Form No. 3358-822 Rev A Z441 Z Master® with 48in or 52in TURBO FORCE® Side Discharge Mower Model No. 74441—Serial No. 280000001 and Up Model No. 74442—Serial No. 280000001 and Up Register at www.Toro.com.
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) .......................................................... 13 Think Safety First ............................................... 14 Operating the Parking Brake ............................... 15 Starting and Stopping the Engine ........................ 15 Operating the Power Take Off (PTO) ................. 17 The Safety Interlock System................................ 17 Driving Forward or Backward............................. 18 Stopping the Machine.............
Safety • 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. • Check that operator’s presence controls, safety switches and shields are attached and functioning properly. Do not operate unless they are functioning properly.
• Check the area to be mowed and never fold the ROPS in areas where there are slopes, drop offs or water. • Use extreme care when loading or unloading the machine into a trailer or truck. • Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision. • Lower the rollbar only when absolutely necessary. Do not wear the seat belt with the roll bar folded down. Slope Operation • Check carefully for overhead clearances (i.e.
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 1-403005 66-1340 1-523552 65-2690 1-633818 68-8340 98-4387 54-9220 1. Warning—wear hearing protection.
98-5954 103-2644 107-1687 105-7798 107-1688 107-1613 8
Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 2. No fire, open flame, or smoking. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 5. Read the Operator’s Manual. 107-2112 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. 10. Contains lead; do not discard.
7-8445 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 3. Neutral 2. Slow 4. Reverse 110-0439 1. Choke 2. Engine—stop 3. Engine—run 4. Engine—start 5. Fast 6. Continuous variable setting Product Overview 10 7. Slow 8.
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. Rollbar Fuel cap (both sides) Seat belt Motion control lever Height-of-cut lever 6. 7. 8. 9. 10.
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 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: Do not use fuel additives containing methanol or ethanol. Add the correct amount of gas stabilizer/conditioner to the gas. There is no rollover protection when the roll bar is in the down position. Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline. To minimize the chance of varnish deposits in the fuel system, use fuel stabilizer at all times. • Lower the roll bar only when absolutely necessary.
Think Safety First 5. To raise the roll bar, remove the hairpin cotter pins and remove the two pins (Figure 8). Please read all safety instructions and symbols in the safety section. Knowing this information could help you or bystanders avoid injury. 6. Raise the roll bar to the upright position and install the two pins and secure them with the hairpin cotter pins (Figure 8). 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.
Figure 15 1. Throttle—fast 6. Turn the ignition key to Start. When the engines starts, release the key (Figure 16). Figure 13 1. PTO—on 2. Throttle—slow 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).
The Safety Interlock System to remove the key as the fuel pump may run and cause the battery to lose charge. If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. Children or bystanders may be injured if they move or attempt to operate the tractor while it is unattended. • Do not tamper with the interlock switches.
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. Try starting the engine; the engine should not crank.
2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Children or bystanders may be injured if they move or attempt to operate the tractor while it is unattended. 3. After adjusting the height-of-cut, adjust the rollers by removing the flange nut, bushing, spacer, and bolt (Figure 20 , Figure 21 and Figure 50 ). Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes.
Figure 22 Figure 21 1. Anti-scalp roller 2. Bushing 3. Rotate cam to increase or decrease locking pressure 4. Slot 1. Cam lock 3. Flange Nut 4. Bolt 2. Lever Adjusting the Flow Baffle Positioning the Flow Baffle The mower discharge flow can be adjusted for different types of mowing conditions. Position the cam lock and baffle to give the best quality of cut. The following figures are only recommendations for use. Adjustments will vary by grass type, moisture content, and height of grass. 1.
Position B Use this position when bagging. Figure 26 1. Adjustment lever Figure 24 Unlatching the Seat Push the seat latch rearward to unlatch the seat. This will allow access to the machine under the seat (Figure 27). 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.
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. Without the grass deflector, discharge cover, or complete grass catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris. Contact with rotating mower blade(s) and thrown debris will cause injury or death. 3. Disengage parking brake before pushing.
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 29). 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 shredding the grass blades. Tearing and shredding turns grass brown at the edges, which slows growth and increases the chance of disease. Check the cutter blades daily for sharpness, and for any wear or damage. File down any nicks and sharpen the blades as necessary. If a blade is damaged or worn, replace it immediately with a genuine Toro replacement blade. Alternate mowing direction to keep the grass standing straight.
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 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.
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. 3. Clean the grease fittings with a rag. Make sure to scrape any paint off the front of the fitting(s). 4. Connect a grease gun to the fitting. Pump grease into the fittings until grease begins to ooze out of the bearings. 5. Wipe up any excess grease.
Engine Maintenance 3. Remove the belt covers. 4. Grease the three spindle bearings under the pulleys until grease comes out the lower seals (Figure 31). Servicing the Air Cleaner 5. Grease the idler arm on the mower deck (Figure 31). Replace the air filter every 200 operating hours. 6. Grease the fittings on the push arms (Figure 31). Note: Service the filter more frequently if operating conditions are extremely dusty or sandy. Removing the Filters 1.
