FORM NO. 3318–739 Z–MASTER Z118 Zero Radius Tractor Model No. 74105 – 790001 & Up Operator’s Manual IMPORTANT: Read this manual carefully. It contains information about your safety and the safety of others. Also become familiar with the controls and their proper use before you operate the product.
Introduction Thank you for purchasing a Toro product. All of us at Toro want you to be completely satisfied with your new product, so feel free to contact your local Authorized Service Dealer for help with service, genuine replacement parts, or other information you may require. Whenever you contact your Authorized Service Dealer or the factory, always know the model and serial numbers of your product.
Contents Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safe Operating Practices . . . . . . . . . . . . . . Slope Chart . . . . . . . . . . . . . . . . . . . . . . . . . Safety and Instruction Decals . . . . . . . . . . Gasoline and Oil . . . . . . . . . . . . . . . . . . . . . . . . Recommended Gasoline . . . . . . . . . . . . . . Stabilizer/Conditioner . . . . . . . . . . . . . . . . Filling the Fuel Tank . . . . . . . . . . . . . . . . . Check Engine Oil Level . . . . . . . . .
Safety Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means CAUTION, WARNING, or DANGER—“personal safety instruction.” Failure to comply with the instruction may result in personal injury or death. General Operation 1. Read, understand, and follow all instructions in the operator’s manual and on the machine before starting. 2.
Safety 14. Do not operate the machine while under the influence of alcohol or drugs. 15. Watch for traffic when operating near or crossing roadways. 16. Use extra care when loading or unloading the machine onto a trailer or truck. 17. Do not touch equipment or attachment parts which may be hot from operation. Allow to cool before attempting to maintain, adjust or service. 18.
Safety Children Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the machine and the mowing activity. Never assume that children will remain where you last saw them. The following requirements must be followed to prevent injury to children. 1. Keep children out of the mowing area and under the watchful care of another responsible adult. 2. Be alert and turn the machine off if children enter the area. 3.
Safety Slope Chart Read all safety instructions on pages 2–4.
Safety Safety and Instruction Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. ON RIGHT SIDE CONTROL PANEL (Part No. 95–0849) ON REAAR OF SEAT SUPPORT (Part No. 88–2790) ON PTO SWITCH (Part No. 112845) ON LEFT FENDER (Part No. 92–4952) ON RIGHT FENDER (Part No. 92–4951) ON CENTER OF FOOTREST (Part No.
Gasoline and Oil Recommended Gasoline Stabilizer/Conditioner Use UNLEADED Regular Gasoline suitable for automotive use (85 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available. Add the correct amount of gas stabilizer/conditioner to the gas. Using a stabilizer/conditioner in the machine: IMPORTANT: Never use methanol, gasoline containing methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged. Do not mix oil with gasoline.
Assembly Loose Parts Note: 8 Use the chart below to verify all parts have been shipped. DESCRIPTION QTY.
Assembly Install Traction Control Rods Install Seat 1. Locate index tab on left and right rods vertical and slide into control block (Fig. 1). 1. Tip seat pan up, place stop wire through hole and align seat with adjustment slots (Fig. 2). 2. Position (3) 1/2” (13 mm) spring washers onto threaded end of rod, alternating as shown (Fig. 1). Secure with 1/2” locknut. 2. Secure with (4) 5/16 x 3/4” (19 mm) bolts, 5/16” washers and 5/16” spacers (Fig. 2). 3.
Assembly Install Armrests and Tube Tire Pressure 1. Align left and right armrests to seat back and start outer bolts (Fig. 3). Check the air pressure in the front and rear tires (Fig. 23). 2. Place (2) R–clamps around manual tube and space to align with inside armrest mounting holes (Fig. 3). Pressure: 12 psi (83 kPa) rear and 6 psi (41 kPa) front tires. 3. Insert inner armrest bolts through R–clamps and secure to seat (Fig. 3). 1 m–1872 Figure 4 1. Valve stem m–3092 Figure 3 1.
