Form No. 3354-564 Rev B Z453 Z Master® with 48in or 52in TURBO FORCE® Side Discharge Mower Model No. 74416—Serial No. 260000001 and Up Model No. 74417—Serial No. 260000001 and Up Register your product at www.Toro.
Warning CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Important: This engine is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate the engine on any forest-covered, brush-covered, or grass-covered land. Other states or federal areas may have similar laws. Figure 1 1.
Using the Rollover Protection System (ROPS).................. 15 Think Safety First .............................. 16 Operating the Parking Brake .............. 17 Starting and Stopping the Engine .............................. 17 Operating the Power Take Off (PTO) ............................... 19 The Safety Interlock System............... 19 Driving Forward or Backward ............ 20 Stopping the Machine ........................ 21 Adjusting the Height-of-Cut ..............
Safety 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. They are flammable and vapors are explosive. – Use only an approved container – Never refuel or drain the machine indoors. – Never remove gas cap or add fuel with engine running. Allow engine to cool before refueling. Do not smoke.
• Never carry passengers and keep pets and bystanders away. • Be alert, slow down and use caution when making turns. Look behind and to the side before changing directions. • Slow down and use caution when crossing roads and sidewalks. Stop blades if not mowing. • Be aware of the mower discharge direction and do not point it at anyone. • Do not operate the mower under the influence of alcohol or drugs. • Use extreme care when loading or unloading the machine into a trailer or truck.
• Carefully release pressure from components with stored energy. • Disconnect battery or remove spark plug wire before making any repairs. Disconnect the negative terminal first and the positive last. Reconnect positive first and negative last. • Use care when checking blades. Wrap the blade(s) or wear gloves, and use caution when servicing them. Only 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.
Slope Chart 7
Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. 58-6520 1. Grease 1-403005 66-1340 1-523552 65-2690 1-633818 68-8340 98-4387 54-9220 1. Warning—wear hearing protection.
8-5954 107-1687 103-2644 105-7798 107-1688 107-1613 9
Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 6. 2. No re, open ame, or smoking. 7. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 8. 5. Read the Operator’s Manual. 9. 10. 107-2112 Keep bystanders a safe distance from the battery. Wear eye protection; explosive gases can cause blindness and other injuries Battery acid can cause blindness or severe burns. Flush eyes immediately with water and get medical help fast.
Manufacturer’s Mark 1. Indicates the blade is identied as a part from the original machine manufacturer. 107-8445 107-9309 1. Warning—read the Operator’s Manual for information on charging the battery; contains lead; do not discard. 2. Read the Operator’s Manual. 108-5995 1. Fast 2. Slow 3. Neutral 11 4.
110-0439 1. Choke 2. Engine—stop 3. 4. Engine—run Engine—start 5. Fast 6. Continuous variable setting 12 7. Slow 8.
Product Overview Using the Hour Meter The hour meter (Figure 5) records the number of hours the engine has operated. It operates when the engine is running. Use these times for scheduling regular maintenance. Figure 5 1. Hour meter Using the Fuel Shutoff Valve The machine has 2 fuel tanks, one on the left side and the other on the right side. Each tank connects to a check valve and then to a tee. From there a common fuel line leads to the engine (Figure 6). Figure 3 1. 2. 3. 4. 5.
Operation 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. Note: Determine the left and right sides of the machine from the normal operating position. Adding Fuel • Always place gasoline containers on the ground away from your vehicle before filling. Use Unleaded Regular Gasoline suitable for automotive use (85 pump octane minimum).
• Cleans the engine while it runs • Eliminates gum-like varnish buildup in the fuel system, which causes hard starting There is no rollover protection when the roll bar is in the down position. Important: Do not use fuel additives containing methanol or ethanol. • Lower the roll bar only when absolutely necessary. Add the correct amount of gas stabilizer/conditioner to the gas. • Do not wear the seat belt when the roll bar is in the down position.
Think Safety First 5. To raise the roll bar, remove the hairpin cotter pins and remove the two pins (Figure 8). 6. Raise the roll bar to the upright position and install the two pins and secure them with the hairpin cotter pins (Figure 8). Please read all safety instructions and symbols in the safety section. Knowing this information could help you or bystanders avoid injury. Important: Always use the seat belt with the roll bar in the raised position.
Setting the Parking Brake 1. Move the motion control levers (Figure 18) out to the neutral lock position. 2. Pull up and back on the parking brake lever to set the parking brake (Figure 12). 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 Figure 10 1. Safe Zone-use the Z Master 3.
