Form No. 3359-105 Rev A Z419 Z Master® with 122 cm TURBO FORCE® Side Discharge Mower Model No. 74421TE—Serial No. 280000001 and Up Register at www.Toro.com.
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.
Safety Greasing the Mower Deck and Belt Idlers.............................................................. 28 Engine Maintenance............................................... 29 Servicing the Air Cleaner .................................... 29 Servicing the Engine Oil ..................................... 30 Servicing the Spark Plugs.................................... 32 Fuel System Maintenance ....................................... 33 Replacing the Fuel Filter .....................................
Preparation • While mowing, always wear substantial footwear and long trousers. Do not operate the equipment when barefoot or wearing open sandals. • Thoroughly inspect the area where the equipment is to be used and remove all objects which may be thrown by the machine. • Warning–Fuel is highly flammable. – Store fuel in containers specifically designed for this purpose. – Refuel outdoors only and do not smoke while refuelling. – Add fuel before starting the engine.
• Do not make sudden turns or rapid speed changes. • Allow the engine to cool before storing in any enclosure. • To reduce the fire hazard, keep the engine, silencer, battery compartment and fuel storage area free of grass, leaves, or excessive grease. • Check the grass catcher frequently for wear or deterioration. • Replace worn or damaged parts for safety. • If the fuel tank has to be drained, this should be done outdoors.
Slope Chart 6
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 99-8936 1. Machine speed 2. Fast 3. Slow 4. Neutral 5. Reverse 93-7010 1. Thrown object hazard— 2. Thrown object hazard, mower—keep the deflector in place. 3. Cutting/dismemberment of hand or foot—stay away from moving parts. 93-7818 99-8939 1.
99-8944 1. Explosion hazard—wear eye protection. 2. Caustic liquid/chemical burn hazard—to perform first aid, flush with water. 3. Fire hazard—no fire, open flames, or smoking. 4. Poison hazard—keep children away from the battery. 106-5517 107-1686 1. Warning—do not touch the hot surface. 5. Tire pressure 1. Read the Operator’s Manual before servicing or performing maintenance. 2. Time interval 6. Grease here 3. Air filter 7. Check and perform any maintenance necessary 4.
107-2131 1. Hydraulic oil level 2. Warning—do not touch the hot surface. 108-1052 107-2132 1. Height of cut adjustment 1. Warning—engage the parking brake and chock the wheels when parking on a hill. 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 1. Explosion hazard 110-2068 1. Read the Operator’s Manual. 2. No fire, open flame, or smoking. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 112-9028 5. Read the Operator’s Manual. 1. Warning—stay away from moving parts; keep all guards in place. 6. Keep bystanders a safe distance from the battery. 7. Wear eye protection; explosive gases can cause blindness and other injuries 8.
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. Engine—run 4. Engine—start 5. Fast 6. Continuous variable setting 11 7. Slow 8.
Using the Hour Meter Product Overview 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 Throttle Control The throttle control has two positions: Fast and Slow. Figure 3 1. 2. 3. 4. 5. Rollbar Fuel cap (both sides) Seat belt Motion control lever Height-of-cut lever 6. 7. 8. 9. 10.
Operation Close the fuel shutoff valve before transporting or storing the machine. Note: Determine the left and right sides of the machine from the normal operating position. Adding Fuel Use Unleaded Regular Gasoline suitable for automotive use (85 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available. Important: Never use methanol, gasoline containing methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged.
Important: Do not use fuel additives containing methanol or ethanol. 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. Add the correct amount of gas stabilizer/conditioner to the gas. Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline.
Important: Always use the seat belt with the roll bar in the raised position. There is no rollover protection when the roll bar is in the down position. 1 • Lower the roll bar only when absolutely necessary. 2 • Do not wear the seat belt when the roll bar is in the down position. • Drive slowly and carefully. • Raise the roll bar as soon as clearance permits. • Check carefully for overhead clearances (i.e. branches, doorways, electrical wires) before driving under any objects and do not contact them.
Operating on wet grass or steep slopes can cause sliding and loss of control. This machine produces sound levels in excess of 85 dBA at the operators ear and can cause hearing loss through extended periods of exposure. Wheels dropping over edges can cause rollovers, which may result in serious injury, death or drowning. Wear hearing protection when operating this machine. There is no rollover protection when the roll bar is down. Use protective equipment for your eyes, ears, feet, and head.
