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Toro Z557 Z Master, Operator'S Manual

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Toro Z557 Z Master Operator'S Manual Download Page 42

Figure 52

1. Brake lever

5. 3/16–1/4 inch (5–7 mm)

2. Spring (2-3/4 inches/70

mm)

6. Jam nut and yoke

3. Adjusting nuts

7. Trunnion

4. Collar on brake rod

3. If adjustment is necessary, loosen the jam nut

below the spring and tighten the nut directly
below the yoke (Figure 52). 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 distance between the trunnion

roller and the collar on brake rod.

The measurement should be 3/16-1/4 inch
(5-7 mm) (Figure 52).

7. If adjustment is necessary, loosen the jam nut

directly below the yoke. Turn the bottom rod
until the correct measurement is obtained
(Figure 52). Tighten jam nut at yoke

Belt Maintenance

Inspecting the Belts

Inspect all belts 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.

2. Stop the engine, remove the key, and wait for

all moving parts to stop before leaving the
operating position.

3. Remove the bolts holding the belt covers in

place and remove the belt covers.

4. Loosen the nut securing the idler plate and

move the idler plate to relieve the belt tension
on the idler pulley (Figure 53).

5. Remove the nut, washer and belt guide from

the rear left side pulley.

6. Remove the mower belt from the belt guides

and remove the belt (Figure 53).

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 53).

8. Install the belt guide with a washer and nut

onto the rear left side pulley.

Note:

Check the amount of twist in the belt

between the pulleys. Ensure it is only what is
specified in Figure 53.

42

Summary of Contents for Z557 Z Master

Page 1: ...Form No 3355 354 Rev A Z557 Z Master With 152cm Turbo Force Side Discharge Mower Model No 74246TE Serial No 260000001 and Up Register your product at www Toro com Original Instructions EN ...

Page 2: ...s Figure 2 1 Safety alert symbol This manual uses 2 other words to highlight information Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention Contents Introduction 2 Safety 4 Safe Operating Practices 4 Toro Riding Mower Safety 5 Sound Pressure 6 Sound Power 6 Vibration 6 Slope Chart 7 Safety and Instructional Decals 8 Produ...

Page 3: ...ance 41 Cleaning the Engine Screen and the Oil Cooler 41 Cleaning the Engine Fins 41 Brake Maintenance 41 Adjusting the Parking Brake 41 Belt Maintenance 42 Inspecting the Belts 42 Replacing the Mower Belt 42 Adjusting the Mower Belt Tension 43 Replacing the Pump Drive Belt 44 Controls System Maintenance 45 Adjusting the Control Handle Neutral Position 45 Hydraulic System Maintenance 46 Checking t...

Page 4: ...the control levers The main reasons for loss of control are insufficient wheel grip especially on wet grass being driven too fast inadequate braking the type of machine is unsuitable for its task lack of awareness of the effect of ground conditions especially slopes incorrect hitching and load distribution Preparation While mowing always wear substantial footwear and long trousers Do not operate th...

Page 5: ... the ignition key before clearing blockages or unclogging chute before checking cleaning or working on the lawnmower after striking a foreign object Inspect the lawnmower for damage and make repairs before restarting and operating the equipment if the machine starts to vibrate abnormally check immediately Disengage drive to attachments when transporting or not in use Stop the engine and disengage ...

Page 6: ...k behind mower and or a hand trimmer near drop offs ditches steep banks or water Reduce speed and use extreme caution on slopes Remove or mark obstacles such as rocks tree limbs etc from the mowing area Tall grass can hide obstacles Watch for ditches holes rocks dips and rises that change the operating angle as rough terrain could overturn the machine Avoid sudden starts when mowing uphill because...

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

Page 8: ...n place 3 Cutting dismemberment of hand or foot stay away from moving parts 93 7818 1 Warning read the Operator s Manual for instructions on torquing the blade bolt nut to 115 149 N m 85 110 ft lb 93 7824 1 Thrown object hazard stay a safe distance from the machine 2 Thrown object hazard mower keep the de ector in place 3 Cutting dismemberment of hand or foot stay away from moving parts 98 1977 1 ...

Page 9: ...ng 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 2131 1 Hydraulic oil level 2 Warning do not touch the hot surface 107 3069 1 Warning there is no rollover protection when the roll bar is down 2 To avoid injury or death from a rollover accident keep the roll bar in the raised and locked position and we...

Page 10: ...berment 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 3 Thrown object hazard keep bystanders a safe distance from the machine and keep the de ector in place 4 Before starting the engine clean grass and debris from the mower belt and pulleys insert the ignition key and start the engine 10 ...

Page 11: ...968 1 Disengage 3 Parking brake 2 Engage 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 3978 1 Cutting dismemberment hazard fan and entanglement hazard belt stay away from moving parts 2 Before starting the engine clean grass and debris from the mower belt and pulleys inse...