Figure 15 1. Throttle—fast 2. Throttle—slow 6. Turn the ignition key to Start. When the engines starts, release the key (Figure 16). Figure 13 1. PTO—on 2. PTO—off 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. 4. Move the choke control to the on position before starting a cold engine (Figure 14).
Important: Make sure that the fuel shut off valve is closed before transporting or storing the machine, as fuel leakage may occur. Set the parking brake before transporting. Make sure to remove the key as the fuel pump may run and cause the battery to lose charge. Children or bystanders may be injured if they move or attempt to operate the tractor while it is unattended. Figure 17 Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes.
engaged or if you rise from the seat when the PTO is engaged. Machine can spin very rapidly. Operator may lose control of machine and cause personal injury or damage to machine. Testing the Safety Interlock System Test the safety interlock system before you use the machine each time. If the safety system does not operate as described below, have an Authorized Service Dealer repair the safety system immediately. • Use caution when making turns. • Slow the machine down before making sharp turns.
Driving Backward 1. Move the levers to the center, un-locked position. 2. To go backward, slowly pull the motion control levers rearward (Figure 18). To go straight, apply equal pressure to both motion control levers (Figure 18). To turn, release pressure on the motion control lever toward the direction you want to turn (Figure 18). To stop, push the motion control levers to the neutral position. Figure 19 1.
4. Adjust the baffle and cam lock in the slot to the desired discharge flow. 5. Swing the lever back over to tighten the baffle and cam lock (Figure 22). 6. If the cam does 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 20 1. Anti-scalp roller 2. Spacer 3. Bushing 4. 5. Flange Nut Bolt Figure 22 1. Cam lock 3. 2. Lever 4.
Figure 25 Figure 23 Positioning the Seat Position B The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable. Use this position when bagging. Important: To adjust, move the lever sideways to unlock seat (Figure 26). Slide the seat to the desired position and release lever to lock in position. Figure 24 Position C This is the full open position. The suggested use for this position is as follows.
Figure 28 Figure 27 1. Seat latch 2. Fuel cap 3. 1. Side console controls 2. By-pass valve Seat 3. Hydraulic pumps Using the Side Discharge Pushing the Machine by Hand The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. Important: Always push the machine by hand. Never tow the machine because hydraulic damage may occur.
Please carefully read all the safety instructions. Knowing this information could help you, your family, pets or bystanders avoid injury. ramp. Both maneuvers can cause the unit to tip backward. To transport the machine: • Lock the brake and block the wheels. • Securely fasten the machine to the trailer or truck with straps, chains, cable, or ropes. • Secure a trailer to the towing vehicle with safety chains.
Operating Tips Long Grass Fast Throttle Setting If the grass is ever allowed to grow slightly longer than normal, or if it contains a high degree of moisture, raise the cutting height higher than usual and cut the grass at this setting. Then cut the grass again using the lower, normal setting. For best mowing and maximum air circulation, operate the engine at the fast throttle position.
Maintenance Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the rst 8 operating hours • Change the engine oil. • Check the hydraulic uid. • Change the hydraulic lter and oil. Before each use or daily • • • • • Check the safety system. Check the engine oil level. Clean the air intake screen. Check the mower blades. Clean the mower deck. Every 25 hours • • • • • Grease the mower deck and spindles. Grease the mower belt idler arm.
Lubrication Greasing and Lubrication Lubricate the machine when shown on the Check Service Reference Aid decal (Figure 30). Grease more frequently when operating conditions are extremely dusty or sandy. Grease Type: General-purpose grease. How to Grease 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Figure 30 3.
4. Grease the three spindle bearings under the pulleys until grease comes out the lower seals (Figure 31). 3. Release the latches on the air cleaner and pull the air cleaner cover off the air cleaner body (Figure 32). 5. Grease the idler arm on the mower deck (Figure 31). 6. Grease the fittings on the push arms (Figure 31). Figure 32 1. 2. 3. Air cleaner body Primary lter Latch 4. 5. Air cleaner cover Safety lter 4. Clean the inside of the air cleaner cover with compressed air. 5.
Important: Never attempt to clean the safety filter. If the safety filter is dirty, then the primary filter is damaged. Replace both filters. Installing the Filters Important: To prevent engine damage, always operate the engine with both air filters and cover installed. 1. If installing new filters, check each filter for shipping damage. Do not use a damaged filter. 2. If the safety filter is being replaced, carefully slide it into the filter body (Figure 32). Figure 33 3.
Important: Do not overfill the crankcase with oil and run the engine; engine damage can result. 10. Check the oil level; refer to Checking the Engine Oil Level. 11. Slowly add the additional oil to bring it to the Full mark. Changing the Oil Changing the Oil Filter 1. Start the engine and let it run five minutes. This warms the oil so it drains better. Replace the oil filter every 200 operating hours or every other oil change. 2.
