Form No. 3364-226 Rev A Z400 Z Master with a 48in or 52in TURBO FORCE® Side Discharge Mower Model No. 74444—Serial No. 310000001 and Up Model No. 74445—Serial No. 310000001 and Up g012081 To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com.
This rotary-blade, riding lawn mower is intended to be used by residential homeowners or professional, hired operators. It is designed primarily for cutting grass on well-maintained lawns on residential or commercial properties. It is not designed for cutting brush or for agricultural uses. 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. 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) ................. 17 The Safety Interlock System................................ 18 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. 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.
• Be aware there is no rollover protection when the roll bar is down. • Check the area to be mowed and never fold the ROPS in areas where there are slopes, drop offs or water. • Lower the rollbar only when absolutely necessary. Do not wear the seat belt with the roll bar folded down. • Check carefully for overhead clearances (i.e. branches, doorways, electrical wires) before driving under any objects and do not contact them. • Be aware of the mower discharge direction and do not point it at anyone.
Slope Indicator G011841 Figure 3 This page may be copied for personal use. 1. The maximum slope you can safely operate the machine on is 15 degrees. Use the slope chart to determine the degree of slope of hills before operating. Do not operate this machine on a slope greater than 15 degrees. Fold along the appropriate line to match the recommended slope. 2. Align this edge with a vertical surface, a tree, building, fence pole, etc. 3. Example of how to compare slope with folded edge.
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. 66-1340 1-403005 65-2690 1-633818 68-8340 54-9220 98-4387 1. Warning—wear hearing protection. 58-6520 98-5954 1.
103-2644 105-7798 107-2102 Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 2. No fire, open flame, or smoking. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 5. Read the Operator’s Manual. 6. Keep bystanders a safe distance from the battery. 7. Wear eye protection; explosive gases can cause blindness and other injuries 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. 10.
110-2068 1. Read the Operator’s Manual. 108-1050 112-8651 1. 2. 3. 4. 5. 6. Interval Power Take-off (PTO) Parking brake Neutral Operator presence switch Battery 108-1051 109-7949 115-4212 1. Hydraulic oil level 3. Warning—do not touch the hot surface. 2. Read the Operator’s Manual.
Manufacturer’s Mark 1. Indicates the blade is identified as a part from the original machine manufacturer. 117-3821 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 3. Neutral 2. Slow 10 4.
7-0904 1. Fast 2. Continuous variable setting 3. Slow 1 2 Product Overview 3 4 5 4 5 6 7 8 9 123 g012084 7 6 Figure 5 1. 2. 3. 4. 10 g012082 11 Motion control lever Fuel cap (both sides) Throttle control Choke 5. Hour meter 6. PTO Switch 7. Ignition switch Figure 4 1. 2. 3. 4. 5. 6. Side discharge Lift assist lever Height-of-cut lever Motion control lever Seat belt Rollbar 7. 8. 9. 10. 11.
Attachments/Accessories displayed in the area where the hours are normally displayed. A selection of Toro approved attachments and accessories are available for use with the machine to enhance and expand its capabilities. Contact your Authorized Service Dealer or Distributor or go to www.Toro.com for a list of all approved attachments and accessories. The battery light turns on when the ignition is turned on and when the charge is below the correct operating level (Figure 6). Figure 6 1.
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.
Important: Always use the seat belt with the roll bar in the raised position. Operating on wet grass or steep slopes can cause sliding and loss of control. 1 Wheels dropping over edges can cause rollovers, which may result in serious injury, death or drowning. 2 There is no rollover protection when the roll bar is down. Always keep the roll bar in the raised and locked position and use the seat belt. Read and follow the rollover protection instructions and warnings.
This machine produces sound levels in excess of 85 dBA at the operators ear and can cause hearing loss through extended periods of exposure. Wear hearing protection when operating this machine. Use protective equipment for your eyes, ears, feet, and head. Figure 11 1. Parking brake-ON 2. Parking brake-OFF Starting and Stopping the Engine Figure 10 1. Warning— wear hearing protection Starting the Engine Operating the Parking Brake 1.
the throttle lever to desired setting. Repeat this as required. Stopping the Engine 1. Push the PTO to the off position (Figure 12). 2. Move the throttle lever midway between the slow and fast positions (Figure 14). 3. Let the engine idle for 60 seconds. 4. Turn the ignition key to the off position and remove the key (Figure 15). Figure 13 1. Choke—on 5. Close the fuel shut off valve before transporting or storing the machine. 2.
