Form No. 3353–536 Rev B Z400 Z Masterr With 52in 7-Gauge Side Discharge Mower Model No. 74410—Serial No. 250000001 and Up Operator’s Manual Register your product at www.Toro.
Warning Stopping the Machine . . . . . . . . . . . . . . . . . . . . . . Adjusting the Height-of-Cut . . . . . . . . . . . . . . . . . Adjusting the Anti-scalp Rollers . . . . . . . . . . . . . . Positioning the Seat . . . . . . . . . . . . . . . . . . . . . . . . Pushing the Machine by Hand . . . . . . . . . . . . . . . . Operating with the Side Discharge . . . . . . . . . . . . Transporting the Machine . . . . . . . . . . . . . . . . . . . Loading the Machines . . . . . . . . . . . . . . . . . . . . . .
Introduction 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. Read this manual carefully to learn how to operate and maintain your product properly. The information in this manual can help you and others avoid injury and product damage. Although Toro designs and produces safe products, you are responsible for operating the product properly and safely.
• Do not operate the mower under the influence of alcohol or drugs. • Inspect the area where the equipment is to be used and remove all objects such as rocks, toys and wire which can be thrown by the machine. • Use extreme care when loading or unloading the machine into a trailer or truck. • Use extra care when handling gasoline and other fuels. They are flammable and vapors are explosive. • Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision.
Using the Rollover Protection System (ROPS) • Shut off fuel while storing or transporting. Do not store fuel near flames or drain indoors. • Keep the roll bar in the raised and locked position and use the seat belt when operating the machine. • Park machine on level ground. Never allow untrained personnel to service machine. • Be certain that the seat belt can be released quickly in the event of an emergency. • Use jack stands to support components when required.
Slope Chart Fold along appropriate line Example: Compare slope with folded edge. Align this edge with a vertical surface (Tree, Building, Fence post, pole, etc.
Safety and Instruction 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.
98-5954 98-4387 1. Warning—wear hearing protection.
107-1687 Battery Symbols Some or all of these symbols are on your battery. 1. Explosion hazard 2. No fire, open flames, or smoking. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 5. Read the Operator’s Manual. 6. Keep bystanders a safe distance from the battery. 107-2102 11 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.
107-2148 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.
108-1050 108-1051 Manufacturers Mark 1. Indicates the blade is identified as a part from the original machine manufacturer.
Gasoline and Oil Warning Recommended Gasoline Gasoline is harmful or fatal if swallowed. Long-term exposure to vapors can cause serious injury and illness. Use unleaded regular gasoline suitable for automotive use (85 pump octane minimum). You may use leaded regular gasoline if unleaded regular is not available. • Avoid prolonged breathing of vapors. • Keep your face away from the nozzle and fuel tank or conditioner opening. • Keep gasoline away from eyes and skin.
Operation 2. Remove the hairpin cotter pins and remove the 2 pins (Fig. 3). Note: Determine the left and right sides of the machine from the normal operating position. 1 Using the Rollover Protection System (ROPS) 2 Warning To avoid injury or death from a rollover, keep the roll bar in the raised locked position and use the seat belt. 3 Ensure that the rear part of the seat is secured with the seat latch. 4 m-7431 Warning Figure 3 1. Roll bar 2.
7. Tighten the front handles against the center roll bar ends (Fig. 2). 2 1 Think Safety First Read all safety instructions and symbols in the safety section. Knowing this information could help you or bystanders avoid injury. Danger Operating the machine on wet grass or steep slopes can cause sliding and loss of control. 3 Wheels dropping over the edges can cause rollovers, which may result in serious injury, death, or drowning.
Controls Using the Fuel Shutoff Valve Become familiar with all the controls (Fig. 7) before you start the engine and operate the machine. 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 (Fig. 9). 2 9 5 8 1 4 1 7 3 6 m–7702 m–7701 Figure 9 Figure 7 1. 2. 3. 4. 5. 6. 7. 8. 9. Ignition switch Motion control levers Parking brake lever Throttle Choke 1.
5. Move the throttle control to Fast before starting a cold engine (Fig. 13). 2. Pull back and up on the parking brake lever to set the parking brake (Fig. 10). Note: The parking brake lever should stay firmly in the Engaged position. 1 1 2 Releasing the Parking Brake Push forward and down on the parking brake lever to release the parking brake (Fig. 10). 3 2 Starting and Stopping the Engine m-4268 m–2720a Figure 13 Starting the Engine 1. Fast 2. Slow 1.
The Safety Interlock System Caution Caution Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. If safety interlock switches are disconnected or damaged, the machine could operate unexpectedly, causing personal injury. Always remove the ignition key and set the parking brake when leaving the machine unattended, even for a few minutes. • Do not tamper with the interlock switches.