Figure 13 Figure 11 1. Parking brake-ON 2. Parking brake-OFF 1. Choke—on 2. Choke—off 3. Brake Stop 5. Move the throttle control to the Fast position before starting a cold engine (Figure 14). Starting and Stopping the Engine Starting the Engine 1. Sit on the seat and move the motion controls to neutral locked position. 2. Set the parking brake; refer to Setting the Parking Brake. Figure 14 1. Throttle—fast 3. Move the PTO (power take off) switch to the Off position (Figure 12). 2. Throttle—slow 6.
Engaging the PTO 1. If the engine is cold, allow the engine to warm up 5 to 10 minutes before engaging the PTO. 2. While seated in the seat, 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 16). Figure 15 1. Off 2. Run 3. Start 7.
• You are sitting on the seat. • The parking brake is engaged. Machine can spin very rapidly. Operator may lose control of machine and cause personal injury or damage to machine. • The power take off (PTO) is disengaged. • The motion control levers are in the neutral locked position • Use caution when making turns.
Children or bystanders may be injured if they move or attempt to operate the tractor while it is unattended. Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes. Adjusting the Height-of-Cut The height-of-cut is adjusted from 1-1/2 to 4-1/2 inch (38 to 114 mm) in 1/4 inch (6 mm) increments by relocating the clevis pin into different hole locations. 1.
2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. After adjusting the height-of-cut, adjust the rollers by removing the flange nut, bushing, spacer, and bolt (Figure 19 , Figure 20 and Figure 49 ). Note: The two middle rollers will not have a spacer (Figure 20). 4. Select a hole so the anti-scalp roller is positioned to the nearest corresponding height-of-cut desired. 5. Install the flange nut bushing, spacer, and bolt.
Figure 23 Figure 21 1. Cam lock 2. Lever 3. Rotate cam to increase or decrease locking pressure 4. Slot 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 in wet conditions. • Lowers the engine power consumption. • Allows increased ground speed in heavy conditions. • This position is similar to the benefits of the Toro SFS mower.
Important: Do not rotate by-pass valves more than 1 turn. This prevents valves from coming out of the body and causing fluid to run out. Slide the seat to the desired position and release lever to lock in position. 3. Disengage parking brake before pushing. Changing to Machine Operation Rotate the by-pass valves clockwise 1 turn to operate machine (Figure 27). Note: Do not over tighten the by-pass valves. The machine will not drive unless by-pass valves are turned in. Figure 25 1.
Loading Machines Use extreme caution when loading units on trailers or trucks. One full width ramp that is wide enough to extend beyond the rear tires is recommended instead of individual ramps for each side of the unit (Figure 28). The lower rear section of the tractor frame extends back between the rear wheels and serves as a stop for tipping backward. Having a full width ramp provides a surface for the frame members to contact if the unit starts to tip backward.
Mowing Direction Alternate mowing direction to keep the grass standing straight. This also helps disperse clippings which enhances decomposition and fertilization. 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.
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.
Maintenance Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 8 hours • Change the engine oil. • Check the hydraulic fluid. After the first 25 hours • Change the hydraulic filter. Before each use or daily • • • • • Check the safety system. Check the engine oil level. Clean the engine air intake screen from grass and debris. 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). Engine Maintenance 5. Grease the idler arm on the mower deck (Figure 30). Servicing the Air Cleaner 6. Grease the fittings on the push arms (Figure 30). Service Interval: Every 25 hours—Clean foam air cleaner element (more often in dirty or dusty conditions). Every 50 hours—Check the paper air cleaner element (more often in dirty or dusty conditions).
2. Place the air cleaner assembly onto the air cleaner base and secure it with the 2 wing nuts (Figure 31). 3. Place the air cleaner cover into position and tighten the cover knob (Figure 31). Servicing the Engine Oil Note: Change the oil more frequently when the operating conditions are extremely dusty or sandy. Oil Type: Detergent oil (API service SF, SG, SH, or SJ) Crankcase Capacity: 58 ounces (1.7 liter) with the filter removed; 51 ounces (1.
Figure 33 2. Filler tube 1. Oil dipstick 5. Unscrew the oil dipstick and wipe the end clean (Figure 33). 6. Slide the oil dipstick fully into the filler tube, but do not thread onto tube (Figure 33). Figure 34 7. Pull the dipstick out and look at the metal end. If the oil level is low, slowly pour only enough oil into the filler tube to raise the level to the Full mark. 1. Oil drain valve 2. Oil drain hose 9. Slowly pour approximately 80% of the specified oil into the filler tube (Figure 33). 10.
Checking the Spark Plugs 3. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Figure 35). 4. 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 3/4 turn (Figure 35). 5. Fill the crankcase with the proper type of new oil; refer to Servicing the Engine Oil. 6.