Figure 17 1. Triangles light up when the interlock components are in the correct position Figure 16 1. PTO-On 2. PTO-Off Testing the Safety Interlock System Service Interval: Before each use or daily Disengaging the PTO 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. To disengage, push the PTO switch to the off position (Figure 16).
performance. Always operate in the full throttle position when mowing. Machine can spin very rapidly. Operator may lose control of machine and cause personal injury or damage to machine. • Use caution when making turns. • Slow the machine down before making sharp turns. Driving Forward 1. Release the parking brake; refer to Releasing the Parking Brake in , page . 2. Move the levers to the center, un-locked position. 3. To go forward, slowly push the motion control levers forward (Figure 18).
2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Children or bystanders may be injured if they move or attempt to operate the tractor while it is unattended. 3. After adjusting the height-of-cut, adjust the rollers by removing the flange nut, bushing, spacer, and bolt (Figure 20 , Figure 21 and Figure 52 ). Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes.
Positioning the Flow Baffle The following figures are only recommendations for use. Adjustments will vary by grass type, moisture content, and height of grass. Note: If the engine power draws down and the mower ground speed is the same, open up the baffle. Position A This is the full rear position. The suggested use for this position is a follows. • Use for short, light grass mowing conditions. Figure 21 1. Anti-scalp roller 2. Bushing • Use in dry conditions. 3. Flange Nut 4.
Position C To adjust, move the lever sideways to unlock seat (Figure 27). This is the full open position. The suggested use for this position is as follows. • Use in tall, dense grass mowing conditions. • Use in wet conditions. • Lowers the engine power consumption. • Allows increased ground speed in heavy conditions. • This position is similar to the benefits of the Toro SFS mower. 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. Without the grass deflector, discharge cover, or complete grass catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris. Contact with rotating mower blade(s) and thrown debris will cause injury or death. 3. Disengage parking brake before pushing.
Driving on the street or roadway without turn signals, lights, reflective markings, or a slow moving vehicle emblem is dangerous and can lead to accidents causing personal injury. Loading a unit onto a trailer or truck increases the possibility of backward tip-over and could cause serious injury or death. • Use extreme caution when operating a unit on a ramp. Do not drive machine on a public street or roadway. • Use only a single, full width ramp; Do Not use individual ramps for each side of the unit.
to thoroughly cut grass clippings, so do not set the height-of-cut so low as to totally surround the mower by uncut grass. Always try to have one side of the mower free from uncut grass, which allows air to be drawn into the mower. this setting. Then cut the grass again using the lower, normal setting. When Stopping If the machine’s forward motion must be stopped while mowing, a clump of grass clippings may drop onto your lawn. To avoid this, move onto a previously cut area with the blades engaged.
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. After the first 100 hours • Check the wheel hub slotted nut. • Check the wheel lug nuts. Before each use or daily • • • • • Check the safety interlock system. Check the engine oil level. Clean the engine air intake screen from grass and debris. Check the mower blades.
Lubrication Greasing and Lubrication Lubricate the machine when shown on the Check Service Reference Aid decal (Figure 32). Grease more frequently when operating conditions are extremely dusty or sandy. Grease Type: General-purpose grease. Figure 31 1. Seal guard How to Grease 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2. Spacer nut with wrench flats 2. Remove the caster wheel from the caster forks. 3.
13. Torque the nut to 75-80 in-lb (8-9 N-m), loosen, then re-torque to 20-25 in-lb (2-3 N-m). Make sure axle does not extend beyond either nut. Greasing the Mower Deck and Belt Idlers 14. Reinstall the seal guards over the wheel hub and insert wheel into caster fork. Reinstall caster bolt and tighten nut fully. Service Interval: Every 50 hours—Grease the mower deck idler arm and spindles. Every 50 hours—Grease the pump belt idler arm.
