Form No. 3358-292 Rev A Z400 Z Master with a 48in or 52in 7-Gauge Side Discharge Mower Model No. 74410—Serial No. 270002001 and Up Model No. 74418—Serial No. 270002001 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 107-1687 103-2644 Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 105-7798 2. No fire, open flame, or smoking. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 107-1613 5. Read the Operator’s Manual. 8 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.
107-2112 108-1050 107-2102 Manufacturer’s Mark 1. Indicates the blade is identified as a part from the original machine manufacturer.
7-9309 1. Warning—read the Operator’s Manual for information on charging the battery; contains lead; do not discard. 2. Read the Operator’s Manual. 108-5278 1. 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.
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 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. 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.
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.
Adjusting the Height-of-Cut 5. Install the flange nut bushing, spacer, and bolt. Torque to 40-45 ft-lb (54-61 N•m) (Figure 20 , Figure 21 and Figure 50 ). 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. 6. Repeat this adjustment on the other anti-scalp rollers. 1. Raise the height-of-cut lever to the transport position (also the 4-1/2 inch (114 mm) cutting height position) (Figure 19). 2.
Important: To adjust, move the lever sideways to unlock seat (Figure 22). 2. Rotate the by-pass valves counterclockwise 1 turn to push. This allows hydraulic fluid to by-pass the pump enabling the wheels to turn (Figure 24). Slide the seat to the desired position and release lever to lock in position. 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. 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 25). 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 and oil. Before each use or daily • • • • • Check the safety system. Check the engine oil level. Clean the air intake screen. Check the mower blades. Clean the mower deck. Every 25 hours • • • • • • Grease the mower deck and spindles. Grease the mower belt idler arm.
Lubrication Greasing and Lubrication Lubricate the machine when shown on the Check Service Reference Aid decal (Figure 26). 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 26 3.
3. Remove the belt covers. 4. Grease the three spindle bearings under the pulleys until grease comes out the lower seals (Figure 27). 5. Grease the idler arm on the mower deck (Figure 27). 6. Grease the fittings on the push arms (Figure 27). Figure 28 1. Caster fork 2. Bolt 3. Seal guard 4. Caster wheel 5. Nut 6. Remove one of the spacer nuts (with wrench flats) from the axle (Figure 30). Figure 27 Note: Thread locking adhesive has been applied to the spacer nuts. Lubricating the Caster Wheel Hubs 7.
Figure 30 1. Spacer nut 2. Bearing seal (new seals required) 3. Bearing Figure 29 1. 1/8 inch (3 mm) of the nut past the axle 12. Install the assembled nut and axle into the wheel on the side with the bearing and a new seal (Figure 30). 13. Place the wheel with the open end facing up and fill the area inside the wheel with multi-purpose grease. 14. Install the second bearing and a new seal into the wheel (Figure 30). 15.
Engine Maintenance Servicing the Air Cleaner Service Interval/Specification Foam element: Clean it after every 25 operating hours. Paper element: Check it after every 50 operating hours. Replace it after every 200 operating hours or yearly, which ever comes first. Inspect the foam and paper elements and replace them if they are damaged or excessively dirty. Note: Service the air cleaner more frequently (every few operating hours) if the operating conditions are extremely dusty or sandy.
Installing the Foam and Paper Elements 3. Wait for all moving parts to stop before leaving the operating position and then chock or block tires. Important: To prevent engine damage, always operate the engine with the complete foam and paper air cleaner assembly installed. 1. Carefully slide the foam element onto the paper air cleaner element (Figure 31). 2. Place the air cleaner assembly onto the air cleaner base and secure it with the 2 wing nuts (Figure 31). 3.
Note: Dispose of the used oil at a recycling center. Figure 35 1. Oil filter 2. Adapter 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). Figure 34 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 37). Figure 36 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 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 41 and Adjusting the Hydraulic Pump Neutral in Hydraulic System Maintenance , page 42. 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 front and rear tires at 13 psi (90 kPa). Uneven tire pressure can cause uneven cut. Check the tires when they are cold to get the most accurate pressure reading. Figure 44 1. Slotted Nut 2. Two threads or less showing 3. Hole in threaded shaft 4. Washer (if needed) 5. Check the distance from bottom of slot in nut to inside edge of hole.
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. Check tire pressure of all 4 tires. Refer to Checking the Tire Pressure. 2. Disengage the brake lever (lever down). 3. Measure the distance vertically between the front of the brake bar and the crown of the tire; the measurement should be 7/8 inch to 1 inch (22 to 25 mm) (Figure 47). 4. If the measurement is not correct, proceed to the following steps. Figure 46 1. Guard 2. Air intake screen 5.
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. 1.
Figure 50 1. Ratchet with short extension or breaker bar 2. Square hole Figure 51 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 55 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. Important: Use oil specified or equivalent. Other fluids could cause system damage. Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Hydraulic System Oil Capacity: 67 ounces (2.
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. 3. Place a drain pan under filter, remove the old filter and wipe the filter adapter gasket surface clean (Figure 56). Figure 57 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 12. 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. 2. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. Figure 60 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.
Adjusting the Front-to-Rear Mower Pitch 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). 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). 3. Adjust this distance, by loosening the spring jam nut and turning the nut in front of each spring (Figure 63).
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. 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.
the machine, use genuine Toro replacement blades. Replacement blades made by other manufacturers may result in nonconformance with safety standards. Figure 67 1. Blade Contact with a sharp blade can cause serious injury. Wear gloves or wrap sharp edges of the blade with a rag. 2. Balancer Installing the Blades 1. Install the blade onto the spindle shaft (Figure 68). 1. Hold the blade end using a rag or thickly-padded glove.
Cleaning 1. Remove the locknut, bolt, spring and spacer holding the deflector to the pivot brackets (Figure 69). Remove the damaged or worn grass deflector. Cleaning Under the Mower 2. Place the spacer and spring onto grass deflector. Place the L end of spring behind deck edge. Service Interval: Before each use or daily Note: Make sure the L end of the spring is installed behind the deck edge before installing the bolt as shown in Figure 69. Remove the grass buildup under the mower daily. 1.
Storage B. Run the engine to distribute conditioned fuel through the fuel system (5 minutes). 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. C.
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: 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.
