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.
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.
98-4387 1. Warning—wear 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.
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 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 Operating the Parking Brake Become familiar with all the controls (Fig. 7 and 8) before you start the engine and operate the machine. Always set the parking brake when you stop the machine or leave it unattended. 8 7 Setting the Parking Brake 6 1. Move the motion control levers (Fig. 7) out to the neutral lock position. 1 2. Pull back and up on the parking brake lever to set the parking brake (Fig. 9). The parking brake lever should stay firmly in the engaged position.
Operating in Cool Weather 2 The engine on this machine may take 5 to15 minutes to reach full operating temperature in cool weather conditions. 1 2 Keep the choke applied slightly to keep the engine running smoothly from cold startup or when engaging the mower deck. 1 m–4201 Starting and Stopping the Engine m–2719 Figure 10 Figure 11 1. PTO-On 2. PTO-Off Starting the Engine 1. Choke–On 2. Choke–Off 1. Sit on the seat and move the motion controls to neutral locked position. 2.
The Safety Interlock System Caution Caution Children or bystanders may be injured if they move or attempt to operate the tractor while it is unattended. If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes. • Do not tamper with the interlock switches.
To turn, move the motion control lever toward neutral in the direction you want to turn (Fig. 15). 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. Sitting on the seat, disengage the parking brake, move the PTO switch to off and move the motion control levers to neutral lock position.
3. Select a hole in height-of-cut bracket corresponding to the height-of-cut desired and, insert the clevis pin (Fig. 16). 2. After adjusting the height-of-cut, adjust the rollers by removing the flange nut, bushing, spacer, and bolt (Fig. 18). 4. Move the lever to the selected height. Note: The two middle rollers will not have a spacer (Fig. 19). 1 3. Select a hole so the anti–scalp roller is positioned to the nearest corresponding height-of-cut desired (Fig. 18). 2 4.
Positioning the Flow Baffle The following figures are only recommendations for use. Adjustments will vary by grass type, moisture content, and height of grass. Note: If the engine power draws down and the mower ground speed is the same, open up the baffle. 1 Position A This is the full rear position. The suggested use for this position is a follows. 2 5 1 3 m–6844 • Use for short, light grass mowing conditions. Figure 20 1. Anti–scalp roller 2. Spacer 3. Bushing • Use in dry conditions. 4.
Position C Unlatching the Seat This is the full open position. The suggested use for this position is as follows. Push the seat latch rearward to unlatch the seat. This will allow access to the machine under the seat. • Use in tall, dense grass mowing conditions. 3 • Use in wet conditions. • Lowers the engine power consumption. 2 • Allows increased ground speed in heavy conditions. • This position is similar to the benefits of the Toro SFS mower. 1 Full Forward Position m–6840 Figure 26 1.
1 Breaking in a New Machine 2 New engines take time to develop full power. Mower decks and drive systems have higher friction when new, placing additional load on the engine. Allow 40 to 50 hours of break–in time for new machines to develop full power for best performance. 1 Transporting Machines Use a heavy–duty trailer or truck to transport the machine. Ensure that the trailer or truck has all necessary lighting and marking as required by law. Please carefully read all the safety instructions.
of the slope and the ramp extends up the slope. This will minimize the ramp angle. The trailer or truck should be as level as possible. Tips for Mowing Grass Important Do Not attempt to turn the unit while on the ramp; you may lose control and drive off the side. For best mowing and maximum air circulation, operate the engine at the fast throttle position. Air is required to thoroughly cut grass clippings, so do not set the height-of-cut so low as to totally surround the mower by uncut grass.
Long Grass If the grass is ever allowed to grow slightly longer than normal, or if it contains a high degree of moisture, raise the cutting height higher than usual and cut the grass at this setting. Then cut the grass again using the lower, normal setting. When Stopping If the machine’s forward motion must be stopped while mowing, a clump of grass clippings may drop onto your lawn. To avoid this, move onto a previously cut area with the blades engaged.
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.
