. Operator Testing the Safety Interlock System may lose control of machine and cause personal injury or damage to machine. Test the safety interlock system before you use •...

  • Page 26: Stopping The Machine

    Driving Backward 1. Move the levers to the center, un-locked position. 2. To go backward, slowly pull the motion control levers rearward (Figure 17). To go straight, apply equal pressure to both motion control levers (Figure 17). To turn, release pressure on the motion control lever toward the direction you want to turn (Figure 17).

  • Page 27: Adjusting The Flow Baffle

    3. After adjusting the height-of-cut, adjust the rollers by removing the flange nut, bushing, spacer, and bolt (Figure 20 , Figure 21 and Figure 22 ). Note: The two middle rollers will not have a spacer (Figure 21). 4. Select a hole so the anti-scalp roller is positioned to the nearest corresponding height-of-cut desired.

  • Page 28: Positioning The Flow Baffle

    • Use for short, light grass mowing conditions. • This position is similar to the benefits of the Toro SFS mower. • Use in dry conditions. • For smaller grass clippings. • Propels grass clippings farther away from the mower.

  • Page 29: Positioning The Seat

    Positioning the Seat To adjust it, turn the knob, under the right-side arm rest, in either direction to provide the best comfort (Figure 28). Changing the Seat Position The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable.

  • Page 30: Pushing The Machine By Hand

    Pushing the Machine by Hand Important: Always push the machine by hand. Never tow the machine because hydraulic damage may occur. Pushing the Machine 1. Disengage the power take off (PTO) and turn the ignition key to off. Move the levers to neutral locked position and apply parking brake.

  • Page 31: Transporting Machines

    Transporting Machines Important: Do Not attempt to turn the unit while on the ramp; you may lose control and Use a heavy-duty trailer or truck to transport the drive off the side. machine. Ensure that the trailer or truck has all Avoid sudden acceleration when driving up a ramp necessary lighting and marking as required by law.

  • Page 32: Using The Z Stand

    2. Remove the bracket pin (Figure 32). Figure 32 1. Z Stand 4. Bracket Pin 2. Latch 5. Bottom of slot 3. Bracket 3. Raise the latch. Swing the stand foot out Figure 31 front and slide stand toward machine, into the 1.

  • Page 33: Operating Tips

    uneven ground. However, the cutting height used in the past is generally the best one to use. When cutting grass longer than six inches tall, you may Parking brake may not hold machine want to cut the lawn twice to ensure an acceptable parked on Z Stand and could cause quality of cut.
  • Page 34 Check the cutter blades daily for sharpness, and for any wear or 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.

  • Page 35: Maintenance

    Maintenance Recommended Maintenance Schedule(s) Maintenance Service Maintenance Procedure Interval • Check cooling system level. After the rst 8 operating • Check the hydraulic uid. hours After the rst 25 • Change the hydraulic lter and oil. operating hours • Change the engine oil. After the rst 50 •...

  • Page 36: Lubrication

    If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition and disconnect the wire from the spark plug(s) before you do any maintenance. Set the wire aside so that it does not accidentally contact the spark plug. Lubrication Where to Add Grease Lubricate the grease fittings as shown on the...

  • Page 37: Where To Add Light Oil Or Spray

    Grease the Idler Arms 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the 1. Grease the cooling fan belt idler arm operating position. (Figure 37). 3. Remove the screws and belt covers. 2.
  • Page 38 Removing the Filters 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.

  • Page 39: Servicing The Engine Oil

    Important: Do not press on the soft Important: Do not overfill the crankcase inside area of the filter. with oil because this may cause engine damage. Do not run the engine with oil 4. Install the air cleaner cover with the side below the low mark because the engine indicated as UP facing up and secure the may be damaged as a result.
  • Page 40 Note: Dispose of the used oil at a recycling Important: Add the oil very slowly and center. do not block the opening of the filler hole (Figure 45). If you add oil too fast or block Adding Engine Oil the hole, the oil could back up and foul the air intakes, causing engine damage.

  • Page 41: Fuel System Maintenance

    3. Before installing the filter, lightly oil the gasket 3. Disconnect the negative battery cable; Refer to on the filter with fresh, clean oil. Screw the Removing the Battery. filter on by hand until the gasket contacts the 4. Allow the machine to cool down. oil filter adapter.

  • Page 42: Servicing The Fuel Tank

    Electrical System Maintenance Servicing the Battery Warning CALIFORNIA Proposition 65 Warning Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of Figure 48 California to cause cancer and reproductive 1. Fuel lter 4. O-ring harm.
  • Page 43 Installing the Battery 1. Position battery in the tray with the terminal Incorrect battery cable routing could posts opposite from the hydraulic tank damage the machine and cables causing (Figure 50). sparks. Sparks can cause the battery gasses 2. First, install the positive (red) battery cable to to explode, resulting in personal injury.

  • Page 44: Servicing The Fuses

    Drive System Maintenance Adjusting the Tracking The machine has a knob for adjusting the tracking located under the seat. Important: Adjust the handle neutral and hydraulic pump neutral before adjusting the tracking. Refer to Adjusting the Handle Neutral in Controls System Maintenance, page 51 and Adjusting the Hydraulic Pump Neutral in Hydraulic System Maintenance, Figure 51...

  • Page 45: Checking The Tire Pressure

    Checking the Tire Pressure 8. Tighten the nut until the next set of slots line up with the hole in the shaft (Figure 55). Check the pressure at the valve stem after every 9. Replace the cotter pin. 50 operating hours or monthly, whichever occurs first (Figure 54).

  • Page 46: Cooling System Maintenance

    Rotating shaft and fan can cause personal injury. • Do not operate the machine without the covers in place. • Keep fingers, hands and clothing clear of rotating fan and drive shaft. • Shut off the engine and remove the ignition key before performing maintenance.

