Form No. 3351–995 Z557 Z Master with 72in TURBO FORCE Side Discharge Mower Model No. 74247–250000001 & 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 43-8480 1-643339 54-9220 1-523552 58-6520 1. Grease 98-4387 1. Warning—wear hearing protection.
5-7797 66-1340 104-8569 68-8340 98-5954 105-7798 107-1613 103-0368 107-1864 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.
107-1621 107-2102 106-9969 107-1622 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 before you start the engine and operate the machine (Figures 7 and 8). 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). 1. Disengage the power take off (PTO) and turn the ignition key to off. Move levers to neutral locked position and apply the parking brake. Remove the key. 4. Move the lever to the selected height. 2. After adjusting the height-of-cut, adjust the rollers by removing the flange nut, bushing, spacer, and bolt (Fig. 18). 1 2 4 m–6820 2 Figure 16 1. Height of cut lever 2.
Positioning the Flow Baffle 5. Repeat this adjustment on the other anti–scalp rollers. 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 • Use for short, light grass mowing conditions. 1 3 m–6844 • Use in dry conditions.
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. Servicing the Cutting Blades 2. Inspect the blades, especially the curved area (Fig. 29).
F ront Warning A Contact with sharp blade can cause serious injury. A A Wear gloves or wrap sharp edges of the blade with a rag. 1. Hold the blade end using a rag or thickly-padded glove. Remove the blade bolt, spring disk and blade from the spindle shaft (Fig. 34). m–1078 Figure 30 Sharpening the Blades Warning MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE When sharpening blade, pieces of blade could be thrown and cause serious injury. Wear proper eye protection when sharpening blade.
7. Inspect the primary filter for damage by looking into the filter while shining a bright light on the outside of the filter. Holes in the filter will appear as bright spots. If the filter is damaged discard it. Important The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting. 2. Install the spring disk and blade bolt (Fig. 34). Torque the blade bolt to 85–110 ft-lb (115–150 N m). 3 3 4 1 5 4 2 1 3 5 4 2 1 M–4226 Figure 35 Figure 34 1.
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 36 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 PTO, move the motion control levers to the neutral locked position and set the parking brake. Note: Change the oil filter more frequently when operating conditions are extremely dusty or sandy. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 1.
2 3 1 0.030 inch (0.76 mm) 2 m–3215 1 2 3 Figure 40 1. Center electrode insulator 2. Side electrode 3. Air gap (not to scale) m–6842 Figure 41 1. Filter 2. Hose clamp 3. Fuel shut-off valve Installing the Spark Plug(s) 1. Install the spark plug(s). Make sure the air gap is set correctly. Servicing the Fuel Tank 2. Tighten the spark plug(s) to 20 ft-lb (27 N m). Draining The Fuel Tank 3. Push the wire(s) onto the spark plug(s) (Fig. 39).
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.
Important Make sure cutting unit spindles are full of grease weekly. 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. 2 ÓÓÓ ÓÓÓ ÓÓÓ ÓÓÓ ÓÓÓ 1 m–3801 Figure 45 3. Grease the three spindle bearings under the pulleys until grease comes out the lower seals (Fig. 44). 1. Engine screen 2. Oil cooler 4.
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 Check the hydraulic fluid level: 4 • Before the engine is first started. 3 • After the first 8 operating hours. • After every 25 operating hours. Fluid Type: Mobil 1 15W-50 synthetic motor oil or equivalent synthetic oil. m–5615 Figure 50 Important Use oil specified or equivalent. Other fluids could cause system damage. 1. Cap 2. Baffle 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.
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.
1. Remove the battery from the machine. 4 2. Clean the top of the battery with a paper towel. 2 3. Remove the vent caps from the battery (Fig. 60). 3 4. Slowly pour distilled water into each battery cell until the level is up to the upper line (Fig. 60) on the battery case. 1 Important Do not overfill the battery because electrolyte (sulfuric acid) can cause severe corrosion and damage to the chassis. m–4970 5. Wait five to ten minutes after filling the battery cells.
Leveling the Mower Side–to–Side Front 1. Position the right blade front-to-rear (Fig. 63). 2 2. Measure the right blade at the B location (Fig. 63), from a level surface to the cutting edge of the blade tip (Fig. 64). 6 3. Record this measurement. This measurement needs to be 3–1/8 to 3–1/4 inches. 4. Position the left blade front-to-rear (Fig. 63). 5. Measure the left blade at the C location (Fig. 63), from a level surface to the cutting edge of the blade tip (Fig. 64). 2 7 1 3 4 1 6.
8 1 8 MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE 4 m–2539 Figure 67 Note: Both of the front swivels need to be adjusted the same amount to maintain equal chain tension. 6 2 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). 7 5 Front 3 m–6831 Figure 68 8. Adjust the lift nuts on both the left and the right side of the machine to achieve 1/4 to 3/8 inch (6 to 10 mm) lower in front at A than in the rear at B (Fig. 68). 1.
Replacing the Mower Belt 1 3 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. 4 8 9 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 5 4 3 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 4 3.
Adjusting the Mower Belt Tension 3 4 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. 3. Raise the mower to the transport position. 2 Important Check the amount of twist in the belt between the pulleys. Make sure it is only what is specified in Figure 69.
6 1 2 4 8 7 2 3 1 8 7 m–3746 Figure 74 1. Fixed Idler 2. Adjustment slot 5 m–6846 Figure 75 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.
Cleaning and Storage B. Run engine to distribute conditioned fuel through the fuel system (5 minutes). 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. C. Stop engine, allow to cool and drain the fuel tank; refer to Servicing the Fuel Tank, page 34. D. Restart engine and run it until it stops. 2.
PTO CLUTCH GND BK BK BN VIO VIO Y SHOWN WITH SW5 LEVER IN (NEUTRAL) NEUTRAL POSITION W SHOWN WITH SW4 LEVER IN (NEUTRAL) NEUTRAL POSITION SHOWN WITH PARK BRAKE DISENGAGED SW3 (BRAKE) Y SHOWN IN OFF POSITION GY BN SW2 (PTO) OR BK P1–B T Y K2 (START RELAY) P2–C SW6 (SEAT SW) SHOWN WITH OPERATOR IN SEAT SW7 (TILT SW) SWITCH OPENS WHEN TILTED PAST 60 DEGREES FROM VERTICAL TERMINAL VIEW FROM BACK OF SWITCH P1–A DELAY MODULE 100–6186 P1–C PK S I A B KEY SW Y X GY BN GY GN F1 20
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.
