Form No. 3358-881 Rev A Z550 Z Master®with 52in, 60in or 72in TURBO FORCE® Side Discharge Mower Model No. 74271—Serial No. 280000001 and Up Model No. 74272—Serial No. 280000001 and Up Model No. 74273—Serial No. 280000001 and Up Register at www.Toro.com.
Warning CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Important: This engine is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate the engine on any forest-covered, brush-covered, or grass-covered land. Other states or federal areas may have similar laws. Figure 1 1.
Using the Rollover Protection System (ROPS) .......................................................... 14 Think Safety First ............................................... 15 Operating the Parking Brake ............................... 16 Starting and Stopping the Engine ........................ 17 Operating the Power Take Off (PTO) ................. 18 The Safety Interlock System................................ 18 Driving Forward or Backward............................. 19 Stopping the Machine.............
Safety • Use extra care when handling gasoline and other fuels. They are flammable and vapors are explosive. – Use only an approved container – Never refuel or drain the machine indoors. – Never remove gas cap or add fuel with engine running. Allow engine to cool before refueling. Do not smoke. • Check that operator’s presence controls, safety switches and shields are attached and functioning properly. Do not operate unless they are functioning properly.
• Check the area to be mowed and never fold the ROPS in areas where there are slopes, drop offs or water. • Use extreme care when loading or unloading the machine into a trailer or truck. • Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision. • Lower the rollbar only when absolutely necessary. Do not wear the seat belt with the roll bar folded down. Slope Operation • Check carefully for overhead clearances (i.e.
Slope Chart 6
Safety and Instructional 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. 1-403005 54-9220 1-523552 58-6520 1.
98-4387 1. Warning—wear hearing protection.
107-2112 107-1861 107-1860 107-1864 107-1613 9
Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 2. No fire, open flame, 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. 7. Wear eye protection; explosive gases can cause blindness and other injuries 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. 10. Contains lead; do not discard.
106-7492 106-9989 107-8076 1. Fast 3. Neutral 2. Slow 11 4.
Controls Product Overview Become familiar with all the controls before you start the engine and operate the machine (Figure 3 and Figure 4). Figure 4 1. Gas cap 2. Choke 3. Ignition switch Figure 3 1. 2. 3. 4. Motion control lever Parking brake lever Height-of-cut lever Fuel cap (both sides) 5. Controls 6. Seat belt 7. Roll bar 4. Throttle 5. Power take off (PTO) 6. Hour meter Hour Meter The hour meter records the number of hours the engine has operated. It operates when the engine is running.
Operation Authorized Service Dealer or Distributor or go to www.Toro.com for a list of all approved attachments and accessories. Note: Determine the left and right sides of the machine from the normal operating position. Adding Fuel Use unleaded regular gasoline suitable for automotive use (85 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available.
Important: Do not use fuel additives containing methanol or ethanol. In certain conditions during fueling, static electricity can be released causing a spark which can ignite the gasoline vapors. A fire or explosion from gasoline can burn you and others and can damage property. Add the correct amount of gas stabilizer/conditioner to the gas. Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline.
Important: Always use the seat belt with the roll bar in the raised position. There is no rollover protection when the roll bar is in the down position. 1 • Lower the roll bar only when absolutely necessary. 2 • Do not wear the seat belt when the roll bar is in the down position. • Drive slowly and carefully. • Raise the roll bar as soon as clearance permits. • Check carefully for overhead clearances (i.e. branches, doorways, electrical wires) before driving under any objects and do not contact them.
Operating on wet grass or steep slopes can cause sliding and loss of control. This machine produces sound levels in excess of 85 dBA at the operators ear and can cause hearing loss through extended periods of exposure. Wheels dropping over edges can cause rollovers, which may result in serious injury, death or drowning. Wear hearing protection when operating this machine. There is no rollover protection when the roll bar is down.
Figure 11 Figure 9 1. Parking brake-ON 2. Parking brake-OFF 1. Choke—on 2. Choke—off 3. Brake Stop 5. Move the throttle control to the Fast position before starting a cold engine (Figure 12). Starting and Stopping the Engine Starting the Engine 1. Sit on the seat and move the motion controls to neutral locked position. 2. Set the parking brake; refer to Setting the Parking Brake. 3. Move the PTO (power take off) switch to the Off position (Figure 10). Figure 12 1. Throttle—fast 2. Throttle—slow 6.
