Form No. 3356-164 Rev A Z449 Z Master® with 48in or 52in TURBO FORCE® Side Discharge Mower Model No. 74413—Serial No. 270000001 and Up Model No. 74415—Serial No. 270000001 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. Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means CAUTION, WARNING, or DANGER-“personal safety instruction." Failure to comply with the instruction may result in personal injury or death.
• Keep hands and feet away from the cutting units. • 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.
• 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. 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 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). 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. Latches Air cleaner cover 3. 4. Air lter body Primary lter 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 32). Avoid knocking the filter into the side of the body. 6.
Servicing the Engine Oil Service Interval/Specication Change the engine oil as follows: • After the first 8 operating hours • After every 100 operating hours Note: Change the oil more frequently when the operating conditions are extremely dusty or sandy. Figure 34 1. Oil dipstick Oil Type: Detergent oil (API service SF, SG, SH, or SJ) 2. Filler tube 5. Unscrew the oil dipstick and wipe the end clean (Figure 34). Crankcase Capacity: 58 ounces (1.7 liter) with the filter removed; 51 ounces (1.
Figure 36 1. Oil lter 2. Adapter 11. Slowly add the additional oil to bring it to the Full mark. 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). 5. Fill the crankcase with the proper type of new oil; refer to Servicing the Engine Oil. 6.
Important: Always replace the spark plugs when it has a black coating, worn electrodes, an oily film, or cracks. 3. Disconnect the wires from the spark plugs (Figure 37). 3. Check the gap between the center and side electrodes (Figure 38). Bend the side electrode (Figure 38) if the gap is not correct. 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.
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). Note: Now is the best time to install a new fuel filter because the fuel tank is empty. 7. Install the fuel line onto the fuel filter. Slide the hose clamp close to the fuel filter to secure the fuel line (Figure 39). Figure 39 1. Fuel shutoff valve 2. Hose clamp 3. 4. Electrical System Maintenance Fuel line Fuel lter 6.
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 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.
3. Remove the air intake screen, recoil starter and fan housing (Figure 46). 4. Clean the debris and grass from the engine parts. 5. Install air intake screen, recoil starter and fan housing (Figure 46). Figure 45 1. Curved washers 2. Lock Nut 3. Dust Cap Figure 46 Cooling System Maintenance 1. 2. Cleaning the Air Intake Screen Guard Air intake screen 3. 4.
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. 2.
7. Release the pressure on the spring loaded idler (Figure 50). 8. Install the mower belt. Figure 49 1. Ratchet with short extension or breaker bar 2. Square hole Figure 50 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. 1. 2. 3. Note: Do not increase the belt tension beyond the point where the fixed idler arm stops. 9.
5. Move lever to the neutral position but not locked (Figure 52). Figure 51 1. Push arm 2. 15–1/8 inch (384 mm) 3. 4. Figure 52 Jam nut Ball joint 1. Neutral locked position 2. Control lever 2. Adjust each side the same amount. Each push arm should have a length of 15–1/8 inch (384 mm) (Figure 51). 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 53).
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 53 1. 2. 3. 4. 5.
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 54 1. Cap 2. Bafe 3. 4. Cold uid level-full Hot uid level-full Hydraulic fluid escaping under pressure can penetrate skin and cause injury.
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 56 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 57 3.
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. 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 60 Figure 59 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 60). 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 61). 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 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.
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 63). 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 63).
Contact with a sharp blade can cause serious injury. Figure 66 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 67). 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.
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 68 • 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 68).
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.
