Form No. 3356-159 Rev B Z400 Z Master, With a 48in or 52in 7-Gauge Side Discharge Mower Model No. 74410—Serial No. 270000001 and Up Model No. 74418—Serial No. 270001001 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).................. 14 Think Safety First .............................. 15 Operating the Parking Brake .............. 16 Starting and Stopping the Engine .............................. 16 Operating the Power Take Off (PTO) ............................... 18 The Safety Interlock System............... 18 Driving Forward or Backward ............ 19 Stopping the Machine ........................ 20 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 Battery Symbols Some or all of these symbols are on your battery 105-7798 1. Explosion hazard 2. No re, open ame, or smoking. 3. Caustic liquid/chemical burn hazard Wear eye protection 4. 107-1613 5. 9 Read the Operator’s Manual. 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.
7-2112 108-1050 107-2102 Manufacturer’s Mark 1. Indicates the blade is identied as a part from the original machine manufacturer.
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. 108-5278 1. Read the Operator’s Manual. 108-5995 1. Fast 2. Slow 1. Choke 2. Engine—stop 3. 4. Engine—run Engine—start 3. Neutral 4. Reverse 110-0439 5. Fast 6. Continuous variable setting 11 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. 2. 2. Throttle—slow 6. Turn the ignition key to Start. When the engines starts, release the key (Figure 16). Figure 13 1. PTO—on Throttle—fast 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.
Figure 22 1. Adjustment lever Unlatching the Seat Figure 20 1. Anti-scalp roller 2. Spacer 3. Bushing 4. 5. Push the seat latch rearward to unlatch the seat. This will allow access to the machine under the seat (Figure 23). Flange Nut Bolt Figure 23 1. 2. Figure 21 1. Anti-scalp roller 2. Bushing 3. 4. Seat latch Fuel cap 3. Seat Pushing the Machine by Hand Flange Nut Bolt Important: Always push the machine by hand. Never tow the machine because hydraulic damage may occur.
by-pass the pump enabling the wheels to turn (Figure 24). 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. 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.
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 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.
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. 2. 3. Caster fork Bolt Seal guard 4. 5. Caster wheel Nut 6. Remove one of the spacer nuts (with wrench flats) from the axle (Figure 30). Note: Thread locking adhesive has been applied to the spacer nuts. Figure 27 7.
Figure 30 1. Spacer nut 2. Bearing seal (new seals required) 3. Bearing Figure 29 4. 5. Caster wheel Nut and axle assembled Engine Maintenance 1. 1/8 inch (3 mm) of the nut past the axle Servicing the Air Cleaner 12. Install the assembled nut and axle into the wheel on the side with the bearing and a new seal (Figure 30). Service Interval/Specication Foam element: Clean it after every 25 operating hours. 13.
5. Remove the 2 wing nuts and remove the air cleaner assembly (Figure 31). 2. Inspect the element for tears, an oily film, or damage to the rubber seal. 6. Carefully pull the foam element off the paper element (Figure 31). 3. Replace the paper element if it is damaged. Installing the Foam and Paper Elements Important: To prevent engine damage, always operate the engine with the complete foam and paper air cleaner assembly installed. 1.
Important: Do not overfill the crankcase with oil and run the engine; engine damage can result. Changing the Oil 1. Start the engine and let it run five minutes. This warms the oil so it drains better. 2. Park the machine so that the drain side is slightly lower than the opposite side to assure the oil drains completely. 3. Disengage the PTO and set the parking brake. Figure 32 4. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
10. Check the oil level; refer to Checking the Engine Oil Level. 11. Slowly add the additional oil to bring it to the Full mark. Changing the Oil Filter Ensure that the air gap between the center and side electrodes is correct before installing the spark plug. Use a spark plug wrench for removing and installing the spark plugs and a gapping tool/feeler gauge to check and adjust the air gap. Install new spark plugs if necessary. Replace the oil filter every 200 operating hours or every other oil change.
4. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 5. Close the fuel shutoff valve (Figure 38). Figure 37 1. Center electrode insulator 2. Side electrode 3. Air gap (not to scale) Important: Always replace the spark plugs when it has a black coating, worn electrodes, an oily film, or cracks. 3. Check the gap between the center and side electrodes (Figure 37). Bend the side electrode (Figure 37) if the gap is not correct. Figure 38 1.
Removing the Battery 2. Disengage the power takeoff (PTO), set the parking brake, stop the engine, and remove the key. 3. Close the fuel shutoff valve (Figure 38). 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. 4. Loosen the hose clamp at the fuel filter and slide it up the fuel line away from the fuel filter (Figure 38).
Charging the Battery Charging the battery produces gasses that can explode. Never smoke near the battery and keep sparks and flames away from battery. Important: Always keep the battery fully charged (1.265 specific gravity). This is especially important to prevent battery damage when the temperature is below 32°F (0°C). 1. Charge battery for 10 to 15 minutes at 25 to 30 amps or 30 minutes at 4-6 amps. 2.
Drive System Maintenance Fuse: • Main, F1-30 amp, blade-type • Charge circuit, F2-25 amp, blade-type • Optional head light kit, 10 amp, blade-type Adjusting the Tracking 1. Raise the seat to gain access to the fuse holder (Figure 41). Note: Determine the left and right sides of the machine from the normal operating position. 2. To replace the fuses, pull out on the fuse to remove it. The machine has a knob for adjusting the tracking located under the seat. 3. Install a new fuse (Figure 41).
Checking the Tire Pressure 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. 4. Hole in threaded shaft Washer (if needed) 5.
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. Spring 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.
Figure 47 1. Brake linkage 2. Yoke 3. Hair pin and cotter pin 6. Adjust the yoke clockwise to shorten the distance; counterclockwise to lengthen distance (Figure 47). 7. 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. (Figure 48). Figure 48 1. Brake lever 2. Tire 8. Repeat steps through if additional adjustment is needed. 3. Brake bar 9.
Note: Do not increase the belt tension beyond the point where the fixed idler arm stops. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the belt covers over the outside spindles. 4. Loosen the fixed idler arm and adjust it to relieve the belt tension on the fixed idler pulley (Figure 49). 9. While holding the belt in tension, tighten the 2 bolts that secure the fixed idler arm. 10.
Adjusting the Push Arms 3. Tilt the seat forward. 4. Begin with either the left or right motion control lever. If needed, adjust the push arms to increase or decrease the mower belt tension. 1. Loosen the jam nut and rotate the ball joint counterclockwise, one turn at a time (Figure 52). 5. Move lever to the neutral position but not locked (Figure 53). Figure 52 3. 1. Push arm 4. 2. 13-1/2 inch (343 mm) nominal at 15 degree twist Jam nut Ball joint Figure 53 1. Neutral locked position 2.
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 54 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 56). Figure 55 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 57 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 58 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 1. Measure here from blade to hard surface 2. Figure 61 Measure at B and C 1. 2. 3. 4. 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). 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 62). 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 62). 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 64). 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 64).
Contact with a sharp blade can cause serious injury. Figure 67 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 68). 1. Install the blade onto the spindle shaft (Figure 68). 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. • Make sure the grass deflector is in the down position. Figure 69 1. Remove the locknut, bolt, spring and spacer holding the deflector to the pivot brackets (Figure 69).
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 Corrective Action 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. 1. Move the blade control (PTO) to disengaged. 2. Set the parking brake. 3. Sit on the seat. 4. Charge the battery. 5. Check the electrical connections for good contact. 6. Replace the fuse. 7. Contact an Authorized Service Dealer. 6. Fuse is blown. 7.
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.