Checking for Bent Blades Removing the Blades 1. Rotate the blades until the ends face forward and backward (Fig. 30). Measure from a level surface to the cutting edge, position A, of the blades (Fig. 31). Note this dimension. Blades must be replaced if a solid object is hit, if the blade is out of balance or is bent. To ensure optimum performance and continued safety conformance of the machine, use genuine TORO replacement blades.
3. Release the latches on the air cleaner and pull the air cleaner cover off of the air cleaner body (Fig. 35). blade is not balanced, file some metal off the end of the sail area only (Fig. 34). Repeat this procedure until the blade is balanced. 4. Clean the inside of the air cleaner cover with compressed air. 5. Gently slide the primary filter out of the air cleaner body (Fig. 35). Avoid knocking the filter into the side of the body. 2 1 m–1855 Figure 33 1. Blade 6.
1. If installing new filters, check each filter for shipping damage. Do not use a damaged filter. 3. Clean around the oil dipstick (Fig. 36) so dirt cannot fall into the filler hole and damage the engine. 2. If the safety filter is being replaced, carefully slide it into the filter body (Fig. 35). 4. Pull the oil dipstick and wipe the metal end clean (Fig. 36). 3. Carefully slide the primary filter over the safety filter (Fig. 35).
5. Install the replacement oil filter to the filter adapter. Turn the oil filter clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 1/2 turn (Fig. 38). 6. Fill the crankcase with the proper type of new oil; refer to Changing the Oil, page 32. 1 Servicing the Spark Plug Check the spark plug(s) after every 200 operating hours. Make sure the air gap between the center and side electrodes is correct before installing the spark plug.
7. Install a new filter and move the hose clamps close to the filter (Fig. 42). Important Never clean the spark plug(s). Always replace the spark plug(s) when it has: a black coating, worn electrodes, an oily film, or cracks. 8. Wipe up any spilled fuel. 2. Check the gap between the center and side electrodes (Fig. 40). Bend the side electrode (Fig. 40) if the gap is not correct. 2 9. Open fuel shut-off valve (Fig. 41). 3 1 0.030 inch (0.76 mm) 2 1 2 3 m–3215 Figure 40 1.
Note: Now is the best time to install a new fuel filter because the fuel tank is empty. 2. Remove the hex plug. Thread a grease zerk into the hole. 5. Install the fuel line onto the fuel filter. Slide the hose clamp close to the fuel filter to secure the fuel line (Fig. 42). 3. Pump grease into the zerk until it oozes out around the top bearing. 4. Remove the grease zerk in the hole. Install the hex plug and cap.
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 28. Grease with No. 2 general purpose lithium base or molybdenum base grease. Cleaning the Engine Screen and the Oil Cooler Important Make sure cutting unit spindles are full of grease weekly. Before each use, check and clean engine screen and oil cooler.
Checking the Tire Pressure 5. Check the distance from bottom of slot in nut to inside edge of hole. Two threads or less should be showing (Fig. 48). 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. 47). Check the tires when they are cold to get the most accurate pressure reading. 6.
Servicing the Hydraulic System 1 2 Checking the Hydraulic Fluid 4 Check the hydraulic fluid level: 3 • Before the engine is first started. • After the first 8 operating hours. • After every 25 operating hours. m–5615 Fluid Type: Mobil 1 15W-50 synthetic motor oil or equivalent synthetic oil. Figure 50 1. Cap 2. Baffle Important Use oil specified or equivalent. Other fluids could cause system damage. 3. Cold fluid level—full 4. Hot fluid level—full Hydraulic System Oil Capacity: 67 oz. (2.
Bleeding the Hydraulic System 3. Place a drain pan under filter, remove the old filter and wipe the filter adapter gasket surface clean (Fig. 51). 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.
Adjusting the Handle Neutral 2 9 1 6 If motion control levers do not align, or move easily into the console notch, adjustment is required. Adjust each lever, spring and rod separately. 7 3 Note: The motion control levers must be installed correctly. See Installing the Motion Control Levers in the set up instructions. 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2.
1. Raise the frame and use jack stands to hold up the machine so drive wheels can rotate freely. Setting the Left–hand Hydraulic Pump Neutral 2. Unlatch the seat, tilt the seat forward and 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.