Engaging the PTO 1. If the engine is cold, allow the engine to warm up 5 to 10 minutes before engaging the PTO. 2. While seated in the seat, release the pressure on the traction control levers and place in neutral. 3. Place the throttle in the fast position. Note: Engaging the PTO with the throttle at the half or less position will cause excessive wear to the drive belts. 4. Pull out on the power take off (PTO) switch to engage it (Figure 14). Figure 13 1. Off 2. Run 3. Start 7.
• You are sitting on the seat. • The parking brake is engaged. Machine can spin very rapidly. Operator may lose control of machine and cause personal injury or damage to machine. • The power take off (PTO) is disengaged. • The motion control levers are in the neutral locked position • Use caution when making turns.
Children or bystanders may be injured if they move or attempt to operate the tractor while it is unattended. Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes. Adjusting the Control Lever Resistance The top damper mounting bolt can be adjusted to obtain a desired motion control lever resistance. Refer to Figure 16 for the mounting options. Torque the bolt to 200 in-lb (22.6 N⋅m). Figure 15 1.
Figure 17 1. Height of cut lever 2. Clevis Pin Figure 18 2. To adjust, remove the clevis pin from the height-of-cut bracket (Figure 17). 1. Outer roller 2. Spacer 3. Bushing 3. Select a hole in the height-of-cut bracket corresponding to the height-of-cut desired and, insert the clevis pin (Figure 17). 4. Bolt 5. Nut 4. Move the lever to the selected height. 4. Select a hole so that the outer roller is positioned to the nearest corresponding height-of-cut desired (Figure 18).
Figure 20 3. Rotate cam to increase or decrease locking pressure 4. Slot 1. Cam lock 2. Lever Figure 19 1. Outer roller 2. Spacer 3. Bushing Positioning the Flow Baffle 4. Bolt 5. Nut The following figures are only recommendations for use. Adjustments will vary by grass type, moisture content, and height of grass. 4. Select a hole so that the center rollers are positioned to the nearest corresponding height-of-cut desired (Figure 19).
1. Place your foot onto lift assist lever. 2. Press on the lift assist lever while pulling up on the height-of-cut lever (Figure 24). Figure 24 1. Lift Assist Lever Figure 22 Positioning the Seat Position C The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable. This is the full open position. The suggested use for this position is as follows. • Use in tall, dense grass mowing conditions.
Figure 26 1. Seat latch 2. Fuel cap 3. Seat Pushing the Machine by Hand Figure 27 1. By-pass valve 2. Controls Important: Always push the machine by hand. Never tow the machine because hydraulic damage may occur. 3. Disengage parking brake before pushing. Pushing the Machine Changing to Machine Operation 1. Disengage the power take off (PTO) and turn the ignition key to off. Move the levers to neutral locked position and apply parking brake. Remove the key.
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 the 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.
Loading a unit onto a trailer or truck increases the possibility of backward tip-over and could cause serious injury or death. to thoroughly cut grass clippings, so do not set the height-of-cut so low as to totally surround the mower by uncut grass. Always try to have one side of the mower free from uncut grass, which allows air to be drawn into the mower. • Use extreme caution when operating a unit on a ramp.
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. Keep the Underside of the Mower Clean Clean clippings and dirt from the underside of the mower after each use.
Maintenance Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 8 hours • Change the engine oil. • Check the hydraulic fluid level. After the first 25 hours • Change the hydraulic filter. Before each use or daily • • • • • • Check the safety interlock system. Check the engine oil. Clean the engine screen and the oil cooler. Check the mower blades. Clean the hydraulic pump shrouds. Clean the mower deck.
Lubrication Greasing and Lubrication Lubricate the machine when shown on the Check Service Reference Aid decal (Figure 29). Grease more frequently when operating conditions are extremely dusty or sandy. Grease Type: General-purpose grease. How to Grease 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.
Engine Maintenance Servicing the Air Cleaner Note: Check the filter more frequently (every few hours) if operating conditions are extremely dusty or sandy. Removing the Filters 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. Figure 30 3. Clean around the air cleaner to prevent dirt from getting into the engine and causing damage.