Servicing the Fuel Tank Fuel System Maintenance In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property. Replacing the Fuel Filter Service Interval: Every 200 hours or yearly, whichever occurs first. • 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 install a dirty filter if it is removed from the fuel line. 1.
Electrical System Maintenance Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. Servicing the Battery • Always Disconnect the negative (black) battery cable before disconnecting the positive (red) cable.
6. Remove both wing nuts (1/4 inch) securing the battery clamp (Figure 39). 7. Remove the battery. Installing the Battery 1. Position battery in the tray with the terminal posts toward the engine (Figure 39). 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 with 2 bolts (1/4 x 3/4 inch), 2 washers (1/4 inch), and 2 locknuts (1/4 inch) (Figure 39).
Drive System Maintenance Adjusting the Tracking Note: Determine the left and right sides of the machine from the normal operating position. The machine has a knob for adjusting the tracking located under the seat. Important: Adjust the handle neutral and hydraulic pump neutral before adjusting the tracking. Refer to Adjusting the Handle Neutral in Controls System Maintenance , page 42 and Adjusting the Hydraulic Pump Neutral in Hydraulic System Maintenance , page 43. Figure 41 1. Main, 30 amp 2.
Check the pressure at the valve stem after every 50 operating hours or monthly, whichever occurs first (Figure 43). Maintain the air pressure in the rear tires at 13 psi (90 kPa). Uneven tire pressure can cause an uneven cut. Check the tires when they are cold to get the most accurate pressure reading. Note: The front tires are semi-pneumatic tires and do not require air pressure maintenance. Figure 44 1. Slotted Nut 2. Two threads or less showing 3. Hole in threaded shaft 4. Washer (if needed) 5.
Cooling System Maintenance Cleaning the Air Intake Screen Service Interval: Before each use or daily Before each use remove any build-up of grass, dirt or other debris from the cylinder and cylinder head cooling fins, air intake screen on flywheel end, and carburetor-governor levers and linkage. This will help insure adequate cooling and correct engine speed and will reduce the possibility of overheating and mechanical damage to the engine. Cleaning the Cooling System Figure 45 1. Spring Washers 2.
Brake Maintenance Adjusting the Parking Brake Check the parking brake for proper adjustment. 1. Disengage the brake lever (lever down). 2. Measure the length of the spring; the measurement should be 2-3/4 inch (74 mm) between the washers (Figure 47). Figure 46 1. Guard 2. Air intake screen 3. Bolt 4. Fan housing 5. Bolt Figure 47 1. Brake lever 5. 3/16 to 1/4 inch (5 to 7 mm) 2. Spring, 2-3/4 inch (74 mm) 6. Jam nut and yoke 3. Adjusting nuts 7. Trunnion 4. Collar on brake rod 3.
Belt Maintenance 6. Measure the distance between the trunnion roller and the collar on the brake rod. The measurement should be 3/16 to 1/4 inch (5 to 7 mm) (Figure 47). Inspecting the Belts 7. If an adjustment is necessary, do the following: A. Loosen the jam nut directly below the yoke. Service Interval: Every 100 hours B. Turn the bottom adjusting nuts until the correct measurement is obtained (Figure 47). Check belts for cracks, frayed edges, burn marks or any other damage. Replace damaged belts.
Figure 49 1. Ratchet with short extension or breaker bar 2. Square hole Figure 50 1. Belt 2. Clutch electrical wire 3. Clutch stop 8. To increase the belt tension, rotate the ratchet or breaker bar counterclockwise to move the fixed idler arm until you feel increased resistance and the spring-loaded idler pulley stops moving. 4. Bolt 5. Clutch 6. Idler Adjusting the Push Arms Note: Do not increase the belt tension beyond the point where the fixed idler arm stops.
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. See Installing the Motion Control Levers in the Setup Instructions. 1. Disengage the PTO, move the motion control levers to the neutral locked position, and set the parking brake. 2.
Hydraulic System Maintenance Servicing the Hydraulic System Checking the Hydraulic Fluid Figure 54 Service Interval: After the first 8 hours 1. Cap 2. Baffle Every 25 hours 3. Cold fluid level-full 4. Hot fluid level-full Fluid Type: Mobil 1 15W-50 synthetic motor oil or equivalent synthetic oil. Hydraulic System Oil Capacity: 67 ounces (2.0 l) Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Important: Use oil specified or equivalent.
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 55). Figure 56 1. Hydraulic filter 2. Gasket 3.
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. 3. Unlatch the seat and slide seat forward. 4. Disconnect the seat rod and tilt the seat fully forward. Hydraulic fluid escaping under pressure can penetrate skin and cause injury.