Servicing the Spark Plugs 2. If needed, clean the spark plug with a wire brush to remove carbon deposits. Service Interval/Specication Check the spark plugs after every 100 operating hours. Ensure that the air gap between the center and side electrodes is correct before installing the spark plug. Use a spark plug wrench for removing and installing the spark plugs and a gapping tool/feeler gauge to check and adjust the air gap. Install a new spark plugs if necessary.
4. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 5. Close the fuel shutoff valve (Figure 39). 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).
Removing the Battery Battery terminals or metal tools could short against metal machine components causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. • When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine. • Do not allow metal tools to short between the battery terminals and metal parts of the machine. Figure 40 1. 2. 3. 4. 5. 6.
Charging the Battery Fuse: • Main, F1-30 amp, blade-type • Charge circuit, F2-25 amp, blade-type Charging the battery produces gasses that can explode. • Optional head light kit, 10 amp, blade-type 1. Raise the seat to gain access to the fuse holder (Figure 42). Never smoke near the battery and keep sparks and flames away from battery. 2. To replace the fuses, pull out on the fuse to remove it. Important: Always keep the battery fully charged (1.265 specific gravity).
Drive System Maintenance Checking the Tire Pressure Check the pressure at the valve stem after every 50 operating hours or monthly, whichever occurs first (Figure 44). Adjusting the Tracking Maintain the air pressure in the front and rear tires at 13 psi (90 kPa). Uneven tire pressure can cause uneven cut. Check the tires when they are cold to get the most accurate pressure reading. Note: Determine the left and right sides of the machine from the normal operating position.
Figure 45 1. Slotted Nut 2. Two threads or less showing 3. 4. Hole in threaded shaft Washer (if needed) Figure 46 1. 2. 5. Check the distance from bottom of slot in nut to inside edge of hole. Two threads or less should be showing (Figure 45). Spring Washers Lock Nut 3. Dust Cap Cooling System Maintenance 6. If more than two threads are showing remove nut and install washer between hub and nut. Cleaning the Air Intake Screen 7. Torque the slotted nut to 125 ft-lb. (170 N•m) (Figure 45). 8.
Figure 48 1. Brake lever 2. Spring, 2-3/4 inch (74 mm) 6. 7. 3. Adjusting nuts 4. Collar on brake rod Figure 47 1. Air intake screen 2. Fan housing 3. Recoil starter 4. 5. 5. Bolt Nut 3/16 to 1/4 inch (5 to 7 mm) Jam nut and yoke Trunnion 3. If an adjustment is necessary, do the following: A. Loosen the jam nut below the spring and tighten the nut directly below the yoke (Figure 48). B. Turn the nut until you obtain the correct measurement. C.
Check belts for cracks, frayed edges, burn marks or any other damage. Replace damaged belts. Replacing the Mower Belt The signs of a worn mower belt are squealing while the belt is rotating, blades slipping while you are cutting grass, frayed belt edges, burn marks, and cracks. Replace the mower belt if you detect any of these signs. 1. Disengage the PTO, move the motion control levers to the neutral locked position, and set the parking brake. Figure 50 2.
Note: Increase the tension by lengthening the push arms; decrease the tension by shortening the push arms. 7. Release the pressure on the spring loaded idler (Figure 51). 8. Install the mower belt. Controls System Maintenance Adjusting the Control Handle Neutral Position If the motion control levers do not align or move easily into the console notch, adjustment them. Adjust each lever, spring, and rod separately. Note: The motion control levers must be installed correctly.
Hydraulic System Maintenance Servicing the Hydraulic System Checking the Hydraulic Fluid Fluid Type: Mobil 1 15W-50 synthetic motor oil or equivalent synthetic oil. Important: Use oil specified or equivalent. Other fluids could cause system damage. Hydraulic System Oil Capacity: 67 ounces (2.0 l) Check the hydraulic fluid level: • Before the engine is first started. • After the first 8 operating hours. • After every 25 operating hours. Figure 54 1. 2. 3. 4. 5.
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. Important: Do not substitute automotive oil filter or severe hydraulic system damage may result. Figure 55 1. Cap 2. Bafe 3. 4. 3. Place a drain pan under filter, remove the old filter and wipe the filter adapter gasket surface clean (Figure 56).
Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • If hydraulic fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result if this is not done. • Keep body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid. Figure 57 1. Hydraulic lter 2. Gasket 3. Adapter • Use cardboard or paper to find hydraulic leaks.
