Form No. 3356-174 Rev A Z453 Z Master® with 132cm TURBO FORCE® Side Discharge Mower Model No. 74416TE—Serial No. 270000001 and Up Register your product at www.Toro.
This spark ignition system complies with Canadian ICES-002 Figure 2 Introduction 1. Safety alert symbol Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage. You are responsible for operating the product properly and safely. 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.
Maintenance...................................................... 27 Recommended Maintenance Schedule(s) ............................... 27 Lubrication................................................ 28 Greasing and Lubrication................... 28 Greasing the Mower Deck and Belt Idlers................................. 28 Lubricating the Caster Wheel Hubs ................................. 29 Engine Maintenance.................................. 30 Servicing the Air Cleaner ...................
Safety ◊ the type of machine is unsuitable for its task; ◊ lack of awareness of the effect of ground conditions, especially slopes; This machine meets or exceeds European Standards in effect at the time of production. However, 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.
• Mow only in daylight or in good artificial light. • Before attempting to start the engine, disengage all blade attachment clutches and shift into neutral. • Do not use on slopes greater than 15 degrees. • Remember there is no such thing as a safe slope. Travel on grass slopes requires particular care.
information that you must know that is not included in the CEN standard. • Watch for ditches, holes, rocks, dips, and rises that change the operating angle, as rough terrain could overturn the machine. • Engine exhaust contains carbon monoxide, which is an odorless, deadly poison that can kill you. Do not run engine indoors or in an enclosed area. • Avoid sudden starts when mowing uphill because the mower may tip backwards. • Be aware that loss of traction may occur going downhill.
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. 98-4387 58-6520 1. Warning—wear hearing protection. 1. Grease 93-7010 1. Thrown object hazard— 2. Thrown object hazard, mower—keep the deector in place. 3. Cutting/dismemberment of hand or foot—stay away from moving parts. 99-8936 1. Machine speed 2. Fast 3. Slow 93-7818 1.
9-8939 3. 1. Read the Operator’s Manual. 2. Height of cut Remove the ignition key and read the instructions before servicing or performing maintenance. 107-1686 1. 2. 3. 99-8944 1. Explosion hazard—wear eye protection. 2. Caustic liquid/chemical burn hazard—to perform rst aid, ush with water. 3. 4. 4. 5. Tire pressure Read the Operator’s Manual before servicing or performing maintenance. Time interval 6. Grease here Air lter 7.
7-2131 1. Hydraulic oil level 2. Warning—do not touch the hot surface. 107-2132 108-1052 1. Warning—engage the parking brake and chock the wheels when parking on a hill. 1. Height of cut adjustment 108-1053 1. Height-of-cut 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 wear the seat belt.
Battery Symbols Some or all of these symbols are on your battery 110-2068 1. Read the Operator’s Manual. 1. Explosion hazard 2. No re, open ame, or smoking. 3. Caustic liquid/chemical burn hazard Wear eye protection 4. 5. Read the Operator’s Manual. 6. Keep bystanders a safe distance from the battery. 7. Wear eye protection; explosive gases can cause blindness and other injuries 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast.
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. 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.
4. To raise the roll bar, remove the hairpin cotter pins and remove the two pins (Figure 8). Operating on wet grass or steep slopes can cause sliding and loss of control. 5. Raise the roll bar to the upright position and install the two pins and secure them with the hairpin cotter pins (Figure 8). Wheels dropping over edges can cause rollovers, which may result in serious injury, death or drowning. Important: Always use the seat belt with the roll bar in the raised position.
This machine produces sound levels in excess of 85 dBA at the operators ear and can cause hearing loss through extended periods of exposure. Wear hearing protection when operating this machine. Use protective equipment for your eyes, ears, feet, and head. Figure 11 1. 2. Figure 10 Parking brake-ON Parking brake-OFF 3. Brake Stop Starting and Stopping the Engine 1. Warning— wear hearing protection Starting the Engine Operating the Parking Brake 1.
Note: A warm or hot engine may not require choking. After engine starts, move choke control to Run position. Figure 15 1. Off 2. Run 2. Start 7. After the engine starts, move the choke to off (Figure 13). If the engine stalls or hesitates, move the choke back to on for a few seconds, then move the throttle lever to desired setting. Repeat this as required. Figure 13 1. Choke—on 3. Stopping the Engine Choke—off 1. Push the PTO to the off position (Figure 12). 5.