Replacing the Primary Air Filter Checking the Engine Oil Level Service Interval: Every 250 hours Service Interval: Before each use or daily Do not clean the primary filter. Note: Check the oil when the engine is cold. 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.
3. Disengage the PTO and set the parking brake. 4. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 5. Slide the drain hose over the oil drain valve. 6. Place a pan below the drain hose. Rotate oil drain valve to allow oil to drain (Figure 34). 7. When oil has drained completely, close the drain valve. 8. Remove the drain hose (Figure 34). Figure 35 1. Engine oil filter Note: Dispose of the used oil at a recycling center. 3.
Removing the Spark Plug 2. Check the gap between the center and side electrodes (Figure 38). Bend the side electrode (Figure 38) if the gap is not correct. 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. Pull the wire(s) off the spark plug(s) (Figure 37).
Servicing the Fuel Tank Fuel System Maintenance 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. Replacing the Fuel Filter Service Interval: Every 200 hours or yearly, whichever occurs first. • Drain gasoline from the fuel tank when the engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills. Never install a dirty filter if it is removed from the fuel line. 1.
Electrical System Maintenance Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. Servicing the Battery • Always Disconnect the negative (black) battery cable before disconnecting the positive (red) cable.
6. Remove both wing nuts (1/4 inch) securing the battery clamp (Figure 40). 7. Remove the battery. Installing the Battery 1. Position battery in the tray with the terminal posts toward the engine (Figure 40). 2. First, install the positive (red) battery cable to positive (+) battery terminal. 3. Then install the negative battery cable and ground wire to the negative (-) battery terminal. 4. Secure the cables with 2 bolts (1/4 x 3/4 inch), 2 washers (1/4 inch), and 2 locknuts (1/4 inch) (Figure 40).
Drive System Maintenance Check the pressure at the valve stem (Figure 44). Adjusting the Tracking Maintain the air pressure in the rear tires at 13 psi (90 kPa). Uneven tire pressure can cause uneven cut. Check the tires when they are cold to get the most accurate pressure reading. Note: Determine the left and right sides of the machine from the normal operating position. Note: The front tires are semi-pneumatic tires and do not require air pressure maintenance.
Figure 45 1. Slotted Nut 2. Two threads or less showing 3. Hole in threaded shaft 4. Washer (if needed) 5. Check the distance from bottom of slot in nut to inside edge of hole. Two threads or less should be showing (Figure 45). Figure 46 6. If more than two threads are showing remove nut and install washer between hub and nut. 1. Spring Washers 2. Lock Nut 7. Torque the slotted nut to 125 ft-lb. (170 N⋅m) (Figure 45). 3. Dust Cap 4.
Cooling System Maintenance Brake Maintenance Cleaning the Engine Screen and the Oil Cooler Service Interval: Every 200 hours Service Interval: Before each use or daily 1. Disengage brake lever (lever down). Check and clean engine screen and oil cooler. Remove any build-up of grass, dirt or other debris from the oil cooler screen and engine screen (Figure 47 and Figure 48). 2. Measure the length of the spring. Adjusting the Parking Brake Check the parking brake for proper adjustment.
Belt Maintenance Inspecting the Belts Service Interval: Every 100 hours Check belts for cracks, frayed edges, burn marks or any other damage. Replace damaged belts. Replacing the Mower Belt 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. 1. Disengage the PTO, move the motion control levers to the neutral locked position, and set the parking brake.
Adjusting the Mower Belt Tension 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. Important: Check the amount of twist in the belt between the pulleys. Make sure it is only what is specified in Figure 50. Figure 53 1. Mower idler plate 2.
Controls System Maintenance Adjusting the Control Handle Neutral Position If motion control levers do not align, or move easily into the console notch, adjustment is required. Adjust each lever, spring and rod separately. Figure 55 1. Fixed idler Note: Motion control levers must be installed correctly. See Installing the Motion Control Levers in the set up instructions. 2. Adjustment slot 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake.
Hydraulic System Maintenance 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 the neutral lock position (Figure 58). Checking the Hydraulic Fluid Note: Keeping rearward pressure on the lever will keep the pin at the end of the slot and allow the adjustment bolt to move the lever to the appropriate position.