Page 12: ...m the battery 2 No re open ame or smoking 7 Wear eye protection explosive gases can cause blindness 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 Manufacturer s Mark 1 Indicates the blade is id...

Page 13: ...107 8077 1 Fast 3 Neutral 5 Warning read the Operator s Manual 7 Explosion hazard no re open ames or smoking avoid sparks 2 Slow 4 Reverse 6 Poison and caustic liquid chemical burn hazard keep children a safe distance from the battery 8 To unlock the traction drive turn the by pass valve 1 complete revolution counterclockwise using a 5 8 inch or 16 mm wrench 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 Ignition switch 4 Power take off PTO 2 Throttle 5 Hour meter 3 Choke 6 Gas cap 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 33 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: ...on 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 the fast position for best performance Always operat...

Page 22: ...ed from 1 1 2 to 5 inch 38 to 127 mm in 1 4 inch 6 mm increments by relocating the clevis pin into different hole locations 1 Raise the height of cut lever to the transport position also the 5 inch 127 mm cutting height position Figure 17 Figure 17 1 Height of cut lever 2 Clevis Pin 2 To adjust remove the clevis pin from the height of cut bracket Figure 17 3 Select a hole in the height of cut brac...

Page 23: ...on the cam locks and baffle to give the best quality of cut 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 To adjust the cam locks swing the lever up to loosen the cam lock Figure 21 4 Adjust the baffle and cam locks in the slots ...

Page 24: ...ion The suggested use for this position is a follows Use for short light grass mowing conditions Use in dry conditions For smaller grass clippings Propels grass clippings farther away from the mower Figure 22 Position B Use this position when bagging Figure 23 Position C This is the full open position The suggested use for this position is as follows Use in tall dense grass mowing conditions Use i...

Page 25: ... lock in position Figure 26 1 Adjustment lever Unlatching the Seat Push the seat latch rearward to unlatch the seat This will allow access to the machine under the seat Figure 27 Figure 27 1 Seat latch 3 Seat 2 Fuel cap Pushing the Machine by Hand Important Always push the machine by hand Never tow the machine because hydraulic damage may occur Pushing the Machine 1 Disengage the power take off PT...

Page 26: ... replace it immediately Never put your hands or feet under the mower Never try to clear the discharge area or mower blades unless you move the power take off PTO to the off position rotate the ignition key to off and remove the key Make sure the grass deflector is in the down position Breaking In a New Machine New engines take time to develop full power Mower decks and drive systems have higher fri...

Page 27: ... the unit moves from ramp to trailer or truck Steeper angles may also cause the unit to tip backward If loading on or near a slope position the trailer or truck so it is on the down side 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 Important Do Not attempt to turn the unit while on the ramp you may lose control...

Page 28: ...wing the stand foot out front and slide stand toward machine into the bottom of slot Figure 30 and Figure 31 Figure 31 1 Z Stand Positioned in slot 3 Latch resting on pivot tab 2 Crack in side walk or turf 4 Set the foot of stand on the ground and rest the latch on the pivot tab Figure 31 5 Start the engine and put it at half throttle Note For best results place the foot of stand into seams in sid...

Page 29: ...ilization Mow at Correct Intervals Normally mow every four days But remember grass grows at different rates at different times So to maintain the same cutting height which is a good practice mow more often in early spring As the grass growth rate slows in mid summer mow less frequently If you cannot mow for an extended period first mow at a high cutting height then mow again two days later at a low...

Page 30: ...th 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 replacement blade 30 ...

Page 31: ...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 32: ... 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 33 Figure 33 Where to Add Light Oil or Spray Lubrication Lubricate the machine in the following areas with spray type lubricant o...

Page 33: ...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 35 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 34: ...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 37 so that dirt cannot fall into the filler hole and damage the engine Figure 37 1 Oil dipstick 2 Filler tube 5 Unscrew the oil dipstick and wipe the end clean Figure 37 6 Slide...

Page 35: ...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 39 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 39 7 Fill the crankcase with the proper type...

Page 36: ...es from the spark plugs Figure 41 Figure 41 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 37: ...at the fuel filter and slide it up the fuel line away from the fuel filter Figure 42 5 Disconnect the fuel line from the fuel filter Figure 42 6 Open the fuel shutoff valve Note Allow gasoline to drain into a fuel container can or drain pan Figure 42 Note Now is the best time to install a new fuel filter because the fuel tank is empty 7 Install the fuel line onto the fuel filter Slide the hose clamp cl...

Page 38: ...4 x 3 4 inch 6 Remove both wing nuts 1 4 inch securing the battery clamp Figure 43 7 Remove the battery Installing the Battery 1 Position battery in the tray with the terminal posts toward the engine Figure 43 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 wit...

