Toro Z500 Series Z Master Operator'S Manual Download Page 3

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Think Safety First .............................. 17
Operating the Parking Brake .............. 18
Starting and Stopping the

Engine .............................. 18

Operating the Power Take Off

(PTO) ............................... 20

The Safety Interlock System............... 20
Driving Forward or Backward ............ 21
Stopping the Machine ........................ 22
Adjusting the Control Lever

Resistance ......................... 22

Adjusting the Height-of-Cut .............. 22
Adjusting the Anti-Scalp

Rollers............................... 23

Adjusting the Flow Bafﬂe................... 24
Positioning the Flow Bafﬂe ................ 24
Using the Lift Assist Lever ................. 25
Positioning the Seat ........................... 25
Unlatching the Seat............................ 26
Pushing the Machine by Hand ............ 26
Using the Side Discharge ................... 26
Breaking In a New Machine ............... 27
Transporting Machines ...................... 27
Loading Machines ............................. 27
Operating Tips .................................. 28

Maintenance...................................................... 30

Recommended Maintenance

Schedule(s) ............................... 30

Lubrication................................................ 30

Greasing and Lubrication................... 30

Engine Maintenance.................................. 32

Servicing the Air Cleaner ................... 32
Servicing the Engine Oil .................... 33
Servicing the Spark Plugs ................... 34

Fuel System Maintenance .......................... 35

Replacing the Fuel Filter .................... 35
Servicing the Fuel Tank...................... 36

Electrical System Maintenance................... 36

Servicing the Battery.......................... 36
Servicing the Fuses ............................ 38

Drive System Maintenance......................... 39

Adjusting the Tracking....................... 39
Checking the Tire Pressure................. 39
Checking the Wheel Hub Slotted

Nut ................................... 39

Adjusting the Caster Pivot

Bearing.............................. 40

Cooling System Maintenance ..................... 40

Cleaning the Engine Screen and the

Oil Cooler ......................... 40

Cleaning the Engine Fins ................... 41

Brake Maintenance .................................... 41

Adjusting the Parking Brake ............... 41

Belt Maintenance ....................................... 41

Inspecting the Belts ........................... 41
R eplacing the Mower Belt .................. 41
Adjusting the Mower Belt

Tension ............................. 43

R eplacing the Pump Drive

Belt ................................... 44

Controls System Maintenance.................... 44

Adjusting the Control Handle

Neutral Position ................ 44

Hydraulic System Maintenance .................. 45

Chec king the Hydraulic Fluid ............. 45
R eplacing the Hydraulic Filter and

Oil..................................... 46

Bleeding the Hydraulic System ........... 47
Chec king the Hydraulic Hoses ........... 47
Setting the Hydraulic Pump

Neutral Position ................ 48

Mower Deck Maintenance ......................... 50

Lev eling the Mower at Three

Positions ........................... 50

Ser vicing the Cutting Blades............... 52
R eplacing the Grass Deﬂector............ 54

Cleaning .................................................... 55

Cleaning Under the Mower ................ 55
W aste Disposal .................................. 55

Storage .............................................................. 56
Troubleshooting ................................................ 57
Schematics ........................................................ 60

Summary of Contents for Z500 Series Z Master

Page 1: ...ide Discharge Mower or a Z557 Z Master with 72in Turbo Force Side Discharge Mower Model No 74261 Serial No 270000001 and Up Model No 74262 Serial No 270000001 and Up Model No 74263 Serial No 270000001 and Up Register your product at www Toro com Original Instructions EN ...

Page 2: ...com for product and accessory information help ﬁnding a dealer or to register your product Whenever you need service genuine Toro parts or additional information contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready Figure 1 identiﬁes the location of the model and serial numbers on the product Write the numbers in the space provid...

Page 3: ...ter 35 Servicing the Fuel Tank 36 Electrical System Maintenance 36 Servicing the Battery 36 Servicing the Fuses 38 Drive System Maintenance 39 Adjusting the Tracking 39 Checking the Tire Pressure 39 Checking the Wheel Hub Slotted Nut 39 Adjusting the Caster Pivot Bearing 40 Cooling System Maintenance 40 Cleaning the Engine Screen and the Oil Cooler 40 Cleaning the Engine Fins 41 Brake Maintenance ...

Page 4: ...cessories and attachments approved by the manufacturer Wear appropriate clothing including hard hat safety glasses and hearing protection Long hair loose clothing or jewelry may get tangled in moving parts Inspect the area where the equipment is to be used and remove all objects such as rocks toys and wire which can be thrown by the machine Use extra care when handling gasoline and other fuels The...

