Form No. 3351–976 Z557 Z Master with 52in TURBO FORCE Side Discharge Mower Model No. 74243–250000001 & Up Operator’s Manual Register your product at www.Toro.
Warning Operating the Power Take Off (PTO) . . . . . . . . . The Safety Interlock System . . . . . . . . . . . . . . . . Driving Forward or Backward . . . . . . . . . . . . . . . Stopping the Machine . . . . . . . . . . . . . . . . . . . . . Adjusting the Height-of-Cut . . . . . . . . . . . . . . . . Using the Lift Assist Lever . . . . . . . . . . . . . . . . . Adjusting the Anti-Scalp Rollers . . . . . . . . . . . . . Adjusting the Flow Baffle . . . . . . . . . . . . . . . . . .
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. Improper use or maintenance by the operator or owner can result in injury.
• Use extreme care when loading or unloading the machine into a trailer or truck. • Use extra care when handling gasoline and other fuels. They are flammable and vapors are explosive. • Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision. • Use only an approved container • Never remove gas cap or add fuel with engine running. Allow engine to cool before refueling. Do not smoke. Slope Operation • Never refuel or drain the machine indoors.
• 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.
Slope Chart Fold along appropriate line Example: Compare slope with folded edge. 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 54-9220 1-643339 58-6520 1.
4-8569 98-4387 1. Warning—wear hearing protection. 98-5954 105-7797 103-0368 105-7798 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.
107-1864 107-1622 107-2102 107-1621 11
107-1860 106-9969 107-1861 107-2112 107-1857 12
107-8076 106-9989 13
106-7492 104-4164 1. Contains lead; do not discard. 2. Recycle 3. Wear eye protection; explosive gases can cause blindness and other injuries 4. No sparks, flame, or smoking 14 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.
Gasoline and Oil Warning Gasoline is harmful or fatal if swallowed. Long–term exposure to vapors can cause serious injury and illness. 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. • Avoid prolonged breathing of vapors. • Keep face away from nozzle and gas tank or conditioner opening. • Keep gas away from eyes and skin.
Operation 2 Note: Determine the left and right sides of the machine from the normal operating position. 1 Using the Rollover Protection System (ROPS) m–7447 Figure 2 Warning 1. Full down position To avoid injury or death from rollover: keep the roll bar in the raised locked position and use the seat belt. Important Always use the seat belt with the roll bar in the raised position. Ensure that the rear part of the seat is secured with the seat latch.
7. Tighten the front handles against the center roll bar ends (Fig. 3). 2 1 1 m–6897 Figure 4 1. Front handle 3 Think Safety First m–6478 Figure 5 Please read all safety instructions and symbols in the safety section. Knowing this information could help you or bystanders avoid injury. 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.
Controls Using the Hour Meter Become familiar with all the controls (Fig. 7 and 8) before you start the engine and operate the machine. 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. 8 7 1 6 1 4 3 m–3077 Figure 9 5 1. Hour meter Operating the Parking Brake Always set the parking brake when you stop the machine or leave it unattended. 2 m–6834 Setting the Parking Brake Figure 7 1.
Important Do not engage starter for more than 10 seconds at a time. If engine fails to start allow 30 second cool-down period between attempts. Failure to follow these instructions can burn out starter motor. 1 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. 2 2 1 3 2 m–4163 Figure 10 1. Parking brake-ON 2. Parking brake-OFF 1 3.
The Safety Interlock System 5. Close the fuel shut off valve before transporting or storing the machine (Fig. 42). Important Make sure that the fuel shut off valve is closed before transporting or storing the machine, as fuel leakage may occur. Set the parking brake before transporting. Make sure to remove the key as the fuel pump may run and cause the battery to lose charge. Caution If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury.
To turn, move the motion control lever toward neutral in the direction you want to turn (Fig. 16). While the engine is running, center either motion control and move (forward or reverse); the engine should stop. Repeat for other motion control. The farther you move the traction control levers in either direction, the faster the machine will move in that direction. 5.