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. 1. Raise the frame and block up the machine so drive wheels can rotate freely. 2. Disconnect the electrical connector from the seat safety switch. Temporarily install a jumper wire across terminals in the wiring harness connector. Figure 58 3.
Mower Deck Maintenance Leveling the Mower at Three Positions Important: There are only three measuring positions needed to level the mower. Setting Up the Machine 1. Position mower on a flat surface. 2. Disengage the PTO, move the motion control levers to the neutral locked 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.
Figure 61 Figure 60 1. Measure here from blade to hard surface 2. 1. 2. 3. 4. Measure at B and C 7. If the measurements at positions B or C are not correct, loosen the bolt attaching the rear chain to the rear support arm (Figure 61). Rear chain Rear support arm Bolt Jam Nut 5. 6. 7. Adjustment bolt Front swivel Front support arm Adjusting the Front-to-Rear Mower Pitch 8.
4. Measure the right blade at the B location, from a level surface to the cutting edge of the blade tip (Figure 62). 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 62). If it is not correct, proceed to the following steps. Note: Both of the front swivels need to be adjusted the same amount to maintain equal chain tension. 7.
Before Inspecting or Servicing the Blades Park the machine on a level surface, disengage the blade control (PTO), and set the parking brake. Turn the ignition key to Off. Remove the key. Inspecting the Blades 1. Inspect the cutting edges (Figure 64). If the edges are not sharp or have nicks, remove and sharpen the blades. Refer to Sharpening the Blades. 2. Inspect the blades, especially the curved area (Figure 64).
Contact with a sharp blade can cause serious injury. Figure 67 Wear gloves or wrap sharp edges of the blade with a rag. 1. 1. Hold the blade end using a rag or thickly-padded glove. Blade 2. Balancer Installing the Blades 2. Remove the blade bolt, spring disk and blade from the spindle shaft (Figure 68). 1. Install the blade onto the spindle shaft (Figure 68). Important: The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting.
Replacing the Grass Deector An uncovered discharge opening could allow the lawn mower to throw objects in the operator’s or bystander’s direction and result in serious injury. Also, contact with the blade could occur. • Never operate the lawn mower unless you install a cover plate, a mulch plate, or a grass chute and catcher. Figure 69 • 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 69).
Storage A. Add a petroleum based stabilizer/conditioner to fuel in the tank. Follow mixing instructions from the stabilizer manufacturer. Do not use an alcohol based stabilizer (ethanol or methanol). 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to Off. Remove the key. 2. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine and hydraulic system.
Troubleshooting Problem Starter does not crank Possible Cause 1. Blade control (PTO) is engaged. 2. Parking brake is not on. 3. Operator is not seated. 4. Battery is dead. 5. Electrical connections are corroded or loose. 6. Fuse is blown. 7. Relay or switch is defective. Engine will not start, starts hard, or fails to keep running. 1. Fuel tank is empty. 2. Air cleaner is dirty. 3. Dirt in the fuel lter. 4. Dirt, water, or stale fuel is in the fuel system. Engine loses power. 1.
Problem Machine does not drive. Abnormal vibration. Possible Cause 1. By pass valve is not closed tight. 2. Drive or pump belt is worn, loose or broken. 3. Drive or pump belt is off a pulley. 4. Broken or missing idler spring. 5. Hydraulic uid level is low or too hot. 1. Tighten the by pass valve. 2. Change the belt. 1. Cutting blade(s) is/are bent or unbalanced. 2. Blade mounting bolt is loose. 3. Engine mounting bolts are loose. 4. Loose engine pulley, idler pulley, or blade pulley. 5.
Problem Blades do not rotate. Possible Cause 1. Drive belt is worn, loose or broken. 2. Drive belt is off pulley. 3. Deck belt is worn, loose or broken. 4. Deck belt is off pulley. 5. Broken or missing idler spring. 54 Corrective Action 1. Check the belt tension. 2. Install the drive belt and check adjusting shafts and belt guides for correct position. 3. Install a new deck belt. 4. Install the deck pulley and check the idler pulley, idler arm and spring for correct position and function. 5.
Schematics Wire Diagram (Rev.
Evaporative Emission Control Warranty Statement California Evaporative Emission Control Warranty Statement Your Warranty Rights and Obligations Introduction The California Air Resources Board and The Toro® Company are pleased to explain the evaporative emission control system’s warranty on your 2006 model year equipment. In California, new equipment that use small off-road engines must be designed, built, and equipped to meet the State’s stringent anti-smog standards.
LCE The Toro Total Coverage Guarantee A Limited Warranty Conditions and Products Covered Items and Conditions Not Covered The Toro® Company and its afliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair the listed Toro Products if defective in materials or workmanship.