Driving Backward 5. While sitting on the seat, disengage the parking brake, disengage the PTO, and move the motion control levers to the neutral lock position. Try starting the engine; the engine should not crank. 1. Move the levers to the center, unlocked position. 2. To go backward, slowly pull the motion control levers rearward (Fig. 16). Driving Forward or Backward Driving Tips The throttle control regulates the engine speed as measured in RPM (revolutions per minute).
Adjusting the Height-of-Cut The height-of-cut adjusts from 1-1/2 to 4-1/2 inches (38 to 114 mm) in 1/4 inch (6 mm) increments by relocating the clevis pin in different hole locations. 1. Raise the height-of-cut lever to the transport position (also the 4-1/2 inch [114 mm] cutting height position) (Fig. 17). 5 1 2 4 2 3 1 m–7713a Figure 18 1. Outer roller 2. Spacer 3. Bushing m–4122 Figure 17 1. Height-of-cut lever 4. Bolt 5. Nut 2. Clevis pin 4.
1 4 m–3655 Figure 20 1. Adjustment lever 2 3 2. Slide the seat to the desired position and release the lever to lock the seat in position. m–7712a 1 Figure 19 1. Center rollers 2. Bushing Pushing the Machine by Hand 3. Bolt 4. Nut Important Always push the machine by hand. Never tow the machine, because hydraulic damage may occur. 4. Select a hole so that the center rollers are positioned to the nearest corresponding height-of-cut desired (Fig. 19). To Push the Machine 1.
Note: Do not overtighten the bypass valves. Warning Note: The machine will not drive unless the bypass valves are turned in. Driving on a street or roadway without turn signals, lights, reflective markings, or a slow moving vehicle emblem is dangerous and can lead to accidents that cause personal injury. Operating with the Side Discharge Do not drive the machine on a public street or roadway. The mower has a hinged grass deflector that disperses the clippings to the side and down toward the turf.
Mowing Direction Important Do not attempt to turn the machine while on the ramp; you may lose control and drive off the side. Alternate the mowing direction to keep the grass standing straight. This also helps disperse clippings, which enhances decomposition and fertilization. Avoid sudden acceleration when driving up a ramp and sudden deceleration when backing down a ramp. Both maneuvers can cause the machine to tip backward. Mow at Correct Intervals Warning Normally, mow every 4 days.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule Maintenance Service Interval After First 8 Hours Each Use Maintenance Procedure • Check the hydraulic fluid level. • Change the engine oil. • Change the hydraulic filter. • • • • Check the engine oil level. Check the safety system. Clean the engine air intake1. Clean the mower housing. Every 5 Hours • Check the cutting blades.
Important Refer to your engine operator’s manual for additional maintenance procedures. Caution If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition and disconnect the wire from the spark plug(s) before you do any maintenance. Set the wire aside so that it does not accidentally contact the spark plug.
Checking for Bent Blades Removing the Blades 1. Rotate the blades until the ends face forward and backward (Fig. 24). Measure from a level surface to the cutting edge of the blades (Fig. 25). Note this dimension. Replace any blade if it hits a solid object, is out of balance, or is bent. To ensure optimum performance and continued safety conformance of the machine, use genuine Toro replacement blades.
3. Remove air intake screen, cylinder covers and fan housing. 1 4. Clean debris and grass from parts. 5. Reinstall air intake screen, cylinder covers and fan housing. m–1854 Figure 27 1 1. Sharpen at original angle Note: The blade retains its balance if the same amount of material is removed from both cutting edges. 2 2. Check the balance of the blade by putting it on a blade balancer (Fig. 28). If the blade stays in a horizontal position, the blade is balanced and can be used.
3 1 Cleaning the Paper Element 5 4 1. Lightly tap the element on a flat surface to remove dust and dirt (Fig. 32). 2. Inspect the element for tears, an oily film, and damage to the rubber seal. Important Never clean the paper element with pressurized air or liquids, such as solvent, gas, or kerosene. Replace the paper element if it is damaged or cannot be cleaned thoroughly. 2 6 m–4289 Figure 30 1. Cover 2. Foam element 3. Paper element 4. Wing nut 5. Air cleaner base 6. Latches 2 4.
• After the first 8 operating hours 7. Pull the dipstick out and look at the end. If the oil level is low, slowly pour only enough oil into the filler tube to raise the level to the Full mark. • After every 100 operating hours Note: Change the oil more frequently when the operating conditions are extremely dusty or sandy. Important Do not overfill the crankcase with oil and run the engine; engine damage can result.