Page 5: ...nsfer to the front wheels may cause drive wheels to slip and cause loss of braking and steering Always avoid sudden starting or stopping on a slope If tires lose traction disengage the blades and proceed slowly off the slope Follow the manufacturer s recommendations for wheel weights or counterweights to improve stability Use extreme care with grass catchers or other attachments These can change t...

Page 6: ...nly replace blades Never straighten or weld them Keep hands and feet away from moving parts If possible do not make adjustments with the engine running Charge batteries in an open well ventilated area away from spark and ﬂames Unplug charger before connecting or disconnecting from battery Wear protective clothing and use insulated tools Keep all parts in good working condition and all hardware tig...

Page 7: ...Slope Chart 7 ...

Page 8: ...afety 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 1 523552 1 633462 1 643339 54 9220 58 6520 1 Grease 66 1340 68 8340 8 ...

Page 9: ...98 4387 1 Warning wear hearing protection 98 5954 103 5881 105 7798 105 7797 107 1621 107 1622 9 ...

Page 10: ...107 1857 107 2112 107 1860 107 1861 107 1864 107 1613 10 ...

Page 11: ...indness and other injuries 3 Caustic liquid chemical burn hazard 8 Battery acid can cause blindness or severe burns 4 Wear eye protection 9 Flush eyes immediately with water and get medical help fast 5 Read the Operator s Manual 10 Contains lead do not discard 108 5278 1 Read the Operator s Manual Manufacturer s Mark 1 Indicates the blade is identi ed as a part from the original machine manufactur...

Page 12: ...110 5731 1 Engine stop 5 Continuous variable setting 2 Engine run 6 Slow 3 Engine start 7 Power take off PTO 4 Fast 106 7492 12 ...

Page 13: ...106 9989 107 8076 1 Fast 2 Slow 3 Neutral 4 Reverse 13 ...

Page 14: ...liar with all the controls before you start the engine and operate the machine Figure 3 and Figure 4 Figure 4 1 Gas cap 4 Throttle 2 Choke 5 Power take off PTO 3 Ignition switch 6 Hour meter Hour Meter The hour meter records the number of hours the engine has operated It operates when the engine is running Use these times for scheduling regular maintenance Figure 4 14 ...

Page 15: ...ystem in place and in proper working condition 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 Always place gasoline containers on the ground away from your vehicle before ﬁlling Do not ﬁll gasoline containers inside a vehicle or on a truck o...

Page 16: ...Checking the Oil Level in Engine Maintenance page 32 Using the Rollover Protection System ROPS To avoid injury or death from rollover keep the roll bar in the raised locked position and use the seat belt Ensure that the rear part of the seat is secured with the seat latch There is no rollover protection when the roll bar is in the down position Lower the roll bar only when absolutely necessary Do ...

Page 17: ...ymbols in the safety section Knowing this information could help you or bystanders avoid injury Operating on wet grass or steep slopes can cause sliding and loss of control Wheels dropping over edges can cause rollovers which may result in serious injury death or drowning There is no rollover protection when the roll bar is down Always keep the roll bar in the raised and locked position and use th...

Page 18: ...he motion control levers Figure 16 out to the neutral lock position 2 Pull up and back on the parking brake lever to set the parking brake Figure 10 The parking brake lever should stay ﬁrmly in the engaged position Parking brake may not hold machine parked on a slope and could cause personal injury or property damage Do not park on slopes unless wheels are chocked or blocked Releasing the Parking ...

Page 19: ...rt Figure 14 When the engines starts release the key Important Do not engage starter for more than 10 seconds at a time If engine fails to start allow 30 second cool down period between attempts Failure to follow these instructions can burn out starter motor Figure 14 1 Off 3 Start 2 Run 7 After the engine starts move the choke to off Figure 12 If the engine stalls or hesitates move the choke back...

Page 20: ...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 15 Figure 15 1 PTO On 2 PTO Off Disengaging the PTO To disengage push the PTO switch to the Off position Fi...

Page 21: ...reverse the engine should stop Repeat for other motion control 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 Driving Forward or Backward The throttle control regulates the engine speed as measured in rpm revolutions per minute Place the throttle control in ...

Page 22: ...ke Remember to remove the key from the ignition switch 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 co...

Page 23: ...y and wait for all moving parts to stop before leaving the operating position 3 After adjusting the height of cut remove the ﬂange nut bushing spacer and bolt Figure 19 Figure 19 1 Outer roller 4 Bolt 2 Spacer 5 Nut 3 Bushing 4 Select a hole so that the outer roller is positioned to the nearest corresponding height of cut desired Figure 19 5 Install the outer roller bushing spacer bolt and nut Fig...