3. Select a hole in height-of-cut bracket corresponding to the height-of-cut desired and, insert clevis pin (Fig. 17). Adjusting the Anti-Scalp Rollers 4. Move lever to selected height. Whenever you change the height-of-cut, it is recommended to adjust the height of the anti-scalp rollers. 1 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 2.
Adjusting the Flow Baffle The mower discharge flow can be adjusted for different types of mowing conditions. Position the cam locks and baffle to give the best quality of cut. 1. To adjust the cam locks, swing the lever up to loosen the cam lock (Fig. 26). 3 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 1 2 4.
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. Note: If the engine power draws down and the mower ground speed is the same, open up the baffle. • Use in wet conditions. Position A • Allows increased ground speed in heavy conditions. This is the full rear position.
Unlatching the Seat Changing to Machine Operation Push the seat latch rearward to unlatch the seat. This will allow access to the machine under the seat. 1. Rotate the by-pass valves clockwise 1 turn to operate machine (Fig. 28). Note: Do not over tighten the by–pass valves. 3 Note: The machine will not drive unless the by-pass valves are turned in. 2 1 2 1 1 m–6840 Figure 27 1. Seat latch 2. Gas cap 3. Seat 1 Pushing the Machine by Hand Important Always push the machine by hand.
Danger Warning 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. Driving on 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. Do not drive machine on a public street or roadway.
Cutting a Lawn for the First Time Warning 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. When cutting grass longer than six inches tall, you may want to cut the lawn twice to ensure an acceptable quality of cut. Loading a unit onto a trailer or truck increases the possibility of backward tip–over and could cause serious injury or death.
Keep the Underside of the Mower Clean Clean clippings and dirt from the underside of the mower after each use. If grass and dirt build up inside the mower, cutting quality will eventually become unsatisfactory. Blade Maintenance Maintain a sharp blade throughout the cutting season because a sharp blade cuts cleanly without tearing or shredding the grass blades. Tearing and shredding turns grass brown at the edges, which slows growth and increases the chance of disease.
Maintenance Recommended Maintenance Schedule Maintenance Service Interval After first 5 hours Each Use Maintenance Procedure • Hydraulic fluid—check level • Hydraulic filter—change • • • • Oil—check level Safety System—check Mower Housing—clean Engine air intake—clean1 Every 8 Hours • Cutting Blades—check Every 25 Hours • • • • • • • • Every 50 Hours • Belts—adjust tension • Belts—check for wear/cracks • Tires—check pressure Every 100 Hours • Engine Oil—change1 • Hydraulic lines—check • Engine Co
Important Refer to your engine operator’s manual for additional maintenance procedures. Caution 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. Note: Determine the left and right sides of the machine from the normal operating position.
Checking for Bent Blades machine, use genuine TORO replacement blades. Replacement blades made by other manufacturers may result in non-conformance with safety standards. 1. Rotate the blades until the ends face forward and backward (Fig. 31). Measure from a level surface to the cutting edge of the blades (Fig. 32). Note this dimension. Warning Front Contact with sharp blade can cause serious injury. Wear gloves or wrap sharp edges of the blade with a rag. 1.
Installing the Blades 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. 1. Install the blade onto the spindle shaft (Fig. 35). Important The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting. 3 4 1 2. Install the spring disk and blade bolt (Fig. 35). Torque the blade bolt to 85–110 ft-lb (115–150 N m).
Servicing the Engine Oil 2 1 3 Change oil: • After every 100 operating hours. Note: Change oil more frequently when operating conditions are extremely dusty or sandy. Oil Type: Detergent oil (API service SH, SJ, SL or higher) Crankcase Capacity: w/filter, 67 oz. (2.0 l) Viscosity: See table below m–4811 m–3219 Figure 37 USE THESE SAE VISCOSITY OILS 1. Oil dipstick 2. Filler tube 3. Metal end 10W–30 Changing the Oil 5W–20, 5W–30 –20 F 0 –30 C –20 20 –10 1.