Note: Change the oil filter more frequently when the operating conditions are extremely dusty or sandy. 3. Disconnect the wire(s) from the spark plug(s) (Fig. 36). 1 1. Drain the oil from the engine; refer to Changing the Oil on page 30. 2. Remove the old oil filter (Fig. 35). 2 1 m–7453 Figure 36 1. Spark-plug wire/spark plug m–7451 4. Clean around the spark plug(s) to prevent dirt from falling into the engine and potentially causing damage. Figure 35 1. Oil filter 2. Adapter 5.
Installing the Spark Plug(s) 7. Remove the filter from the fuel lines. 1. Install the spark plug(s) and the metal washer(s). 8. Install a new filter and move the hose clamps close to the filter (Fig. 38). Note: Ensure that the air gap is set correctly. 9. Open the fuel shutoff valve. 2. Tighten the spark plug(s) to 16 ft-lb (22 NSm). Draining the Fuel Tank 3. Connect the wire(s) to the spark plug(s) (Fig. 36).
Greasing the Front Caster Pivots Lubricate the front caster pivots once a year. 1. Remove the dust cap and adjust the caster pivots. Note: Keep dust cap off until greasing is done. Refer to Adjusting the Caster Pivot Bearing on page 39. 2. Remove the hex plug and thread a grease zerk into the hole. 3. Pump grease into the zerk until it oozes out around the top bearing. 4. Remove the grease zerk in the hole and install the hex plug and cap.
Where to Add Light Oil or Spray Lubrication Important Use the specified oil or equivalent. Other fluids could cause system damage. Lubricate the machine in the following areas with spray type lubricant or light oil. Lubricate every 160 hours. Hydraulic System Oil Capacity: 67 oz. (2.0 l) Note: There are 2 ways of checking the hydraulic oil. One is for warm oil and the other for cold oil. The baffle inside the tank has 2 levels depending on whether the oil is warm or cold.
4. Apply a thin coat hydro fluid to the rubber gasket on the replacement filter (Fig. 44). Warning Hydraulic fluid escaping under pressure can penetrate skin and cause injury. 1 • 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; otherwise, gangrene may result. • Keep your body and hands away from pin hole leaks or nozzles that eject high-pressure hydraulic fluid. • Use cardboard or paper to find hydraulic leaks.
4. When the wheel begins to spin on its own, keep it engaged until wheel drives smoothly. (minimum 2 minutes) Adjusting the Handle Neutral Position 5. Check hydraulic fluid level and add fluid as required to maintain the proper level. If the motion control levers do not align or move easily into the console notch, adjustment them. Adjust each lever, spring, and rod separately. 6. Repeat this procedure on the opposite wheel. Note: The motion control levers must be installed correctly.
Setting the Hydraulic Pump Neutral Position Note: Adjust the handle neutral first. That has to be correct before you can perform the following adjustment. 8 1 4 3 9 Danger Mechanical or hydraulic jacks may fail to support the machine and cause a serious injury. • Use jack stands when supporting the machine. • Do not use hydraulic jacks. 2 6 2 Warning 7 9 The engine must be running so that you can adjust the motion control. Contact with moving parts or hot surfaces may cause personal injury.
Warning The electrical system will not perform the proper safety shutoff with the jumper wire installed. • Remove the jumper wire from the wire harness connector and plug the connector into the seat switch after completing the adjustment. • Never operate the machine with the jumper wire installed and the seat switch bypassed. 1 7. After both pump neutrals are set, shut off the machine. 8. Remove the jumper wire from the wire harness connector and plug the connector into the seat switch. 3 2 9.
1 5. To make the machine move to the left, turn the knob toward the left side of the machine; refer to Figure 48. 4 3 6. Repeat the adjustment until the tracking is correct. 5 Adjusting the Caster Pivot Bearing 2 Check after every 500 operating hours or at storage, whichever occurs first. m–4638 Figure 50 1. Disengage the PTO, move the motion control levers to the neutral locked position, and set the parking brake. 1. Slotted nut 2. Two threads or less showing 2.
• If one rear chain is loose, lower (loosen) the front support arm on the same side. Refer to Adjusting the Front-to-Rear Mower Pitch on page 40. 2 Front 6 • If one front chain is loose, raise (tighten) the front support arm for that chain. Refer to Adjusting the Front-to-Rear Mower Pitch on page 40. Leveling the Mower Side-to-Side 1. Position the right blade front to rear (Fig. 51). 1 Front 3 2 1 7 4 5 Figure 53 B C 1. 2. 3. 4. m–1078 Figure 51 Rear chain Rear support arm Bolt Jam Nut 5.
2. Measure the right blade at the A location (Fig. 54) from a level surface to the cutting edge of the blade tip (Fig. 55). 8. Adjust the lift nuts on both the left and the right side of the machine to achieve 1/4 to 3/8 inch (6 to 10 mm) lower in front at A than in the rear at B (Fig. 56). 9. Tighten both swivel jam nuts against the front swivel to lock the height. 10. Check to ensure that there is equal tension on the chains and adjust again if needed.