Page 24: ...locks swing the lever up to loosen the cam lock Figure 21 4 Adjust the bafﬂe and cam locks in the slots to the desired discharge ﬂow 5 Swing the lever back over to tighten the bafﬂe and cam locks Figure 21 6 If the cams do not lock the bafﬂe into place or it is too tight loosen the lever and then rotate the cam lock Adjust the cam lock until the desired locking pressure is achieved Figure 21 1 Cam...

Page 25: ...st Lever 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 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 25 Figure 25 1 Lift Assist Lever Positioning the Seat The seat can move forward and backward Position the seat where you have the best ...

Page 26: ... 2 Rotate the by pass valves counterclockwise 1 turn to push This allows hydraulic ﬂuid to by pass the pump enabling the wheels to turn Figure 28 Important Do not rotate by pass valves more than 1 turn This prevents valves from coming out of the body and causing ﬂuid to run out Figure 28 1 By pass valve 2 Hydraulic tank 3 Disengage parking brake before pushing Changing to Machine Operation Rotate ...

Page 27: ... levers as anchors for tieing the machine down Secure a trailer to the towing vehicle with safety chains 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 Machines Use extreme caution when loading units on trailers o...

Page 28: ...Cut grass slightly longer than normal to ensure the cutting height of the mower does not scalp any uneven ground However the cutting height used in the past is generally the best one to use When cutting grass longer than six inches tall you may want to cut the lawn twice to ensure an acceptable quality of cut Cut 1 3 of the Grass Blade It is best to cut only about 1 3 of the grass blade Cutting mo...

Page 29: ...of the Mower Clean Clean clippings and dirt from the underside of the mower after each use If grass and dirt build up inside the mower cutting quality will eventually become unsatisfactory Blade Maintenance Maintain a sharp blade throughout the cutting season because a sharp blade cuts cleanly without tearing or shredding the grass blades Tearing and shredding turns grass brown at the edges which ...

Page 30: ...lace the oil lter Check the spark plugs Replace the fuel lter Grease the brake pivot and lever Every 500 hours Check the wheel hub slotted nut Adjust the caster pivot bearing Every 600 hours Replace the safety lter Yearly Grease the front caster pivots more often in dirty or dusty conditions Change the hydraulic lter and oil Important Refer to your Engine Operator s Manual for additional maintenan...

Page 31: ... a grease zerk into the hole 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 Where to Add Grease Lubricate the grease ﬁttings as shown on the Check Service Reference Aid decal Figure 30 Figure 30 Where to Add Light Oil or Spray Lubrication Lubricate the machine in the following areas with spray type lubricant o...

Page 32: ...4 Clean the inside of the air cleaner cover with compressed air 5 Gently slide the primary ﬁlter out of the air cleaner body Figure 32 Note Avoid knocking the ﬁlter into the side of the body 6 Remove the safety ﬁlter only if you intend to replace it Important Never attempt to clean the safety ﬁlter If the safety ﬁlter is dirty then the primary ﬁlter is damaged Replace both ﬁlters 7 Inspect the pri...

Page 33: ...evel surface 2 Disengage the PTO turn the ignition key to off and remove the key 3 Wait for all moving parts to stop before leaving the operating position and then chock or block tires 4 Clean around the oil dipstick Figure 34 so that dirt cannot fall into the ﬁller hole and damage the engine Figure 34 1 Oil dipstick 2 Filler tube 5 Unscrew the oil dipstick and wipe the end clean Figure 34 6 Slide...

Page 34: ...nside 4 Allow the ﬁlter material to absorb the new oil for 1 to 2 minutes 5 Apply a thin coat of new oil to the rubber gasket on the replacement ﬁlter Figure 36 6 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 2 3 to 1 turn Figure 36 7 Fill the crankcase with the proper type...

Page 35: ...es from the spark plugs Figure 38 Figure 38 1 Spark plug wire spark plug 4 Clean around the spark plugs to prevent dirt from falling into the engine and potentially causing damage 5 Remove the spark plugs and the metal washers Installing the Spark Plugs 1 Install the spark plugs and the metal washer Ensure that the air gap is set correctly 2 Tighten the spark plugs to 18 to 22 ft lb 24 4 to 29 8 N...