Engine Maintenance 1. If installing a new filter, check it for shipping damage. Do not use a damaged filter. Servicing the Air Cleaner 2. Carefully slide the air filter into the body (Figure 34). Note: Service the filter more frequently if operating conditions are extremely dusty or sandy. Note: Ensure that it is fully seated by pushing on the outer rim of the filter while installing it. Removing the Filters Important: Do not press on the soft inside area of the filter. 1.
Figure 36 2. Filler tube 1. Oil dipstick 5. Unscrew the oil dipstick and wipe the end clean (Figure 36). 6. Slide the oil dipstick fully into the filler tube, but do not thread onto tube (Figure 36). Figure 37 7. Pull the dipstick out and look at the metal end. If the oil level is low, slowly pour only enough oil into the filler tube to raise the level to the Full mark. 1. Oil drain valve 2. Oil drain hose 9. Slowly pour approximately 80% of the specified oil into the filler tube (Figure 36). 10.
Checking the Spark Plugs 3. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Figure 38). 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 38). 5. Fill the crankcase with the proper type of new oil; refer to Servicing the Engine Oil. 6.
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/Yearly (whichever comes first)—Replace the fuel filter. • 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 42). 7. Remove the battery. Installing the Battery 1. Position battery in the tray with the terminal posts toward the engine (Figure 42). 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 42).
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 and Adjusting the Hydraulic Pump Neutral in Maintenance. 1. Push both control levers forward the same distance. 2. Check if the machine pulls to one side.
cut. Check the tires when they are cold to get the most accurate pressure reading. Figure 47 1. Slotted Nut 2. Two threads or less showing 3. Hole in threaded shaft 4. Washer (if needed) Figure 46 5. Check the distance from bottom of slot in nut to inside edge of hole. Two threads or less should be showing (Figure 47). Checking the Wheel Hub Slotted Nut 6. If more than two threads are showing remove nut and install washer between hub and nut. 7. Torque the slotted nut to 125 ft-lb.
Cooling System Maintenance Cleaning the Air Intake Screen Service Interval: Before each use or daily—Clean the engine air intake screen from grass and debris. 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.
Brake Maintenance Adjusting the Parking Brake Check the parking brake for proper adjustment. 1. Disengage the brake lever (lever down). 2. Measure the length of the spring; the measurement should be 2-3/4 inch (74 mm) between the washers (Figure 50). Figure 49 1. Guard 2. Air intake screen 3. Bolt 4. Fan housing 5. Bolt Figure 50 1. Brake lever 5. 3/16 to 1/4 inch (5 to 7 mm) 2. Spring, 2-3/4 inch (74 mm) 6. Jam nut and yoke 3. Adjusting nuts 7. Trunnion 4. Collar on brake rod 3.
Belt Maintenance 6. Measure the distance between the trunnion roller and the collar on the brake rod. The measurement should be 3/16 to 1/4 inch (5 to 7 mm) (Figure 50). Inspecting the Belts 7. If an adjustment is necessary, do the following: A. Loosen the jam nut directly below the yoke. Service Interval: Every 100 hours B. Turn the bottom adjusting nuts until the correct measurement is obtained (Figure 50). Check belts for cracks, frayed edges, burn marks or any other damage. Replace damaged belts.
3 5 4 2 Figure 52 1. Ratchet with short extension or breaker bar 1 2. Square hole 6 g012213 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. Figure 53 1. Belt 2. Clutch electrical wire 3. Clutch stop Note: Do not increase the belt tension beyond the point where the fixed idler arm stops. 4. Bolt 5. Clutch 6. Idler Adjusting the Push Arms 9.
Controls System Maintenance Note: Increase the tension by lengthening the push arms; decrease the tension by shortening the push arms. 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.
