Form No. 3351–983 Z557 Z Master with 60in TURBO FORCE Side Discharge Mower Model No. 74246–250000001 & 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.
98-5954 104-8569 98-4387 1. Warning—wear hearing protection. 105-7797 103-5881 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 106-9969 107-1613 107-2102 107-1857 11
107-2112 107-1860 107-1861 106-7492 12
106-9989 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 13 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.
107-8076 107-1621 107-1622 14
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 Unlatch the seat and lift it up to view the hour meter (Fig. 8). Become familiar with all the controls (Fig. 7 and 8) before you start the engine and operate the machine. Operating the Parking Brake 8 7 Always set the parking brake when you stop the machine or leave it unattended. 6 Setting the Parking Brake 1 4 1. Move the motion control levers (Fig. 7) out to the neutral lock position. 3 2. Pull back and up on the parking brake lever to set the parking brake (Fig. 9).
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.
the engine is running, center either motion control and move (forward or reverse); the engine should stop. Repeat for other motion control. 2 3 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. Try starting the engine; the engine should not crank. 1 4 Driving Forward or Backward m–2715 Figure 15 The throttle control regulates the engine speed as measured in rpm (revolutions per minute).
1. Raise the height-of-cut lever to the transport position (also the 5 inch (127 mm) cutting height position) (Fig. 16). Adjusting the Anti-Scalp Rollers 2. To adjust, remove the clevis pin from the height-of-cut bracket (Fig. 16). Whenever you change the height-of-cut, it is recommended to adjust the height of the anti-scalp rollers. 3. Select a hole in height-of-cut bracket corresponding to the height-of-cut desired and, insert the clevis pin (Fig. 16). 1.
1 3 1 2 1 3 m–6844 m–6845 Figure 20 Figure 19 1. Anti–scalp roller 2. Bushing 2 5 4 1. Anti–scalp roller 2. Spacer 3. Bushing 3. Flange Nut 4. Bolt 4. Flange Nut 5. Bolt 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. 25). 2.
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 1 2 Push the seat latch rearward to unlatch the seat. This will allow access to the machine under the seat. 3 1 2 1 1 m–6840 Figure 26 1. Seat latch 2. Gas cap 3. Seat Figure 27 1. By-pass valve Pushing the Machine by Hand 2. Hydraulic tank Breaking in a New Machine Important Always push the machine by hand. Never tow the machine because hydraulic damage may occur. New engines take time to develop full power.
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.
Tips for Mowing Grass Warning Fast Throttle Setting Loading a unit onto a trailer or truck increases the possibility of backward tip–over and could cause serious injury or death. 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 33. 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.
8. Wipe up any spilled fuel. 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. 9. Open fuel shut-off valve (Fig. 41). 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 3 1 2 0.030 inch (0.76 mm) 1 2 3 m–6842 m–3215 Figure 41 Figure 40 1. Center electrode insulator 2. Side electrode 1. Filter 2. Hose clamp 3.
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. 4 Where to Add Grease Lubricate the grease fittings as shown on the Check Service Reference Aid decal (Fig. 43). 1 3 2 m–6842 Figure 42 1. Fuel shut-off valve 2. Fuel filter 3. Hose clamp 4.
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 Important Make sure cutting unit spindles are full of grease weekly. Before each use, check and clean engine screen and oil cooler.
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. 47). 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 48 1 1. Slotted Nut 2. Two threads or less showing 3. Hole in threaded rod 4.
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.
Replacing the Hydraulic Filter 10. Recheck the fluid level while the fluid is warm. The fluid should be between cold and hot. Change the hydraulic filter: 11. If required, add fluid to the hydraulic tank. Do not overfill. • After the first 8 operating hours. • After every 200 operating hours. Use summer filter above 32°F (0°C) 1 Use winter filter below 32°F (0°C) 3 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2 2.
Warning 2 3 Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • If hydraulic fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result if this is not done. • Keep body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid. • Use cardboard or paper to find hydraulic leaks.