Change the Oil Filter Removing the Spark Plug(s) Replace the oil filter every 200 hours or every other oil change. 1. Disengage the power take off (PTO) and turn the ignition key to off. Move levers to neutral locked position and apply parking brake. Remove the key. Note: Change the oil filter more frequently when operating conditions are extremely dusty or sandy. 2. Pull the wire(s) off the spark plug(s) (Fig. 40).
Installing the Spark Plug(s) Servicing the Fuel Tank 1. Install the spark plug(s). Make sure the air gap is set correctly. Draining The Fuel Tank 2. Tighten the spark plug(s) to 20 ft-lb (27 N.m). Danger 3. Push the wire(s) onto the spark plug(s) (Fig. 40). 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.
Greasing and Lubrication Where to Add Grease Lubricate the machine when shown on the Check Service Reference Aid decal (Fig. 44). Grease more frequently when operating conditions are extremely dusty or sandy. Lubricate the grease fittings as shown on the Check Service Reference Aid decal (Fig. 44). Grease Type: General-purpose grease. 1. Disengage the power take off (PTO) and turn the ignition key to off. Move the levers to the neutral locked position and apply parking brake. Remove the key. 2.
Greasing the Spindles Cleaning the Cooling Systems The cutting unit must be lubricated weekly or every 25 hours. Refer to the Service Interval Chart on page 29. Grease with No. 2 general purpose lithium base or molybdenum base grease. 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).
1 Checking the Tire Pressure 4 Maintain the air pressure in the front and rear tires as specified. Uneven tire pressure can cause uneven cut. Check the pressure at the valve stem after every 50 operating hours or monthly, whichever occurs first (Fig. 48). Check the tires when they are cold to get the most accurate pressure reading. 3 2 Pressure: 13 psi (90 kPa) drive wheels and caster wheels. m–4638 Figure 49 1. Slotted nut 2. Two threads or less showing 1 3. Hole in threaded rod 4.
Servicing the Hydraulic System 5. Run the machine at low idle for 15 minutes to allow any air to purge out of the system and warm the fluid. Refer to Starting and Stopping the Engine on page 19. Checking the Hydraulic Fluid 6. Recheck the fluid level while the fluid is warm. The fluid should be between cold and hot. Check the hydraulic fluid level: 7. If required, add fluid to the hydraulic tank. • Before the engine is first started. • After the first 8 operating hours.
Bleeding the Hydraulic System 3. Place a drain pan under filter, remove the old filter and wipe the filter adapter gasket surface clean (Fig. 52). 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.
Note: Motion control levers must be installed correctly. See Installing the Motion Control Levers in the set up instructions. 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 neutral lock position (Fig. 55). 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2 2.
1. Raise the frame and use jack stands to hold up the machine so the drive wheels can rotate freely. Setting the Left–hand Hydraulic Pump Neutral 2. Disconnect electrical connector from the seat safety switch. 1. Loosen the locknuts at the ball joints on pump control rod (Fig. 54). 3. Temporarily install a jumper wire across terminals in the wiring harness connector. 2. Start the engine, open throttle 1/2 way and release parking brake. Refer to Starting and Stopping the Engine, page 19. 4.
Adjusting the Tracking 3. Pull spring loaded idler down and align below traction belt. Release pressure on spring loaded idler (Fig. 58). The right hand pump has a knob for adjusting the tracking. Important Adjust the handle neutral and hydraulic pump neutral before adjusting the tracking. Refer to Adjusting the Handle Neutral on page 40 and 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.
6. If adjustment is necessary, loosen the jam nut directly below the yoke. Turn the bottom rod until the correct measurement is obtained (Fig. 59). Tighten jam nut at yoke 3. If the electrolyte is low, add the required amount of distilled water; refer to Adding Water to the Battery, page 45. Servicing the Fuse 1 Service Interval/Specification 2 The electrical system is protected by fuses. It requires no maintenance, however, if a fuse blows check component/circuit for malfunction or short.