2. Start the engine, open throttle 1/2 way and release parking brake. Refer to Starting and Stopping the Engine in Operation , page 13. Electrical system will not perform proper safety shut off with jumper wire installed. Note: The motion control lever must be in neutral while making any adjustments. • Remove jumper wire from wire harness connector and plug connector into seat switch when adjustment is completed. Note: The front nut on the pump rod has left-hand threads.
Mower Deck Maintenance 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. Figure 59 2. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 1. Measure here from blade to hard surface 3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 2. Measure at B and C 7.
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 61). 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. Loosen the front swivel jam nuts, at the front of the right and left swivels, approximately a 1/2 inch (13 mm) (Figure 60). 8.
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 Service Interval: Before each use or daily 1. Inspect the cutting edges (Figure 63). If the edges are not sharp or have nicks, remove and sharpen the blades. Refer to Sharpening the Blades. Figure 62 1. 10-1/2 inch (26.7 cm) for 60in mower decks and 11.125 inch (28.2 cm) for 52in mower decks 2.
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. Remove the blade bolt, spring disk and blade from the spindle shaft (Figure 67). Sharpening the Blades Figure 64 1. Measure here from blade to hard surface 2. Position A When sharpening blade, pieces of blade could be thrown and cause serious injury. 4. Rotate the opposite ends of the blades forward. 5.
Installing the Blades Important: The grass deflector must be able to lower down into position. Lift the deflector up to test that it lowers into the full down position. 1. Install the blade onto the spindle shaft (Figure 67). Important: The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting. 2. Install the spring disk and blade bolt. The spring disk cone must be installed toward the bolt head (Figure 67).
Cleaning Storage 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. Clean dirt and chaff from the outside of the engine cylinder head fins and blower housing. Cleaning Under the Mower Service Interval: Before each use or daily Remove the grass buildup under the mower daily. 1.
C. Stop the engine, allow it to cool, and drain the fuel tank; refer to Servicing the Fuel Tank in Maintenance. D. Restart the engine and run it until it stops. E. Dispose of fuel properly. Recycle as per local codes. Important: Do not store stabilizer/conditioned fuel over 90 days. 13. Check and tighten all bolts, nuts, and screws. Repair or replace any part that is damaged. 14. Paint all scratched or bare metal surfaces. Paint is available from your Authorized Service Dealer. 15.
Troubleshooting Problem Starter does not crank Engine will not start, starts hard, or fails to keep running. Possible Cause 1. Blade control (PTO) is engaged. 1. Move the blade control (PTO) to disengaged. 2. 3. 4. 5. Parking brake is not on. Operator is not seated. Battery is dead. Electrical connections are corroded or loose. 6. Fuse is blown. 7. Relay or switch is defective. 2. 3. 4. 5. 1. Fuel tank is empty. 1. Fill the fuel tank with fuel. 2. Air cleaner is dirty. 2.
Problem Uneven cutting height. Blades do not rotate. Possible Cause Corrective Action 1. Blade(s) not sharp. 1. Sharpen the blade(s). 2. Cutting blade(s) is/are bent. 3. Mower is not level. 4. Underside of mower is dirty. 5. Tire pressure is not correct. 6. Blade spindle bent. 2. Install new cutting blade(s). 3. Level the mower from side-to-side and front-to-rear. 4. Clean the underside of the mower. 5. Adjust the tire pressure. 6. Contact an Authorized Service Dealer. 1.
Schematics Wire Diagram (Rev.
Notes: 57
Notes: 58
The Toro Warranty Conditions and Products Covered Instructions for Obtaining Warranty Service The Toro® Company and its afliate, Toro Warranty Company, pursuant to an agreement between them, jointly promises to the original purchaser* to repair any Toro Product used for normal residential purposes* if defective in materials or workmanship.
International Distributor List—Consumer Products Distributor: Atlantis Su ve Sulama Sisstemleri Lt Balama Prima Engineering Equip B-Ray Corporation Casco Sales Company Ceres S.A CSSC Turf Equipment (pvt) Ltd Cyril Johnston & Co Equiver Femco S.A. G.Y.K. Company ltd. Geomechaniki of Athens Guandong Golden Star Hako Gorund and Garden Hydroturf Int. Co Hydroturf Egypt LLC Ibea S.p.A. Irriamc Jean Heybroek b.v. Lely (U.K. ) Limited Maquiver S.A. Maruyama Mfg. Co. Inc. Metra Kft Mounteld a.s. Munditol S.A.