Page 36: ...e and remove the key 3 Close the fuel shutoff valve Figure 39 4 Loosen the hose clamp at the fuel ﬁlter and slide it up the fuel line away from the fuel ﬁlter Figure 39 5 Disconnect the fuel line from the fuel ﬁlter Figure 39 6 Open the fuel shutoff valve Note Allow gasoline to drain into a fuel container can or drain pan Figure 39 Note Now is the best time to install a new fuel ﬁlter because the ...

Page 37: ...ving the operating position 3 Unlatch the seat and tilt the seat up 4 First disconnect the negative battery cable and ground wire from the negative battery terminal Figure 40 5 Slide the red terminal boot off the positive red battery terminal Then remove the positive red battery cable Figure 40 Figure 40 1 Battery 7 Washer 1 4 inch 2 Terminal boot 8 Locknut 1 4 inch 3 Positive battery cable 9 Batt...

Page 38: ...disconnect the charger leads from the battery posts Fig 67 Figure 41 4 Install the battery in the machine and connect the battery cables refer to Installing the Battery Note Do not run the machine with the battery disconnected electrical damage may occur Servicing the Fuses The electrical system is protected by fuses It requires no maintenance however if a fuse blows check component circuit for ma...

Page 39: ... 43 1 Pump rod 3 Tracking knob 2 Turn this way to track left 4 Turn this way to track right 5 Repeat this adjustment until the tracking is correct Checking the Tire Pressure Check the pressure at the valve stem after every 50 operating hours or monthly whichever occurs ﬁrst Figure 44 Maintain the air pressure in the rear tires at 13 psi 90 kPa Uneven tire pressure can cause uneven cut Check the ti...

Page 40: ...e 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 Remove the dust cap from caster and tighten lock nut Figure 46 Figure 46 1 Spring Washers 3 Dust Cap 2 Lock Nut 4 Tighten the locknut until the spring washers are ﬂat and then back off a 1 4 turn to properly ...

Page 41: ... and yoke 3 If adjustment is necessary loosen the jam nut below the spring and tighten the nut directly below the yoke Figure 49 Turn the nut until the correct measurement is obtained Tighten the two nuts together and repeat on opposite side of unit 4 Turn nuts clockwise to shorten spring length and turn counter clockwise to lengthen the spring 5 Engage parking brake lever up 6 Measure the distanc...

Page 42: ...wer belt from the belt guides and remove the belt Figure 50 7 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 Figure 50 8 Install the belt guide with a washer and nut onto the rear leftside pulley Note Check the amount of twist in the belt between the pulleys Ensure it is only what is speciﬁed in Figure...

Page 43: ...center bolt needs to be near the top alignment hole in left support plate Figure 52 Figure 52 1 Center bolt 3 Left support plate 2 Alignment hole 4 Spring loaded idler 5 If adjustment is required loosen the mower idler plate and adjust it Figure 53 6 Insert a ratchet or breaker bar into the square hole in the mower idler plate to adjust the tension Figure 53 7 To increase belt tension rotate the m...

Page 44: ...6 2 Install new belt around engine and hydro pump pulleys Figure 56 3 Pull spring loaded idler down and align below traction belt Release the pressure on the spring loaded idler Figure 56 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 separa...

Page 45: ... the adjustment bolt to move the lever to the appropriate position 10 Tighten the nut and jam nut Figure 58 11 Repeat for the opposite side of the machine Figure 58 1 Clevis pin in slot 7 Spring 2 Nut against yoke 8 Pivot shaft 3 Adjustment bolt 9 Yoke 4 Pump rod 10 Locknut 5 Double nuts 11 Ball joint 6 Jam nut Hydraulic System Maintenance Checking the Hydraulic Fluid Check the hydraulic ﬂuid leve...

Page 46: ...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 Safely relieve all pressure in the hydraulic system before performing any work on the hydraulic system Make sure all hydraulic ﬂuid hoses and lines are in good condition and all...

Page 47: ...d should be between cold and hot 11 If required add ﬂuid to the hydraulic tank Do not overﬁll Bleeding the Hydraulic System The traction system is self bleeding however it may be necessary to bleed the system if ﬂuid is changed or after work is performed on the system 1 Raise rear of the machine so wheels are off the ground and support with jack stands 2 Start the engine and run at low idle speed ...

Page 48: ...porting machine Do not use hydraulic jacks Engine must be running so motion control adjustment can be performed Contact with moving parts or hot surfaces may cause personal injury Keep hands feet face clothing and other body parts away from rotating parts mufﬂer and other hot surfaces This adjustment must be made with drive wheels turning 1 Raise the frame and use jack stands to hold up the machin...