Hydraulic System Maintenance Servicing the Hydraulic System Hydraulic Oil Type: Toro® HYPR-OIL™ 500 hydraulic oil or Mobil® 1 15W-50. Hydraulic System Oil Capacity: 67 ounces (2.0 l) Important: Use oil specified or equivalent. Other fluids could cause system damage. Checking the Hydraulic Fluid Service Interval: After the first 8 hours Every 50 hours Note: There are two ways of checking the hydraulic oil. One is when the oil is warm and one is when the oil is cold.
Use winter filter below 32°F (0°C) 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Important: Do not substitute automotive oil filter or severe hydraulic system damage may result. Figure 57 1. Cap 2. Baffle 3. Cold fluid level-full 4. Hot fluid level-full 3.
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 59 1. Hydraulic filter 2. Gasket 3. Adapter • Use cardboard or paper to find hydraulic leaks.
1. Raise the frame and block up the machine so drive wheels can rotate freely. 2. Disconnect the electrical connector from the seat safety switch. Temporarily install a jumper wire across terminals in the wiring harness connector. 3. Unlatch the seat and slide seat forward. 4. Disconnect the seat rod and tilt the seat fully forward. 2. Start the engine, open throttle 1/2 way and release parking brake. Refer to Starting and Stopping the Engine in , page .
Mower Deck Maintenance Electrical system will not perform proper safety shut off with jumper wire installed. • Remove jumper wire from wire harness connector and plug connector into seat switch when adjustment is completed. Leveling the Mower at Three Positions • Never operate this unit with jumper installed and seat switch bypassed. Important: There are only three measuring positions needed to level the mower. 7. After both pump neutrals are set, shut off the machine. Preparing the Machine 8.
Adjusting the Front-to-Rear Mower Pitch 1. Position the right blade front-to-rear (Figure 64). 2. Measure the right blade at the A location, from a level surface to the cutting edge of the blade tip (Figure 64). Figure 62 1. Measure here from blade to hard surface 2. Measure at B and C 7. If the measurements at positions B or C are not correct, loosen the bolt attaching the rear chain to the rear support arm (Figure 63). 8.
2. Check the distance between the two large washers, it needs to be 11-1/8 inches (28.2 cm) for 52 inch mower decks and 10-1/2 inches (26.7 cm) for 60 inch mower decks (Figure 65). A worn or damaged blade can break, and a piece of the blade could be thrown into the operator’s or bystander’s area, resulting in serious personal injury or death. 3. Adjust this distance, by loosening the spring jam nut and turning the nut in front of each spring (Figure 65).
to the cutting edge, position A, of the blades (Figure 67). Note this dimension. Contact with a sharp blade can cause serious injury. Wear gloves or wrap sharp edges of the blade with a rag. 1. Hold the blade end using a rag or thickly-padded glove. 2. Remove the blade bolt, spring disk and blade from the spindle shaft (Figure 70). Sharpening the Blades Figure 67 1. Measure here from blade to hard surface When sharpening blade, pieces of blade could be thrown and cause serious injury. 2.
Installing the Blades 2. Place the spacer and spring onto grass deflector. Place the L end of spring behind deck edge. 1. Install the blade onto the spindle shaft (Figure 70). Note: Make sure the L end of the spring is installed behind the deck edge before installing the bolt as shown in Figure 71. Important: The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting. 3. Install the bolt and nut.
Cleaning Storage 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to Off. Remove the key. 2. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine and hydraulic system. Clean dirt and chaff from the outside of the engine cylinder head fins and blower housing. Cleaning Under the Mower Service Interval: Before each use or daily Remove the grass buildup under the mower daily. 1.
C. Stop the engine, allow it to cool, and drain the fuel tank; refer to Servicing the Fuel Tank in Maintenance. D. Restart the engine and run it until it stops. E. Dispose of fuel properly. Recycle as per local codes. Important: Do not store stabilizer/conditioned fuel over 90 days. 13. Check and tighten all bolts, nuts, and screws. Repair or replace any part that is damaged. 14. Paint all scratched or bare metal surfaces. Paint is available from your Authorized Service Dealer. 15.
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.
The Toro Total Coverage Warranty A Limited Warranty (see warranty periods below) The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to the original purchaser to repair the Toro Products listed below if defective in materials or workmanship.