Assembly Activate the Battery 1 Bulk electrolyte with 1.260 specific gravity must be purchased from a local battery supply outlet. 1. Remove the battery from the machine. IMPORTANT: Be careful not to damage the long vent tube when removing the battery box. 2 3 m–1262 Figure 5 POTENTIAL HAZARD • Battery electrolyte contains sulfuric acid which is a deadly poison and it causes severe burns. 1. Filler caps 2. Electrolyte WHAT CAN HAPPEN 3.
Assembly Install Battery 1. Fill battery with electrolyte and charge, refer to BATTERY, page 34. WHAT CAN HAPPEN • Battery gasses can explode. 2. Position battery in tray with terminal posts away from the engine (Fig. 7). HOW TO AVOID THE HAZARD 3. Slide the red terminal boot onto the red battery cable. 4. Install the positive (red) battery cable to positive (+) battery terminal then negative battery cable to the negative (–) battery terminal.
Operation Think Safety First Parking Brake Please carefully read all the safety instructions on pages 2–8. Knowing this information could help you, your family, pets or bystanders avoid injury. Always set the parking brake when you stop the machine or leave it unattended. Setting the Parking Brake Controls 1. Release pressure on the motion control levers they automatically return to neutral (Fig. 1). Become familiar with all the controls (Fig. 1) before you start the engine and operate the machine.
Operation Starting and Stopping the Engine 2 1 Starting 2 1. Sit down on the seat and move the motion controls to neutral locked position. 2. Set the parking brake; refer to Setting the Parking Brake, page 13. 3. Move the PTO (power take off) to “OFF” (Fig. 3). 4. Move the choke control to “ON” position before starting a cold engine. Note: Move the throttle control to the “FAST” position before starting a cold engine. 6. Turn ignition key “START” to energize starter.
Operation Stopping 1. Move the throttle lever to “SLOW” (Fig. 5). 2. Turn the ignition key to “OFF” (Fig. 6). Note: If the engine has been working hard or is hot, let it idle for a minute before turning the ignition key “OFF.” This helps cool the engine before it is stopped. In an emergency, the engine may be stopped by turning the ignition key to “OFF.” 3. Pull wire off spark plug(s) to prevent possibility of accidental starting before transporting or storing machine. 4.
Operation Operating the Power Take Off (PTO) The Safety Interlock System The power take off (PTO) engages and disengages power to the attachment clutch. Understanding the Safety Interlock System The safety interlock system is designed to prevent the engine from starting unless: Engaging the Power Take Off (PTO) • The parking brake is on “ENGAGED” 1. Release pressure on the motion control levers to stop the machine. • The power take off (PTO) is disengaged “OFF” 2.
Operation 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 operate in the full throttle position Forward 1. Release the parking brake; refer to Setting the Parking Brake, page 13. 2. Move levers to the center, un-locked position. 3. To go forward, slowly push the motion control levers forward (Fig. 8).
Operation Hour Meter Positioning the Seat The hour meter records the number of hours the engine has operated (Fig. 9). It operates when the engine is running. Use these times for scheduling regular maintenance. The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable. 1 1. To adjust tip seat forward and loosen the seat mounting bolts (Fig. 11). 2.
Operation Pushing the Machine by Hand IMPORTANT: Always push the machine by hand. Never tow the machine because hydraulic damage may occur. To Push the Machine 1. Disengage the power take off (PTO) and turn the ignition key to “OFF” to stop the engine. 2. Lift the drive control rods (dump valves), on front of hydrostatic pumps, up and latch into hooked slot. This allows hydraulic fluid to by-pass the pump enabling the wheels to turn (Fig. 12). To Operate the Machine 1.
