Form No. 3350–919 Z557 Z Master with 152cm TURBO FORCE Side Discharge Mower Model No. 74246TE—240000001 & Up Operator’s Manual Register your product at www.Toro.
This spark ignition system complies with Canadian ICES-002. Tips for Mowing Grass . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Maintenance Schedule . . . . . . . . Servicing the Cutting Blades . . . . . . . . . . . . . . . . Servicing the Air Cleaner . . . . . . . . . . . . . . . . . . Servicing the Engine Oil . . . . . . . . . . . . . . . . . . . Servicing the Spark Plug . . . . . . . . . . . . . . . . . . .
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. Safe Operation Practices for Ride-on (riding) Rotary Lawnmower Machines This machine meets or exceeds European Standards in effect at the time of production.
• lack of awareness of the effect of ground conditions, especially slopes; – use slow speeds on slopes and during tight turns; – stay alert for humps and hollows and other hidden hazards; • incorrect hitching and load distribution. • Use care when pulling loads or using heavy equipment. Preparation • While mowing, always wear substantial footwear and long trousers. Do not operate the equipment when barefoot or wearing open sandals. – Use only approved drawbar hitch points.
• Reduce the throttle setting during engine run-out and, if the engine is provided with a shut-off valve, turn the fuel off at the conclusion of mowing. Slope Operation • Do not mow slopes greater than 15 degrees. • Do not mow near drop–offs, ditches, steep banks or water. Wheels dropping over edges can cause rollovers, which may result in serious injury, death or drowning. Maintenance and Storage • Keep all nuts, bolts and screws tight to be sure the equipment is in safe working condition.
Sound Pressure This unit has a maximum sound pressure level at the operator ’s ear of 90 dBA, based on measurements of identical machines per Directive 98/37/EC. Sound Power This unit has a guaranteed sound power level of 105 dBA, based on measurements of identical machines per Directive 2000/14/EC. Vibration This unit does not exceed a hand/arm vibration level of 2.15 m/s2, based on measurements of identical machines per Directive 98/37/EC. This unit does not exceed a whole body vibration level of 0.
Slope Chart 7
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. 1-643339 99-8939 1. Read the Operator’s Manual. 2. Height of cut 3. Remove the ignition key and read the instructions before servicing or performing maintenance. 54-9220 98-1977 1. Entanglement hazard, belt—stay away from moving parts. 58-6520 1. Grease 98-4387 1. Warning—wear hearing protection.
93-7828 1. Thrown object hazard, mower—do not operate the mower with the deflector up or removed; keep the deflector in place. 2. Cutting/dismemberment hazard of hand or foot, mower blade—stay away from moving parts. 93-7010 1. Thrown object hazard—stay a safe distance from the machine. 2. Thrown object hazard, mower—keep the deflector in place. 3. Cutting/dismemberment of hand or foot—stay away from moving parts. Battery Symbols Some or all of these symbols are on your battery. 1. Explosion hazard 2.
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 distance from drop–offs; do not turn sharply while traveling fast, instead, slow down and turn gradually; if the roll bar is raised, wear the seat belt; if the roll bar is lowered, do not wear the seat belt. 107-3069 1. Warning—there is no rollover protection when the roll bar is down. 2.
107-2131 1. Hydraulic oil level 2. Warning—do not touch the hot surface. 107-3962 1. Height of cut in millimeters 107-3961 1. Height of cut in millimeters 107-3965 1. 2. 3. 4. 12 Engine—stop Engine—run Engine—start Power take-off (PTO) 5. Fast 6. Continuous variable setting 7.
107-3968 1. Disengage 2. Engage 3. Parking brake 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. 107-3984 1. Read the instructions before servicing or performing maintenance. 2. Grease every 25 operating hours. 3. Engine 4. Check the tire pressure every 25 operating hours. 5. Check the hydraulic oil level every 25 operating hours. 107-3978 1.
107-3996 1. Engine 2. Cutting blade 107-3963 1. Cutting/dismemberment hazard, mower blade—do not carry passengers and keep bystanders away. 2. Cutting/dismemberment hazard of hand or foot, mower blade— remove the ignition key and read the instructions before servicing or performing maintenance; stay away from moving parts. 14 3. Thrown object hazard—keep bystanders a safe distance from the machine and keep the deflector in place. 4.
107-3964 1. Warning—do not use drugs or alcohol. 2. Warning—read the Operator’s Manual and receive training. 3. Warning—engage the parking brake, stop the engine, and remove the ignition key before leaving the machine. 1. 2. 3. 4. 5. 6. Poison and caustic liquid/chemical burn hazard—contains mercury; do not discard; do not adjust or open the switch; keep children a safe distance from the battery. 4. Warning—wear hearing protection. 5. Read the Operator’s Manual.
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–6836 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).
Starting and Stopping the Engine 1 1 2 Starting the Engine 3 1. Sit on the seat and move the motion controls to neutral locked position. 2 2. Set the parking brake; refer to Setting the Parking Brake, page 19. 3. Move the PTO (power take off) switch to the off position (Fig. 10). Figure 12 4. Move the choke control to the on position before starting a cold engine. Figure 13 1. Throttle–Fast 2. Throttle–Slow 1. Off 2. Run 3. Start Note: A warm or hot engine may not require choking.
• You are sitting on the seat. Engaging the PTO • The parking brake is engaged. 1. While seated in the seat, release pressure on the traction control levers and place in neutral. • The power take off (PTO) is disengaged. 2. Place the throttle to the fast position. • The motion control levers are in neutral locked position. 3. Pull out on the power take off (PTO) switch to engage (Fig. 14).