2. Check if the machine pulls to one side. If it does, stop the machine and set the parking brake. 2. Install new belt around engine and hydro pump pulleys (Fig. 57). 3. Unlatch the seat and tip the seat up to access the tracking knob. 3. Pull spring loaded idler down and align below traction belt. Release pressure on spring loaded idler (Fig. 57). Note: Determine the left and right sides of the machine from the normal operating position. Adjusting the Parking Brake 4.
Servicing the Fuse 3. If the electrolyte is low, add the required amount of distilled water; refer to Adding Water to the Battery, page 44. 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. 1 2 Fuse: Main F1–30 amp, blade-type Alternator F2–25 amp, blade-type 3 1. Unlatch the seat and raise the seat to gain access to fuse holder (Fig. 59). m–5004 2.
4 5 11 7 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2 6 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 7 9 3. Unlatch the seat and tilt the seat up. 4. First disconnect the negative battery cable and ground wire from the negative (–) battery terminal (Fig. 61). 3 10 1 5. Slide the red terminal boot off the positive (red) battery terminal.
4. Check tire pressure of all four tires. If needed, adjust to 13 psi (90 kPa) Important Always keep the battery fully charged (1.265 specific gravity). This is especially important to prevent battery damage when the temperature is below 32°F (0°C). 5. Lower the mower to the 3 inch (76 mm) height–of–cut position. 1. Remove the battery from the chassis; refer to Removing the Battery, page 44. 6. Inspect the four chains. The chains need to have tension. 2.
6. The mower blade should be a 1/4 to 3/8 inch (6 to 10 mm) lower at position A than at position B (Fig. 66). If it is not correct, proceed to the following steps. 7. If the measurements at positions B or C are not correct, loosen the bolt attaching the rear chain to the rear support arm (Fig. 65). 8. Loosen the jam nut under the rear support arm and adjust the adjustment bolt to get a measurement of 3–1/8 to 3–1/4 inches.
4. Lock the nut into position by tightening the spring jam nut (Fig. 68). 8 Warning Mechanical or hydraulic jacks may fail to support the machine and cause a serious injury. 1 8 • Use jack stands when supporting the machine. • Do not use hydraulic jacks. 4 Inspecting the Belts Inspect all belts every 100 hours. 6 2 7 5 1. Check belts for cracks, frayed edges, burn marks or any other damage. Replace damaged belts. Front 3 Replacing the Mower Belt m–6831 Figure 68 1. 10–1/2 inch (26.
Important Check the amount of twist in the belt between the pulleys. Make sure it is only what is specified in Figure 69. 2 1 1 1 3 4 8 9 5 4 3 m–6824 4 Figure 70 3 2 1. Belt cover 4 6 10 Adjusting the Mower Belt Tension 7 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. m–7829 Figure 69 1. 2. 3. 4. 5. 2. Latch Clutch Mower belt 1/4 turn belt twist Belt guide Mower spindle pulley 6. 7. 8. 9. 10. 2.
6 4 3 1 5 2 3 M–4417 1 2 Figure 71 1. Center bolt 2. Alignment hole m–6825 3. Left support plate 4. Spring loaded idler 1 Figure 73 1. Spring loaded idler pulley 2. Top alignment hole 3. 0 to 1/4 inch gap (0 to 6 mm) 5. If adjustment is required, loosen the mower idler plate and adjust it (Fig. 72). 6. Insert a ratchet or breaker bar into the square hole in the mower idler plate to adjust the tension (Fig. 72). 4. Idler pulley arm 5. Belt 6. Rubber bumper 11.
1. Remove the locknut, bolt, spring and spacer holding the deflector to the pivot brackets (Fig. 75). Remove damaged or worn grass deflector. 2. Place spacer and spring onto grass deflector. Place the L end of spring behind deck edge. Note: Make sure the L end of spring is installed behind deck edge before installing the bolt as shown in figure 75. 3. Install bolt and nut. Place J hook end of spring around grass deflector (Fig. 75). Important The grass deflector must be able to lower down into position.
Wiring Diagram 51
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. 4. Tension spring is not connected. 4. Connect the tension spring. 1. Cutting blade(s) is/are bent or unbalanced. 1. Install new cutting blade(s). 2.
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.