Maintenance Service Interval Chart Service Operation Each Use Transaxle fluid–check level Initial Oil—check level 8 Hours 25 Hours 50 Hours 100 Hours X X Initial X Oil Filter–change (200 hours or every other oil change) X X X Chassis—grease* Storage Service X X Oil—change* Safety System—check 200 Hours X X X Foam Air Cleaner—service* X X X Paper Air Cleaner—replace* X Spark Plug(s)—check X X X Belts—check for wear/cracks X X Electric clutch—check for wear X X Gasoline—dra
Maintenance Air Cleaner 3. Carefully slide the foam element off the paper element (Fig. 13). Foam Element: Clean and re-oil after every 25 operating hours. 4. Unscrew the cover nut and remove the cover and paper element (Fig. 13). Paper Element: Replace after every 100 operating hours. Note: Cleaning the Foam and Paper Elements Service the air cleaner more frequently (every few hours) if operating conditions are extremely dusty or sandy. Removing the Foam and Paper Elements 1. 2. 1.
Maintenance 2. Paper Element Engine Oil A. Lightly tap the element on a flat surface to remove dust and dirt (Fig. 15). Change oil: B. Inspect the element for tears, an oily film, and damage to the rubber seal. IMPORTANT: Never clean the paper element with pressurized air or liquids, such as solvent, gas, or kerosene. Replace the paper element if it is damaged, defective, or cannot be cleaned thoroughly. • After the first 8 operating hours. • After every 100 operating hours.
Maintenance Checking Oil Level Changing/Draining Oil 1. 1. Start the engine and let it run five minutes. This warms the oil so it drains better. 2. Park the machine so that the drain side is slightly lower than the opposite side to assure the oil drains completely. Then disengage the power take off (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key. 3. Place a pan below the oil drain. Open the drain cap (Fig. 17). 4.
Maintenance Spark Plug Change Oil Filter Replace the oil filter every 200 hours or every other oil change. Note: 1. Change oil filter more frequently when operating conditions are extremely dusty or sandy. Drain the oil from the engine; refer to Changing/Draining Oil, page 23. 2. Remove the old filter and wipe the filter adapter (Fig. 18) gasket surface. 3. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Fig. 18).
Maintenance Greasing and Lubrication Checking the Spark Plug 1. Look at the center of the spark plug(s) (Fig. 20). If you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means the air cleaner is dirty. IMPORTANT: Never clean the spark plug(s). Always replace the spark plug(s) when it has: a black coating, worn electrodes, an oily film, or cracks. 2. Grease the wheel bearings and control lever pivots every 8 operating hours.
Maintenance Cleaning the Cooling Systems Tire Pressure Before each use, check and clean engine cooling systems. Remove any build–up of grass, dirt or other debris from the engine air intake. Every 100 hours clean hydrostatic pump fans and cooling fins, engine cylinder and cylinder head cooling fins. Also clean around carburetor, governor levers and linkage. This will help insure adequate cooling to hydrostatic pumps and engine and will reduce the possibility of overheating and mechanical damage.
Maintenance Fuel Tank POTENTIAL HAZARD • In certain conditions gasoline is extremely flammable and highly explosive. WHAT CAN HAPPEN • A fire or explosion from gasoline can burn you, others, and cause property damage. HOW TO AVOID THE HAZARD • 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 drain gasoline near an open flame or where gasoline fumes may be ignited by a spark. • Never smoke a cigarette, cigar or pipe.
Maintenance Fuel Filter Transaxle Fluid Replace the fuel filter after every 200 operating hours or yearly, whichever occurs first. Service Interval/Specification Replacing the Fuel Filter Never install a dirty filter if it is removed from the fuel line. 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key. Check fluid level initial use and after every 100 hours or yearly whichever comes first.
Maintenance Adjusting Neutral 5. Raise rear of the machine so wheels are off the ground and support with jack stands. If wheels turn when control bars are in neutral, adjustment is required 6. Start engine and run for 5 minutes at 3/4 throttle, to warm hydraulic fluid. 7. Release parking brake with traction controls in neutral position. If either wheel rotates on its own, adjustment is required. 8. Loosen lock bolt in cam. Rotate cam until wheel rotation stops (Fig. 28).
Maintenance Parking Brake Always set the parking brake when you stop the machine or leave it unattended. If the parking brake does not hold securely, an adjustment is required. Adjusting the Brake The brake lever is on top of the transaxles (Fig. 29). If the parking brake does not hold securely, an adjustment is required. 1. Check the brake before you adjust it; refer to Checking the Brake, page 30. 2. Release the parking brake; refer to Releasing the Parking Brake, page 13. 3.