9 5 4 11 Warning 2 Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. 7 6 7 • Always Disconnect the negative (black) battery cable before disconnecting the positive (red) cable. • Always Reconnect the positive (red) battery cable before reconnecting the negative (black) cable. 3 8 10 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to off.
Charging the Battery Leveling the Mower at Three Positions Warning Important There are only three measuring positions needed to level the mower. Charging the battery produces gasses that can explode. Setting Up the Machine Never smoke near the battery and keep sparks and flames away from battery. 1. Position mower on a flat surface. 2. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. Important Always keep the battery fully charged (1.
F ront 9. Tighten the jam nut under the rear support arm and tighten the bolt securing the chain to the rear support arm. 10. Adjust the opposite side if needed. Adjusting the Front–to–Rear Mower Pitch 1. Position the right blade front-to-rear (Fig. 67). B C m–1078 2. Measure the right blade at the A location (Fig. 67), from a level surface to the cutting edge of the blade tip (Fig. 68). Figure 64 3. Record this measurement. 4. Measure the right blade at the B location (Fig.
Cleaning Under the Mower 9. Tighten both swivel jam nuts against the front swivel to lock the height. Remove the grass buildup under the mower daily. 10. Check to make sure there is equal tension on the chains and adjust again if needed. 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. Adjusting the Compression Spring 1. Raise the mower lift lever to the transport position (Fig. 69). 3.
8. Install the belt guide with a washer and nut onto the rear leftside pulley (Fig. 70). 2 1 Important Check the amount of twist in the belt between the pulleys. Make sure it is only what is specified in Figure 70. 1 1 3 4 8 9 5 4 m–6824 3 Figure 71 1. Belt cover 4 3 2 4 6 10 7 m–7829 Figure 70 1. 2. 3. 4. 5. Clutch Mower belt 1/4 turn belt twist Belt guide Mower spindle pulley 6. 7. 8. 9. 10. Mower idler pulley Belt guide installed Nut Washer Rear leftside pulley 9.
Adjusting the Mower Belt Tension 8. Tighten the idler plate bolts (Fig. 73). 3 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 4 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Raise the mower to the transport position. Important Check the amount of twist in the belt between the pulleys. Make sure it is only what is specified in Figure 70.
6 1 2 4 8 7 2 3 1 8 7 m–3746 Figure 75 1. Fixed Idler 2. Adjustment slot 5 m–6882 Figure 76 1. 2. 3. 4. 5. Replacing the Grass Deflector Warning 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. • Never operate the lawn mower unless you install a cover plate, a mulch plate, or a grass chute and catcher.
Wiring Diagram 52
Cleaning and Storage 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). 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. Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline and used at all times. 2.
Troubleshooting Problem Starter does not crank Engine g will not start,, starts hard,, or f il to fails t keep k running. i Engine g loses power. Engine g overheats. Possible Causes Corrective Action 1. Blade control (PTO) is engaged. 1. Move blade control (PTO) to disengaged. 2. Parking brake is not on. 2. Set parking brake. 3. Operator is not seated. 3. Sit on the seat. 4. Battery is dead. 4. Charge the battery. 5. Electrical connections are corroded or loose. 5.
Problem Machine does not drive. Abnormal vibration. Uneven cutting g height. g Blades do not rotate. Possible Causes Corrective Action 1. Traction belt is worn, loose or broken. 1. Contact Authorized Service Dealer. 2. Traction belt is off pulley. 2. Contact Authorized Service Dealer. 3. Hydro fluid level low. 3. Add hydro fluid to reservoir. 1. Cutting blade(s) is/are bent or unbalanced. 1. Install new cutting blade(s). 2. Blade mounting bolt is loose. 2. Tighten blade mounting bolt. 3.
The Toro Total Coverage Guarantee LCE A Limited Warranty Conditions and Products Covered Owner Responsibilities The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair the listed Toro Products if defective in materials or workmanship. The following time periods apply from the date of purchase: You must maintain your Toro Product by following the maintenance procedures described in the operator’s manual.