Driving Backward Caution 1. Move the levers to the center, un-locked position. Machine can spin very rapidly. Operator may lose control of machine and cause personal injury or damage to machine. 2. To go backward, slowly pull the motion control levers rearward (Fig. 15). To go straight, apply equal pressure to both motion control levers (Fig. 15). • Use caution when making turns. • Slow the machine down before making sharp turns.
3. Select a hole so the anti–scalp roller is positioned to the nearest corresponding height-of-cut desired (Fig. 18). 1 4. Install the flange nut bushing, spacer, and bolt. Torque to 40–45 ft–lb (54–61 N⋅m) (Fig. 18). 2 5. Repeat this adjustment on the other anti–scalp rollers. m–6820 Figure 16 1. Height of cut lever 2. Clevis Pin 4 Using the Lift Assist Lever 2 The lift assist lever is used along with the height–of–cut lever for raising the mower. This allows for easier raising of the mower.
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. 4 • Use for short, light grass mowing conditions. 2 5 1 3 m–6844 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.
Transporting Machines 1 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. Knowing this information could help you, your family, pets or bystanders avoid injury. To transport the machine: • Lock the brake and block the wheels. • Securely fasten the machine to the trailer or truck with straps, chains, cable, or ropes.
Warning Warning Loading a unit onto a trailer or truck increases the possibility of backward tip–over and could cause serious injury or death. Unit could fall onto someone and cause serious injury or death. • Use extreme caution when operating unit on Z Stand. • Use only for cleaning mower and removing blades. • Do not keep unit on Z Stand for extended periods of time. • Always turn the engine off, set the parking brake and remove the key before performing any maintenance to mower.
3. Raise the latch. Swing the stand foot out front and slide stand toward machine, into the bottom of slot (Fig. 29 and 30). Tips for Mowing Grass 4. Set the foot of stand on the ground and rest the latch on the pivot tab (Fig. 30). 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. 33). Measure from a level surface to the cutting edge, position A, of the blades (Fig. 34). 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. 38). blade is not balanced, file some metal off the end of the sail area only (Fig. 37). 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. 38). Avoid knocking the filter into the side of the body. 2 1 m–1855 Figure 36 1. Blade 6.
Installing the Filters 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Important To prevent engine damage, always operate the engine with both air filters and cover installed. 3. Clean around the oil dipstick (Fig. 39) so dirt cannot fall into the filler hole and damage the engine. 1. If installing new filters, check each filter for shipping damage. Do not use a damaged filter. 4. Pull the oil dipstick and wipe the metal end clean (Fig.
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. 41). 6. Fill the crankcase with the proper type of new oil; refer to Changing the Oil, page 34. 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. 44). 2. Check the gap between the center and side electrodes (Fig. 43). Bend the side electrode (Fig. 43) if the gap is not correct. 2 3 1 2 0.030 inch (0.76 mm) 1 2 3 m–6842 m–3215 Figure 44 Figure 43 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. 45). 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. 46). 1 3 2 m–6842 Figure 45 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 30. 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. 50). 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 51 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 53 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 59 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. 62). 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. 61). 1 3. If adjustment is necessary, loosen the jam nut below the spring and tighten the nut directly below the yoke (Fig. 61). Turn the nut until the correct measurement is obtained.
Removing the Battery Danger Warning Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns. 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. • 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.
Adding Water to the Battery 4. When the battery is fully charged, unplug the charger from the electrical outlet, then disconnect the charger leads from the battery posts (Fig. 65). 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. 4 The best time to add distilled water to the battery is just before you operate the machine. This lets the water mix thoroughly with the electrolyte solution. 2 3 1.
• 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. 10. Adjust the opposite side if needed. Front 2 Leveling the Mower Side–to–Side 6 1. Position the right blade front-to-rear (Fig. 66). 2. Measure the right blade at the B location (Fig. 66), from a level surface to the cutting edge of the blade tip (Fig. 67). 3. Record this measurement. This measurement needs to be 3–1/8 to 3–1/4 inches. 2 7 1 4.
3. Adjust this distance, by loosening the spring jam nut and turning the nut in front of each spring (Fig. 71). Turning the nut clockwise will shorten the spring; counter–clockwise will lengthen the spring. 4. Lock the nut into position by tightening the spring jam nut (Fig. 71). MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE m–2539 Cleaning Under the Mower Figure 70 Remove the grass buildup under the mower daily.
Adjusting the Mower Belt Tension 4. Remove the belt covers (Fig. 73). 5. Loosen the nut securing the idler plate and move the idler plate to relieve the belt tension on the idler pulley, then remove the worn mower belt (Fig. 75). 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 6. Install the new mower belt around the mower spindle pulleys, mower idler pulley, into the belt guides, into rear idler arm assembly, and the clutch (Fig. 72). 2.
8. Tighten the idler plate bolts (Fig. 75). 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. 77). 3 4 1 2 2 m–3746 1 m–6826 Figure 77 Figure 75 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 machine 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 31. 3 1 11.
BK BK BN GND PTO CLUTCH VIO (NEUTRAL) SW5 W VIO Y SHOWN WITH LEVER IN NEUTRAL POSITION SHOWN WITH LEVER IN NEUTRAL POSITION Y SHOWN IN OFF POSITION GY SW4 (NEUTRAL) SHOWN WITH PARK BRAKE DISENGAGED SW3 (BRAKE) BN SW2 (PTO) OR BK P1–B T Y SW6 (SEAT SW) SHOWN WITH OPERATOR IN SEAT K2 (START RELAY) P2–C P1–A DELAY MODULE 100–6186 P1–C PK B KEY SW S I TERMINAL VIEW FROM BACK OF SWITCH A Y X NO CONNECTION BIA AND X Y BIS GY GY BN PK PK F1 30A BK Y R R B K1 (KILL R
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.