Installing the Air Filter 2. Disengage the PTO, turn the ignition key to off, and remove the key. 3. Wait for all moving parts to stop before leaving the operating position and then chock or block tires. 4. Clean around the oil dipstick (Figure 34) so that dirt cannot fall into the filler hole and damage the engine. Important: To prevent engine damage, always operate the engine with the air filter and cover installed. 1. If installing a new filter, check it for shipping damage.
Note: Dispose of the used oil at a recycling center. Figure 36 1. Oil filter 2. Adapter 3. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Figure 36). 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 36). Figure 35 1. Oil drain valve 2. Oil drain hose 5.
Installing the Spark Plugs 1. Install the spark plugs and the metal washer. Ensure that the air gap is set correctly. 2. Tighten the spark plugs to 16 ft-lb (22 N•m). 3. Connect the wires to the spark plugs (Figure 38). Figure 37 1. Spark-plug wire/spark plug 4. Clean around the spark plugs to prevent dirt from falling into the engine and potentially causing damage. 5. Remove the spark plugs and the metal washers. Checking the Spark Plugs Service Interval: Every 100 hours 1.
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 Replace the fuel filter after every 200 operating 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.
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 40). 7. Remove the battery. Installing the Battery 1. Position battery in the tray with the terminal posts toward the engine(Figure 40). 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 40).
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 39 and Adjusting the Hydraulic Pump Neutral in Hydraulic System Maintenance , page 40. Figure 42 1. Main, 30 amp 2.
Check the pressure at the valve stem after every 50 operating hours or monthly, whichever occurs first (Figure 44). 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 45 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. Figure 46 1. Spring Washers 2. Lock Nut 3.
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 48). Figure 47 1. Guard 2. Air intake screen 3. Bolt 4. Fan housing Figure 48 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 Inspecting the Belts Service Interval: Every 100 hours Inspect all belts every 100 hours. 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. Figure 50 1. Ratchet with short extension or breaker bar 1.
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. Figure 51 1. Belt 2. Clutch electrical wire 3. Clutch stop 1.
Hydraulic System Maintenance Servicing the Hydraulic System Checking the Hydraulic Fluid Service Interval: After the first 8 hours Every 25 hours 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: Figure 54 1. 2. 3. 4. 5. Clevis pin in slot Nut Nut-Left hand thread Adjustment bolt Pump rod 6. 7. 8. 9.
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. Baffle 3. Place a drain pan under filter, remove the old filter and wipe the filter adapter gasket surface clean (Figure 56). 3. Cold fluid level-full 4.
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 filter 2. Gasket 3. Adapter • Use cardboard or paper to find hydraulic leaks.
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. 2. Start the engine, open throttle 1/2 way and release parking brake. Refer to Starting and Stopping the Engine in Operation , page 12.
Mower Deck Maintenance Electrical system will not perform proper safety shut off with jumper wire installed. • Remove jumper wire from wire harness connector and plug connector into seat switch when adjustment is completed. Leveling the Mower at Three Positions • Never operate this unit with jumper installed and seat switch bypassed. Important: There are only three measuring positions needed to level the mower. 7. After both pump neutrals are set, shut off the machine. Preparing the Machine 8.
Adjusting the Front-to-Rear Mower Pitch 1. Position the right blade front-to-rear (Figure 62). 2. Measure the right blade at the A location, from a level surface to the cutting edge of the blade tip (Figure 62). Figure 60 1. Measure here from blade to hard surface 2. 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). 8.
2. Check the distance between the two large washers, it needs to be 11-1/8 inches (28.2 cm) for 52 inch mower decks and 10-1/2 inches (26.7 cm) for 60 inch mower decks (Figure 63). A worn or damaged blade can break, and a piece of the blade could be thrown into the operator’s or bystander’s area, resulting in serious personal injury or death. 3. Adjust this distance, by loosening the spring jam nut and turning the nut in front of each spring (Figure 63).
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. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Rotate the blades until the ends face forward and backward (Figure 65). Measure from a level surface to the cutting edge, position A, of the blades (Figure 65). Note this dimension.
1. Remove the locknut, bolt, spring and spacer holding the deflector to the pivot brackets (Figure 69). Remove the damaged or worn grass deflector. 2. Place the spacer and spring onto grass deflector. Place the L end of spring behind deck edge. Figure 67 1. Blade 2. Balancer Note: Make sure the L end of the spring is installed behind the deck edge before installing the bolt as shown in Figure 69. Installing the Blades 1. Install the blade onto the spindle shaft (Figure 68). 3. Install the bolt and nut.
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.
B. Run the engine to distribute conditioned fuel through the fuel system (5 minutes). C. Stop the engine, allow it to cool, and drain the fuel tank; refer to Servicing the Fuel Tank in Fuel System Maintenance , page 31. 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.
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 contro (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: 54
Notes: 55
The Toro Total Coverage Guarantee Landscape Contractor Equipment (LCE) A Limited Warranty Conditions and Products Covered Owner Responsibilities 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.