Page 49: ... 5 Double nuts 11 Ball joint 6 Jam nut 2 Start the engine open throttle 1 2 way and release parking brake Refer to Starting and Stopping the Engine in Operation page 15 Note The motion control lever must be in neutral while making any adjustments Note The front nut on the pump rod has left hand threads 3 Adjust the pump rod length by rotating double nuts on rod in the appropriate direction until w...

Page 50: ...90 kPa 5 Lower the mower to the 3 inch 76 mm height of cut position 6 Inspect the four chains The chains need to have tension Note Adjust the rear chains to the top of the slot where they are attached to the mower If one rear chain is loose lower loosen the front support arm on the same side Refer to Adjusting the Front to Rear Mower Pitch If one front chain is loose raise tighten the front suppor...

Page 51: ...o the cutting edge of the blade tip Figure 66 3 Record this measurement 4 Measure the right blade at the B location from a level surface to the cutting edge of the blade tip Figure 66 5 Record this measurement 6 The mower blade should be a 1 4 to 3 8 inch 6 to 10 mm lower at position A than at position B Figure 66 If it is not correct proceed to the following steps Note Both of the front swivels n...

Page 52: ...eason 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 Check the cutter blades daily for sharpness and for any wear or damage File down any nicks and sharpen the blades as necessary If a blade is damaged or worn replace it immediately with a genuine Toro replace...

Page 53: ...mm If this dimension exceeds 1 8 inch 3 mm the blade is bent and must be replaced refer to Removing the Blades and Installing the Blades 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 Removing the Blades Blades must be rep...

Page 54: ...tting 2 Install the spring disk and blade bolt The spring disk cone must be installed toward the bolt head Figure 72 Figure 72 1 Sail Area of Blade 4 Blade Bolt 2 Blade 5 Cone Towards Bolt Head 3 Spring Disk 3 Torque the blade bolt to 85 110 ft lb 115 150 N m Replacing the Grass De ector An uncovered discharge opening could allow the lawn mower to throw objects in the operator s or bystander s dir...

Page 55: ... Cleaning Cleaning Under the Mower Remove the grass buildup under the mower 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 Raise the mower to the transport position Waste Disposal Engine oil batteries hydraulic oil and eng...

Page 56: ...11 Prepare the machine for storage when non use occurs over 30 days Prepare machine for storage as follows A Add a petroleum based stabilizer conditioner to fuel in the tank Follow mixing instructions from stabilizer manufacture Do not use an alcohol based stabilizer ethanol or methanol Note A fuel stabilizer conditioner is most effective when mixed with fresh gasoline and used at all times B Run ...

Page 57: ...ails to keep running 4 Dirt water or stale fuel is in the fuel system 4 Contact an Authorized Service Dealer 1 Engine load is excessive 1 Reduce the ground speed 2 Air cleaner is dirty 2 Clean the air cleaner element 3 Oil level in the crankcase is low 3 Add oil to the crankcase 4 Cooling ns and air passages above the engine are plugged 4 Remove the obstruction from the cooling ns and air passages...

Page 58: ...unting bolts are loose 3 Tighten the engine mounting bolts 4 Loose engine pulley idler pulley or blade pulley 4 Tighten the appropriate pulley 5 Engine pulley is damaged 5 Contact an Authorized Service Dealer 6 Blade spindle is bent 6 Contact an Authorized Service Dealer Abnormal vibration 7 Motor mount is loose or worn 7 Contact an Authorized Service Dealer 1 Blade s not sharp 1 Sharpen the blade...

Page 59: ...drive belt and check adjusting shafts and belt guides for correct position 3 Deck belt is worn loose or broken 3 Install new deck belt 4 Deck belt is off pulley 4 Install deck pulley and check the idler pulley idler arm and spring for correct position and function Blades do not rotate 5 Broken or missing idler spring 5 Replace the spring 59 ...

Page 60: ...Schematics Wire Diagram Rev A 60 ...

Page 61: ......

Page 62: ......

Page 63: ...cheduled for replacement as required maintenance in the written instructions must be warranted for the warranty period of two years If any such part fails during the period of warranty coverage it must be repaired or replaced by The Toro Company Any such part repaired or replaced under the warranty must be warranted for a time not less than the remaining warranty period B Any warranted part that i...

Page 64: ... maintenance service or parts such as lters fuel lubricants tune up parts blade sharpening brake and clutch adjustments Any product or part which has been altered or misused or required replacement or repair due to normal wear accidents or lack of proper maintenance Repairs necessary due to improper fuel contaminants in the fuel system or failure to properly prepare the fuel system prior to any pe...

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Toro Z500 Series Z Master, Operator'S Manual

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