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Loading Machines ............................. 27
Using the Z Stand® ........................... 28
Operating Tips .................................. 29

Maintenance...................................................... 31

Recommended Maintenance

Schedule(s) ............................... 31

Lubrication................................................ 31

Greasing and Lubrication................... 31

Engine Maintenance.................................. 33

Servicing the Air Cleaner ................... 33
Servicing the Engine Oil .................... 34
Servicing the Spark Plugs ................... 35

Fuel System Maintenance .......................... 36

Replacing the Fuel Filter .................... 36
Servicing the Fuel Tank...................... 37

Electrical System Maintenance................... 37

Servicing the Battery.......................... 37
Servicing the Fuses ............................ 39

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

Adjusting the Tracking....................... 39
Checking the Tire Pressure................. 40
Checking the Wheel Hub Slotted

Nut ................................... 40

Adjusting the Caster Pivot

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

Cooling System Maintenance ..................... 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 the Hydraulic Fluid ............. 46
Replacing the Hydraulic Filter and

Oil..................................... 47

Bleeding the Hydraulic System ........... 48
Checking the Hydraulic Hoses ........... 48
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

Содержание Z557 Z Master

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 7: ...Slope Chart 7 ...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

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

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