Form No. 3361-212 Rev A Z400 Z Master with a 48in or 52in 7-Gauge Side Discharge Mower Model No. 74448—Serial No. 290000001 and Up Model No. 74449—Serial No. 290000001 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 ........................ 16 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 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 103-2644 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.
Manufacturer’s Mark 1. Indicates the blade is identified as a part from the original machine manufacturer. 107-2112 112-8651 1. 2. 3. 4. 5. 6.
7-8445 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 4. Reverse 117-0904 1. Fast 2. Continuous variable setting Product Overview 10 3.
Use these times for scheduling regular maintenance (Figure 5). Safety Interlock Indicators There are symbols on the hour meter and they indicate with a black triangle that the interlock component is in the correct position (Figure 5). Battery Indicator Light When the ignition key is initially turned to the Run position for a few seconds, the battery voltage will be displayed in the area where the hours are normally displayed.
Blade Control Switch (PTO) Operation The blade control switch (PTO) is used to engage the electric clutch to drive the mower blades with the motion control levers in the center, un-locked position. Pull the switch up to engage the blades and release. To disengage the blades, push the blade control switch (PTO) down. 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).
Important: Do not use fuel additives containing methanol or ethanol. 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. Add the correct amount of gas stabilizer/conditioner to the gas. Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline.
Important: Always use the seat belt with the roll bar in the raised position. There is no rollover protection when the roll bar is in the down position. 1 • Lower the roll bar only when absolutely necessary. 2 • Do not wear the seat belt when the roll bar is in the down position. • Drive slowly and carefully. • Raise the roll bar as soon as clearance permits. • Check carefully for overhead clearances (i.e. branches, doorways, electrical wires) before driving under any objects and do not contact them.
Operating on wet grass or steep slopes can cause sliding and loss of control. This machine produces sound levels in excess of 85 dBA at the operators ear and can cause hearing loss through extended periods of exposure. Wheels dropping over edges can cause rollovers, which may result in serious injury, death or drowning. Wear hearing protection when operating this machine. There is no rollover protection when the roll bar is down. Use protective equipment for your eyes, ears, feet, and head.
Figure 12 Figure 10 1. Parking brake-ON 1. Choke—on 2. Choke—off 2. Parking brake-OFF 5. Move the throttle control to the Fast position before starting a cold engine (Figure 13). Starting and Stopping the Engine Starting the Engine 1. Sit on the seat and move the motion controls to neutral locked position. 2. Set the parking brake; refer to Setting the Parking Brake. Figure 13 1. Throttle—fast 3. Move the PTO (power take off) switch to the Off position (Figure 11). 2. Throttle—slow 6.
the choke back to on for a few seconds, then move the throttle lever to desired setting. Repeat this as required. Stopping the Engine 1. Push the PTO to the off position (Figure 11). 2. Move the throttle lever midway between the slow and fast positions (Figure 13). 3. Let the engine idle for 60 seconds. 4. Turn the ignition key to the off position and remove the key (Figure 14). Figure 15 5. Close the fuel shut off valve before transporting or storing the machine. 1.
the component is in the correct position, a triangle will light up in the corresponding square. the throttle control in the fast position for best 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. Figure 16 1.
Children or bystanders may be injured if they move or attempt to operate the tractor while it is unattended. Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes. Adjusting the Height-of-Cut 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. 1.
2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. After adjusting the height-of-cut, adjust the rollers by removing the flange nut, bushing, spacer, and bolt (Figure 19 , Figure 20 and Figure 46 ). Note: The two middle rollers will not have a spacer (Figure 20). 4. Select a hole so the anti-scalp roller is positioned to the nearest corresponding height-of-cut desired. 5. Install the flange nut bushing, spacer, and bolt.
Figure 23 Figure 22 1. Seat latch 2. Fuel cap 1. Side console controls 2. By-pass valve 3. Seat 3. Hydraulic pumps Pushing the Machine by Hand Using the Side Discharge Important: Always push the machine by hand. Never tow the machine because hydraulic damage may occur. The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf.
To transport the machine: • Lock the brake and block the wheels. • Securely fasten the machine to the trailer or truck with straps, chains, cable, or ropes. Loading a unit onto a trailer or truck increases the possibility of backward tip-over and could cause serious injury or death. • Secure a trailer to the towing vehicle with safety chains. • Use extreme caution when operating a unit on a ramp. • 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 26). Grease more frequently when operating conditions are extremely dusty or sandy. Grease Type: General-purpose grease. Figure 25 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 28). 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 30 2. Filler tube 1. Oil dipstick 5. Unscrew the oil dipstick and wipe the end clean (Figure 30). 6. Slide the oil dipstick fully into the filler tube, but do not thread onto tube (Figure 30). Figure 31 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 30). 10.
Checking the Spark Plugs 3. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Figure 32). 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 32). 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 36). 7. Remove the battery. Installing the Battery 1. Position battery in the tray with the terminal posts toward the engine (Figure 36). 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 36).
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 41 1. Slotted Nut 2. Two threads or less showing 3. Hole in threaded shaft 4. Washer (if needed) Figure 40 5. Check the distance from bottom of slot in nut to inside edge of hole. Two threads or less should be showing (Figure 41). 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 44). Figure 43 1. Guard 2. Air intake screen 3. Bolt 4. Fan housing 5. Bolt Figure 44 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 44). 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 44). Check belts for cracks, frayed edges, burn marks or any other damage. Replace damaged belts.
Figure 46 1. Ratchet with short extension or breaker bar 2. Square hole Figure 47 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 51 Service Interval: After the first 8 hours 1. Cap 2. Baffle Every 50 hours 3. Cold fluid level-full 4. Hot fluid level-full Fluid Type: Mobil 1 15W-50 synthetic motor oil or equivalent synthetic oil. Hydraulic System Oil Capacity: 67 ounces (2.0 l) Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Important: Use oil specified or equivalent.
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 52). Figure 53 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 , page . 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. Figure 56 2. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 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.
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 58). 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. Loosen the front swivel jam nuts, at the front of the right and left swivels, approximately a 1/2 inch (13 mm) (Figure 57). 8.
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 Service Interval: Before each use or daily 1. Inspect the cutting edges (Figure 60). If the edges are not sharp or have nicks, remove and sharpen the blades. Refer to Sharpening the Blades. Figure 59 1. 10-1/2 inch (26.7 cm) for 60in mower decks and 11.125 inch (28.2 cm) for 52in mower decks 2.
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 64). Sharpening the Blades Figure 61 1. Measure here from blade to hard surface 2. Position A When sharpening blade, pieces of blade could be thrown and cause serious injury. 4. Rotate the opposite ends of the blades forward. 5.
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 64). Note: Make sure the L end of the spring is installed behind the deck edge before installing the bolt as shown in Figure 65. 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.
Notes: 54
Notes: 55
The Toro Total Coverage Guarantee A Limited Warranty (see warranty periods below) Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair the listed Toro Products if defective in materials or workmanship.