Maintenance Adjusting Neutral Lock-out Replacing the Traction Belt Before neutral lock-out can be adjusted the parking brake must be adjusted, refer to: Parking Brake. Check traction drive belt for wear after every 50 hours of operation. 1. Apply parking brake. 1. Raise the rear of the machine and support with jack stands. 2. Lock-out lever should press firmly down between left and right neutral return rods (Fig. 30). 2. Remove mower drive belt; refer to mower Operator’s Manual. 3.
Maintenance Replacing the PTO (Power Take Off) Belt Adjust Electric Clutch Check the electric clutch for wear after every 50 hours of operation. Check PTO (Power Take Off) belt for wear after every 50 hours of operation. 1. Raise the rear of the machine and support with jack stands. 2. Remove mower drive belt; refer to mower Operator’s Manual. 3. Remove front mounting bolts and loosen rear mounting bolts from clutch stop plate, allowing plate to swing down (Fig. 32). 4.
Maintenance Fuse Service Interval/Specification The electrical system is protected by fuses. It requires no maintenance, however, if a fuse blows check component/circuit for malfunction or short. To replace fuses pull up on the fuse (Fig. 34) to remove or replace it. Fuse: Main/Starter F1–30 amp, blade-type Alternator F2–25 amp, blade-type Hour meter/Clutch F3–10 amp, blade-type Starter relay F4–7.5 amp, blade-type 4 3 2 1 m–3086 Figure 34 1. Main/Starter-30 amp 2. Alternator-25 amp 3.
Maintenance Battery Check the electrolyte level in the battery before each use. Always keep the battery clean and fully charged. Use a paper towel to clean the battery case. If the battery terminals are corroded, clean them with a solution of four parts water and one part baking soda. Apply a light coating of grease to the battery terminals to prevent corrosion. IMPORTANT: Do not overfill the battery because electrolyte (sulfuric acid) can cause severe corrosion and damage to the chassis. 4.
Maintenance Wiring Diagram IGNITION S B R I IGNITION SWITCH CIRCUITRY OFF = NONE RUN = B + R + I 30 AMP F1 F2 10 AMP F3 7.
Maintenance Cleaning and Storage 1. 2. Disengage the power take off (PTO), set the parking brake and turn the ignition key to “OFF” to stop the engine. Remove the key. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine. Clean dirt and chaff from the outside of the engine’s cylinder head fins and blower housing. IMPORTANT: You can wash the machine with mild detergent and water. Do not pressure wash the machine.
Troubleshooting PROBLEM Starter does not crank Engine g will not start,, starts hard,, or f il to fails t keep k running. i Engine g loses power. p POSSIBLE CAUSES CORRECTIVE ACTION 1. Blade control (PTO) is ENGAGED. 1. Move blade control (PTO) to DISENGAGED. 2. Parking brake is not on. 2. Set parking brake. 3. Operator is not seated. 3. Sit on the seat. 4. Battery is dead. 4. Charge the battery. 5. Electrical connections are corroded or loose. 5.
Troubleshooting PROBLEM Engine g overheats. Abnormal vibration. Machine does not drive. 38 POSSIBLE CAUSES CORRECTIVE ACTION 1. Engine load is excessive. 1. Reduce ground speed. 2. Oil level in crankcase is low. 2. Add oil to crankcase. 3. Cooling fins and air passages under engine blower housing are plugged. 3. Remove obstruction from cooling fins and air passages. 1. Engine mounting bolts are loose. 1. Tighten engine mounting bolts. 2.
THE TORO TOTAL COVERAGE GUARANTEE A OneĆYear Limited Warranty (A TwoĆYear Full Warranty for Residential Use) LCG What Is Covered By This Express Warranty? The Toro Company promises to repair any TORO product used for commercial, institutional, or rental purposes if defective in materials or workmanship for a period of one year from the date of purchase. The cost of parts and labor are included, but the customer pays the transportation cost.