The Safety Interlock System Operating the Power Take Off (PTO) The power take off (PTO) switch starts and stops the mower blades and any powered attachments. Engaging the PTO If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. 1. If the engine is cold, allow the engine to warm up 5 to 10 minutes before engaging the PTO. • Do not tamper with the interlock switches. 2.
PTO and rise slightly from the seat; the engine should stop. 4. Sitting on the seat, engage the parking brake, move the PTO switch to off and move the motion control levers to neutral lock position. Now start the engine. While the engine is running, center either motion control and move (forward or reverse); the engine should stop. Repeat for other motion control. 5. Sitting on the seat, disengage the parking brake, move the PTO switch to off and move the motion control levers to neutral lock position.
Stopping the Machine To stop the machine, move the traction control levers to neutral and move to locked position, disengage the power take off (PTO), and turn the ignition key to off. Set the parking brake when you leave the machine; refer to Setting the Parking Brake in Operation, page 14. Remember to remove the key from the ignition switch. Figure 18 Children or bystanders may be injured if they move or attempt to operate the tractor while it is unattended. 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 21). 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 19 1. Anti-scalp roller 2. Spacer 3. Bushing 4. 5. Flange Nut Bolt Figure 21 1. Cam lock 3. 2. Lever 4.
Figure 22 Position B Figure 24 Use this position when bagging. Positioning the Seat The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable. Important: To adjust, move the lever sideways to unlock seat (Figure 25). Slide the seat to the desired position and release lever to lock in position. Figure 23 Position C This is the full open position. The suggested use for this position is as follows.
Figure 27 Figure 26 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. After the rst 25 operating hours • 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.
Lubrication Greasing and Lubrication Lubricate the machine when shown on the Check Service Reference Aid decal (Figure 29). 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 29 3.
4. Grease the three spindle bearings under the pulleys until grease comes out the lower seals (Figure 30). 5. Grease the idler arm on the mower deck (Figure 30). 6. Grease the fittings on the push arms (Figure 30). Figure 31 1. 2. 3. Caster fork Bolt Seal guard 4. 5. Caster wheel Nut 6. Remove one of the spacer nuts (with wrench flats) from the axle (Figure 33). Note: Thread locking adhesive has been applied to the spacer nuts. Figure 30 7.
Figure 33 1. Spacer nut 2. Bearing seal (new seals required) 3. Bearing 4. 5. Caster wheel Nut and axle assembled Engine Maintenance Figure 32 1. 1/8 inch (3 mm) of the nut past the axle Servicing the Air Cleaner 12. Install the assembled nut and axle into the wheel on the side with the bearing and a new seal (Figure 33). Replace the air filter every 200 operating hours. Note: Service the filter more frequently if operating conditions are extremely dusty or sandy. 13.
4. Clean the inside of the air cleaner cover with compressed air. 5. Gently slide the air filter out of the air cleaner body (Figure 34). Avoid knocking the filter into the side of the body. 6. Inspect the air filter for damage by looking into the filter while shining a bright light on the outside of the filter. Holes in the filter will appear as bright spots. If the filter is damaged discard it. Servicing the Air Filter Do not clean the filter. Replace it after 200 operating hours.
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.
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 new spark plugs if necessary. Type: Champion® RCJ8Y or equivalent Air Gap: 0.030 inch (0.75 mm) Removing the Spark Plugs 1. Disengage the PTO and set the parking brake. Figure 40 1. 2. 2.
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 41). 2. Disengage the power takeoff (PTO), set the parking brake, stop the engine, and remove the key. 3. Close the fuel shutoff valve (Figure 41). 4. Loosen the hose clamp at the fuel filter and slide it up the fuel line away from the fuel filter (Figure 41). 5. Disconnect the fuel line from the fuel filter (Figure 41). 6. Open the fuel shutoff valve.
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 42 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 44). 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 46). Adjusting the Tracking Maintain the air pressure in the 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 47 1. Slotted Nut 2. Two threads or less showing 3. 4. Hole in threaded shaft 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 47). Figure 48 6. If more than two threads are showing remove nut and install washer between hub and nut. 1. Spring Washers 2. Lock Nut 3. Dust Cap 7. Torque the slotted nut to 125 ft-lb. (170 N•m) (Figure 47). 9. Replace the cotter pin.