Check belts for cracks, frayed edges, burn marks, or any other damage. Replace damaged belts. 1 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. 2 1. Disengage the PTO, move the motion control levers to the neutral locked position, and set the parking brake. 2.
2. Disengage the brake lever (lever down). 4 3 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) (Fig. 61). 5 4. If the measurment is not correct, proceed to the following proceedures. 2 5. Remove the hairpin and cotter pin from the brake linkage (Fig. 60). 6. Adjust the yoke clockwise to shorten the distance; counterclockwise to lengthen distance (Fig. 60). 1 6 3 m–7718 1 2 Figure 59 1.
Servicing the Fuses Service Interval/Specification The electrical system is protected by fuses. It requires no maintenance; however, if a fuse blows, check the component/circuit for a malfunction or short. Fuse: Main F1—30 amp, blade-type Charge Circuit F2—25 amp, blade-type Optional Headlight Kit—10 amp, blade type 1. Raise the seat to gain access to the fuse holder (Fig. 62). 1 3 3 4 4 1 5 2 3 m–7724 5 Figure 62 2 1. Main—30 amp 2. Charge circuit—25 amp 3.
Servicing the Battery Installing the Battery 1. Position the battery in the tray with the terminal posts toward the engine (Fig. 64). Warning 9 11 CALIFORNIA 5 4 2 Proposition 65 Warning 7 Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. 6 7 3 Checking the Electrolyte Level 1. Shut off the engine and wait for all moving parts to stop. 1 2.
Removing the Battery Adding Water to the Battery The best time to add distilled water to the battery is just before you operate the machine. This lets the water mix thoroughly with the electrolyte solution. Warning The 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. Note: Never fill the battery with distilled water while the battery installed in the machine.
8 4. When the battery is fully charged, unplug the charger from the electrical outlet, then disconnect the charger leads from the battery posts (Fig. 65). 2 6 4 4 2 3 3 1 5 1 7 m–4970 Figure 65 1. Positive Battery Post 2. Negative Battery Post m–5037 m–7709 3. Red (+) Charger Lead 4. Black (–) Charger Lead Figure 66 1. 2. 3. 4. 5. 5. Install the battery in the machine and connect the battery cables; refer to Installing the Battery on page 45.
PTO CLUTCH GND BK BK BN VIO (NEUTRAL) SW5 W SW4 (NEUTRAL) SHOWN WITH PARK BRAKE DISENGAGED SW3 (BRAKE) VIO Y SHOWN WITH LEVER IN NEUTRAL POSITION SHOWN WITH LEVER IN NEUTRAL POSITION Y SHOWN IN OFF POSITION GY BN SW2 (PTO) I S OR BK P1–B T Y K2 (START RELAY) P2–C SW6 (SEAT SW) SHOWN WITH OPERATOR IN SEAT TERMINAL VIEW FROM BACK OF SWITCH B A KEY SW Y X NO CONNECTION BIA AND X Y BIS P1–A DELAY MODULE 100–6186 P1–C PK OFF ON START OR GY BN GN F1 30A Y R R B BK K1
Cleaning and Storage 11. Prepare the machine for storage when nonuse occurs over 30 days. Prepare machine for storage as follows. 1. Disengage the power takeoff (PTO), set the parking brake and turn the ignition key to off. Remove spark plug wire. Remove the key. A. Add a petroleum based stabilizer/conditioner to fuel in the tank. Follow mixing instructions from stabilizer manufacture. Do not use an alcohol based stabilizer (ethanol or methanol). 2.
Troubleshooting Problem Starter does not crank. Engine g will not start, starts hard, or f il tto keep fails k running. i Engine g loses power. p Engine g overheats. Possible Causes Corrective Action 1. Blade control (PTO) is engaged. 1. Move blade control (PTO) to Disengaged. 2. Parking brake is not on. 2. Set parking brake. 3. Operator is not seated. 3. Sit on the seat. 4. Battery is dead. 4. Charge the battery. 5. Electrical connections are corroded or loose. 5.
Problem Machine does not drive. Abnormal vibration. Uneven cutting g height. g Blades do not rotate. Possible Causes Corrective Action 1. Traction belt is worn, loose or broken. 1. Contact Authorized Service Dealer. 2. Traction belt is off pulley. 2. Contact Authorized Service Dealer. 3. Hydro fluid level low. 3. Add hydro fluid to reservoir. 1. Engine mounting bolts are loose. 1. Tighten engine mounting bolts. 2. Loose engine pulley, idler pulley, or blade pulley. 2.
The Toro Total Coverage Guarantee A Limited Warranty Landscape Contractor Equipment (LCE) Conditions and Products Covered Owner Responsibilities The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair the listed Toro product if defective in materials or workmanship.