  • Page 47: Brake Maintenance

    Contact an Authorized Service Dealer for changing the coolant. Brake Maintenance Adjusting the Parking Brake 1. Disengage the brake lever (lever down). 2. Measure the length of the spring. The measurement should be 2-3/4 inch (70 mm) between the washers (Figure 58). 3.

  • Page 48: Belt Maintenance

    4. Pull on the spring loaded idler arm to loosen the belt tension. 5. Remove the mower belt from the mower pulleys and the top pulley of the three stacked pulleys (Figure 59 and Figure 60). 6. Install the new belt around the mower pulleys and the top pulley of the three stacked pulleys (Figure 59 and Figure 60).

  • Page 49: Replacing The Drive Belts

    Replacing the Drive Belts Squealing when the belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks and cracks are signs of a worn mower belt. Replace the mower belt if any of these conditions are evident. Note: Remove the top drive belt first if the bottom drive belt needs to be replaced.

  • Page 50: Replacing The Pump Drive

    7. Check to make sure the coils of the spring on 2. Pull the spring loaded idler down and remove the spring-loaded idler pulley have the correct the traction belt from the engine and hydro measurement (Figure 63). pump pulleys (Figure 65). Remove the belt between the pulleys.

  • Page 51: Controls System Maintenance

    Figure 66 1. Front engine panel 2. Knob Figure 67 1. Alternator 4. Deection, 3/8 to 1/2 inch 4. Remove the pump drive belt. Refer to (10 to 13 mm) 2. Alternator belt 5. Top bolt Removing the Pump Drive Belt. 3.

  • Page 52: Hydraulic System Maintenance

    7. Check where the control lever is relative to notch in console (Figure 68). It should be centered allowing lever to pivot outward to the neutral lock position. Figure 69 1. Clevis pin in slot 7. Spring 2. Nut against yoke 8.
  • Page 53 2. Clean the area around filler neck of hydraulic tank (Figure 70). Hydraulic fluid escaping under pressure 3. Remove the cap from the filler neck. Look can penetrate skin and cause injury. inside to check if there is fluid in the reservoir (Figure 70).
  • Page 54 Replacing the Cooling Fan Hydraulic Filter Replace the cooling fan hydraulic filter: • After every 500 operating hours. • After any part of the hydraulic cooling fan system is repaired or replaced. 1. Place drain pan under filter, remove the Figure 71 hydraulic hose from the filter (Figure 73).

  • Page 55: Setting The Hydraulic Pump

    Checking the Hydraulic Hoses After every 100 operating hours, check the Mechanical or hydraulic jacks may fail to hydraulic hoses for leaks, loose fittings, kinked support machine and cause a serious injury. lines, loose mounting supports, wear, weather and chemical deterioration. Make necessary repairs •...

  • Page 56: Mower Deck Maintenance

    Figure 74 1. Tracking knob 4. Turn this way to track right 2. Hydraulic tank 5. Turn this way to track left 3. Hydraulic pumps Figure 75 1. Double nuts 4. Locknut 3. Move the motion control lever forward and 2.
  • Page 57 Setting Up the Machine 1. Position the mower on a flat surface. 2. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
  • Page 58 Figure 77 Figure 76 1. Rear chain 5. Adjustment bolt 1. Measure here from blade 2. Measure at B and C 2. Rear support arm 6. Front swivel to hard surface 3. Bolt 7. Front support arm 4. Jam Nut 7.

  • Page 59: Servicing The Cutting Blades

    11-1/2 inches (29.2 cm) damaged or worn, replace it immediately with a (Figure 79). genuine Toro replacement blade. For convenient 3. Adjust this distance, by loosening the spring sharpening and replacement, you may want to jam nut and turning the nut in front of each keep extra blades on hand.
  • Page 60 A, of safety conformance of the machine, use genuine the blades (Figure 81). Note this dimension. TORO replacement blades. Replacement blades made by other manufacturers may result in non-conformance with safety standards.

  • Page 61: Replacing The Grass Deflector

    Installing the Blades 1. Install the blade onto the spindle shaft Contact with a sharp blade can cause serious (Figure 84). injury. Important: The curved part of the blade Wear gloves or wrap sharp edges of the must be pointing upward toward the inside blade with a rag.

  • Page 62: Cleaning

    2. Place the spacer and spring onto grass deflector. Place the L end of spring behind deck edge. The machine could fall onto someone and cause serious injury or death. Note: Make sure the L end of the spring is installed behind the deck edge before installing •...

  • Page 63: Storage

    Storage A. Add a petroleum based stabilizer/conditioner to fuel in the tank. Follow mixing instructions from Cleaning and Storage the stabilizer manufacturer. Do not use 1. Disengage the power take off (PTO), set the an alcohol based stabilizer (ethanol or parking brake, and turn the ignition key to Off.

  • Page 64: Troubleshooting

    Troubleshooting Problem Possible Cause Corrective Action Starter does not crank 1. Blade control (PTO) is 1. Move the blade contro engaged. (PTO) to disengaged. 2. Parking brake is not on. 2. Set the parking brake. 3. Operator is not seated. 3.
  • Page 65 Problem Possible Cause Corrective Action Machine does not drive. 1. By pass valve is not 1. Tighten the by pass closed tight. valve. 2. Drive or pump belt is 2. Change the belt. worn, loose or broken. 3. Drive or pump belt is off 3.
  • Page 66 Problem Possible Cause Corrective Action Blades do not rotate. 1. Drive belt is worn, loose 1. Check the belt tension. or broken. 2. Drive belt is off pulley. 2. Install the drive belt and check adjusting shafts and belt guides for correct position.

  • Page 67: Schematics

    Schematics Wire Diagram (Rev. A)

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