4. Clean the debris and grass from the engine parts. 5. Install air intake screen, recoil starter and fan housing (Figure 49). Figure 50 1. 2. 3. 4. 3. 4. 5. 3/16 to 1/4 inch (5 to 7 mm) Spring, 2-3/4 inch (74 mm) 6. Jam nut and yoke 7. Trunnion Adjusting nuts Collar on brake rod 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 50). 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 52 1. Ratchet with short extension or breaker bar 2.
7. Release the pressure on the spring loaded idler (Figure 53). 8. Install the mower belt. Figure 54 1. 2. Figure 53 1. Belt 2. Clutch electrical wire 3. Clutch stop 4. 5. 6. Bolt Clutch Idler Push arm 15–1/8 inch (384 mm) 3. 4. Jam nut Ball joint 2. Adjust each side the same amount. Each push arm should have a length of 15–1/8 inch (384 mm) (Figure 54). Note: Increase the tension by lengthening the push arms; decrease the tension by shortening the push arms.
5. Move lever to the neutral position but not locked (Figure 55). Figure 55 1. Neutral locked position 2. Control lever 3. Neutral potion 6. Pull the lever back until the clevis pin (on the arm below the pivot shaft) contacts the end of the slot (just beginning to put pressure on the spring) (Figure 56). Figure 56 1. 2. 3. 4. 5. Clevis pin in slot Nut Nut-Left hand thread Adjustment bolt Pump rod 6. 7. 8. 9. Double nuts Jam nut Yoke Ball joint 7.
Hydraulic System Maintenance Servicing the Hydraulic System Checking the Hydraulic Fluid Fluid Type: Mobil 1 15W-50 synthetic motor oil or equivalent synthetic oil. Figure 57 1. 2. Important: Use oil specified or equivalent. Other fluids could cause system damage. Cap Bafe 3. 4. Cold uid level-full Hot uid level-full Hydraulic System Oil Capacity: 67 ounces (2.0 l) Check the hydraulic fluid level: Hydraulic fluid escaping under pressure can penetrate skin and cause injury.
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. 3. Place a drain pan under filter, remove the old filter and wipe the filter adapter gasket surface clean (Figure 58). Figure 59 1. Hydraulic lter 2. Gasket 3.
Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Engine must be running so motion control adjustment can be performed. Contact with moving parts or hot surfaces may cause personal 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 hands, feet, face, clothing and other body parts away from rotating parts, muffler and other hot surfaces.
Figure 60 1. Tracking knob 2. Pump rod 3. Adjustment bolt Setting the Right-hand Hydraulic Pump Neutral Position Figure 61 1. Double nuts 2. Pump rod 1. Loosen the locknuts at the ball joints on the pump control rod (Figure 61). 2. Start the engine, open throttle 1/2 way and release parking brake. Refer to Starting and Stopping the Engine in Operation, page 14. 3. 4. Locknut Ball joint Electrical system will not perform proper safety shut off with jumper wire installed.
Mower Deck Maintenance 6. Record this measurement. This measurement needs to be 3-1/8 to 3-1/4 inches (79 to 83mm). Leveling the Mower at Three Positions Important: There are only three measuring positions needed to level the mower. Preparing 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.
4. Measure the right blade at the B location, from a level surface to the cutting edge of the blade tip (Figure 64). 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 64). 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 66). 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 66).
Removing the Blades 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Blades must be replaced if a solid object is hit, if the blade is out of 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. 3.
Replacing the Grass Deector (Figure 70). Repeat this procedure until the blade is balanced. 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. Figure 69 1. Blade 2. Balancer • Never operate the lawn mower unless you install a cover plate, a mulch plate, or a grass chute and catcher. Installing the Blades 1. Install the blade onto the spindle shaft (Figure 70).
Figure 71 1. Bolt 2. Spacer 3. Locknut 5. 6. 7. 4. Spring 8. Spring installed Grass Deector L end of spring, place behind deck edge before installing bolt J hook end of spring Cleaning Cleaning Under the Mower Remove the grass buildup under the mower daily. 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3.
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 Corrective Action 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. 1. Move the blade control (PTO) to disengaged. 2. Set the parking brake. 3. Sit on the seat. 4. Charge the battery. 5. Check the electrical connections for good contact. 6. Replace the fuse. 7. Contact an Authorized Service Dealer. 6. Fuse is blown. 7.
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. 56 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.