Page 39: ...e it 3 Install a new fuse Figure 45 Drive System Maintenance Adjusting the Tracking Note Determine the left and right sides of the machine from the normal operating position The right hand pump has a knob for adjusting the tracking Important Adjust the handle neutral and hydraulic pump neutral before adjusting the tracking Refer to Adjusting the Handle Neutral and Adjusting the Hydraulic Pump Neut...

Page 40: ... stop before leaving the operating position 3 Remove the cotter pin 4 Torque the slotted nut to 125 ft lb 170 N m Figure 48 Figure 48 1 Slotted Nut 3 Hole in threaded shaft 2 Two threads or less showing 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 48 6 If more than two threads are showing remove nut and insta...

Page 41: ...reen Figure 50 and Figure 51 Figure 50 1 Engine screen 2 Oil cooler Cleaning the Engine Fins Every 100 hours clean the engine cylinder and cylinder head cooling fins Also clean around carburetor governor levers and linkage This will make sure adequate cooling to hydraulic pumps motors and engine and will reduce the possibility of overheating and mechanical damage 1 Remove the engine shroud 2 Clean ...

Page 42: ...lace 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 2 Stop the engine remove the key and wait fo...

Page 43: ...wer 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 53 Imp...

Page 44: ...of the spring loaded idler pulley when the idler plate is tightened It needs to be 0 to 1 4 inch 0 to 6 mm from the rubber stop Figure 57 Figure 57 1 Spring loaded idler pulley 4 Idler pulley arm 2 Top alignment hole 5 Belt 3 0 to 1 4 inch gap 0 to 6 mm 6 Rubber bumper 10 Adjust the belt tension and the idler plate if necessary and tighten all hardware securely Figure 56 11 If the mower idler plat...

Page 45: ...ward 4 Begin with either the left or right motion control lever 5 Move the lever to the neutral position but not locked Figure 60 Figure 60 1 Neutral locked position 3 Neutral potion 2 Control lever 6 Pull the lever back until the clevis pin on arm below pivot shaft contacts the end of the slot just beginning to put pressure on the spring Figure 60 7 Check where the control lever is relative to no...

Page 46: ... has two levels depending if the oil is warm or cold 1 Position the machine on a level surface and set the parking brake 2 Clean the area around filler neck of hydraulic tank Figure 62 Figure 62 1 Cap 3 Cold uid level full 2 Baf e 4 Hot uid level full 3 Remove the cap from the filler neck Look inside to check if there is fluid in the reservoir Figure 62 4 If there is no fluid add fluid to the reservoir...

Page 47: ...gine remove the key and wait for all moving parts to stop before leaving the operating position Important Do not substitute automotive oil filter or severe hydraulic system damage may result 3 Place drain pan under filter remove the old filter and wipe the filter adapter gasket surface clean Figure 63 Figure 63 1 Hydraulic lter 4 Apply a thin coat hydro fluid to the rubber gasket on the replacement filt...

Page 48: ...ate 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 Safely relieve all pressure in the hydraulic system b...

Page 49: ...erse Figure 65 Figure 65 1 Tracking knob 3 Adjustment bolt 2 Pump rod 4 Yoke 3 Move the motion control lever forward and reverse then back to neutral The wheel must stop turning or slightly creep in reverse 4 Open the throttle to fast Make sure wheel remains stopped or slightly creeps in reverse adjust if necessary Setting the Left hand Hydraulic Pump Neutral Position 1 Loosen the locknuts at the ...

Page 50: ...ed position and set the parking brake 3 Stop the engine remove the key and wait for all moving parts to stop before leaving the operating position 4 Check tire pressure of all four tires If needed adjust to 13 psi 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 the...

Page 51: ...2 Measure the right blade at the A location from a level surface to the cutting edge of the blade tip Figure 69 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 69 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 69 If it is not corre...

Page 52: ...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 replacement blade For convenient sharpening and replacement you may want to keep extra blades on hand A worn or damaged blade can break and a piece of the blade could be thrown into the operator s or bystander s area resulting in serious personal injury or deat...

Page 53: ... balance or is bent To ensure optimum performance and continued safety conformance of the machine use genuine Toro replacement blades Replacement blades made by other manufacturers may result in non conformance with safety standards Contact with a sharp blade can cause serious injury Wear gloves or wrap sharp edges of the blade with a rag 1 Hold the blade end using a rag or thickly padded glove 2 ...

Page 54: ...ult 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 Make sure the grass deflector is in the down position 1 Remove the locknut bolt spring and spacer holding the deflector to the pivot brackets Figure 76 2 Remove the damaged or worn grass deflector 3 Place the spacer and spring onto the ...

Page 55: ...ower 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 engine coolant are pollutants to the environment Dispose of these accordin...

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 ...

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