Setting the Hydraulic Pump Neutral 4. Open the throttle to fast. Make sure wheel remains stopped or slightly creeps in reverse, adjust if necessary. Note: Adjust the handle neutral first. That has to be correct before the following adjustment can be made. 2 1 4 Danger Mechanical or hydraulic jacks may fail to support machine and cause a serious injury. • Use jack stand when supporting machine. • Do not use hydraulic jacks. Warning Engine must be running so motion control adjustment can be performed.
Warning 2 Electrical system will not perform proper safety shut off with jumper wire installed. 3 • Remove jumper wire from wire harness connector and plug connector into seat switch when adjustment is completed. • Never operate this unit with jumper installed and seat switch bypassed. 4 1 7. After both pump neutrals are set, shut off the machine. m–6280 8. Remove the jumper wire from the wire harness connector and plug the connector into the seat switch. Figure 56 1. Pump rod 2.
Adjusting the Parking Brake 2. To replace fuses pull out on the fuse to remove it 3. Install a new fuse (Fig. 59). Check parking brake for proper adjustment. 2 1. Disengage brake lever (lever down). 2. Measure the length of the spring. Measurement should be 2-3/4 inch (70 mm) between washers (Fig. 58). 1 3. If adjustment is necessary, loosen the jam nut below the spring and tighten the nut directly below the yoke (Fig. 58). Turn the nut until the correct measurement is obtained.
1 4 5 11 7 6 2 3 2 7 9 3 m–5004 Figure 60 1. Filler caps 2. Upper line 3. Lower line 10 1 8 m–5598 Figure 61 Danger 1. 2. 3. 4. 5. 6. Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns. • Do not drink electrolyte and avoid contact with skin, eyes or clothing. Wear safety glasses to shield your eyes and robber gloves to protect your hands. • Fill the battery where clean water is always available for flushing the skin.
Removing the Battery Adding Water to the Battery Note: Never fill the battery with distilled water while the battery installed in the machine. Electrolyte could be spilled on other parts and cause corrosion. Warning Battery terminals or metal tools could short against metal machine components causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. The best time to add distilled water to the battery is just before you operate the machine.
• If one front chain is loose, raise (tighten) the front support arm for that chain. Refer to Adjusting the Front–to–Rear Mower Pitch on page 48. 4. When the battery is fully charged, unplug the charger from the electrical outlet, then disconnect the charger leads from the battery posts (Fig. 62). Leveling the Mower Side–to–Side 4 2 1. Position the right blade front-to-rear (Fig. 63). 3 2. Measure the right blade at the B location (Fig.
10. Adjust the opposite side if needed. Front 2 MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE 6 m–2539 Figure 67 Note: Both of the front swivels need to be adjusted the same amount to maintain equal chain tension. 2 7 1 3 7. Loosen the front swivel jam nuts, at the front of the right and left swivels, approximately a 1/2 inch (13 mm) (Fig. 68). 4 1 5 m–6830 8.
3. Adjust this distance, by loosening the spring jam nut and turning the nut in front of each spring (Fig. 68). Turning the nut clockwise will shorten the spring; counter–clockwise will lengthen the spring. 3. Remove the belt covers (Fig. 70). 4. Loosen the nut securing the idler plate and move the idler plate to relieve the belt tension on the idler pulley (Fig. 72). 4. Lock the nut into position by tightening the spring jam nut (Fig. 68). 5.
Adjusting the Mower Belt Tension 2 1 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 1 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 69. m–6824 Figure 70 1.
8. Tighten the idler plate bolts (Fig. 72). 11. If the mower idler plate contacts the 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. 74). 3 4 1 2 2 m–3746 1 m–6826 Figure 74 Figure 72 1. Mower idler plate 2. Square hole 1. Fixed Idler 3. Ratchet or breaker bar 4. Idler plate bolt Replacing the Grass Deflector 9.
9. Scrape any heavy buildup of grass and dirt from the underside of the mower, then wash the mower with a garden hose. Important The grass deflector must be able to lower down into position. Lift the deflector up to test that it lowers into the full down position. 6 2 Note: Run the macine with the PTO engaged and the engine at high idle for 2 to 5 minutes after washing. 4 8 7 10. Check the condition of the blades. Refer to Servicing the Cutting Blades on page 30. 3 1 11.
Wiring Diagram 53
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.