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. Figure 60 1. Hydraulic filter 2. Gasket • Use cardboard or paper to find hydraulic leaks. 3. Adapter 4.
Bleeding the Hydraulic System Setting the Hydraulic Pump Neutral Position 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. Note: Adjust the handle neutral first. That needs to be correct before the following adjustment can be made. 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.
Figure 63 1. 2. 3. 4. 5. 6. Figure 62 1. Pump rod 2. Double nuts 3. Lock nut 4. Ball joint 5. Yoke 6. Adjustment bolt 4. Move the motion control lever forward and reverse, then back to neutral. The wheel must stop turning or slightly creep in reverse. Clevis pin in slot Nut against yoke Adjustment bolt Pump rod Double nuts Jam nut 7. 8. 9. 10. 11. Spring Pivot shaft Yoke Locknut Ball joint 2. Start the engine, open throttle 1/2 way, and release parking brake.
Mower Deck Maintenance 7. After both pump neutrals are set, shut off the machine. 8. Remove the jumper wire from the wire harness connector and plug the connector into the seat switch. Leveling the Mower at Three Positions 9. Install the seat rod and lower the seat into position. 10. Remove the jack stands. Important: There are only three measuring positions needed to level the mower. Setting Up the Machine 1. Position mower on a flat surface. 2.
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 (80 to 83 mm)(Figure 65). Note: It is recommended that both sides of the mower are adjusted the same distance. 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 Figure 64 1. Measure here from blade to hard surface 1.
Servicing the Cutting Blades 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 (Figure 65). Maintain sharp blades throughout the cutting season because sharp blades cut 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. 9.
A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders. • Always replace bent or damaged blade with a new blade. • Never file or create sharp notches in the edges or surfaces of blade. Figure 68 1. Cutting Edge 2. Curved Area 3. Wear/slot Forming 4. Crack Removing the Blades 2. Inspect the blades, especially the curved area (Figure 68). Blades must be replaced if a solid object is hit, if the blade is out of balance or is bent.
Replacing the Grass Deflector 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. Figure 70 1. Sharpen at original angle • Never operate the lawn mower unless you install a cover plate, a mulch plate, or a grass chute and catcher. 2. Check the balance of the blade by putting it on a blade balancer (Figure 71).
Waste Disposal Cleaning Engine oil, batteries, hydraulic oil, and engine coolant are pollutants to the environment. Dispose of these according to your state and local regulations. Cleaning the Hydraulic Pump Shrouds Service Interval: Before each use or daily 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.
Storage C. Stop engine, allow to cool and drain the fuel tank; refer to Servicing the Fuel Tank in Fuel System Maintenance , page 34. 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. 2. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine and hydraulic system. Clean dirt and chaff from the outside of the engine’s cylinder head fins and blower housing. 3. 4. 5. 6.
Troubleshooting Problem Starter does not crank Engine will not start, starts hard, or fails to keep running. Possible Cause 1. Blade control (PTO) is engaged. 1. Move blade contro (PTO) to disengaged. 2. 3. 4. 5. Parking brake is not on. Operator is not seated. Battery is dead. Electrical connections are corroded or loose. 6. Fuse is blown. 7. Relay or switch is defective. 2. 3. 4. 5. 1. Fuel tank is empty. 1. Fill fuel tank with fuel. 2. Air cleaner is dirty. 2.
Problem Uneven cutting height. Blades do not rotate. Possible Cause Corrective Action 1. Blade(s) not sharp. 1. Sharpen the blade(s). 2. Cutting blade(s) is/are bent. 3. Mower is not level. 4. Underside of the mower is dirty. 5. Tire pressure is not correct. 6. Blade spindle bent. 2. Install new cutting blade(s). 3. Level mower from side-to-side and front-to-rear. 4. Clean the underside of the mower. 5. Adjust the tire pressure. 6. Contact an Authorized Service Dealer. 1.
Schematics Wire Diagram (Rev.
Notes: 57
Notes: 58
Notes: 59
The Toro Total Coverage Guarantee Landscape Contractor Equipment (LCE) A Limited Warranty Conditions and Products Covered Owner Responsibilities The Toro® Company and its afliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair the listed Toro Products if defective in materials or workmanship.
