Form No. 3359-436 Rev B Z400 Z Master with a 48in or 52in 7-Gauge Side Discharge Mower Model No. 74448—Serial No. 280000001 and Up Model No. 74449—Serial No. 280000001 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 107-1687 103-2644 Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 105-7798 2. No fire, open flame, or smoking. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 107-1613 5. Read the Operator’s Manual. 8 6. Keep bystanders a safe distance from the battery. 7. Wear eye protection; explosive gases can cause blindness and other injuries 8. Battery acid can cause blindness or severe burns. 9.
108-1050 107-2102 108-1051 Manufacturer’s Mark 1. Indicates the blade is identified as a part from the original machine manufacturer.
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 110-0439 1. Choke 2. Engine—stop 3. Engine—run 4. Engine—start 5. Fast 6. Continuous variable setting Product Overview 10 7. Slow 8.
is running. Use these times for scheduling regular maintenance. Figure 5 1. Hour meter Throttle Control The throttle control has two positions: Fast and Slow. Choke Figure 3 1. 2. 3. 4. 5. Rollbar Fuel cap (both sides) Seat belt Motion control lever Height-of-cut lever 6. 7. 8. 9. 10. Use the choke to start a cold engine.
Operation 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: Never use methanol, gasoline containing methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged. Do not mix oil with gasoline. Figure 6 1.
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 13 Figure 11 1. Parking brake-ON 2. Parking brake-OFF 1. Choke—on 2. Choke—off 3. Brake Stop 5. Move the throttle control to the Fast position before starting a cold engine (Figure 14). 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 14 1. Throttle—fast 3. Move the PTO (power take off) switch to the Off position (Figure 12). 2. Throttle—slow 6.
Engaging the PTO 1. If the engine is cold, allow the engine to warm up 5 to 10 minutes before engaging the PTO. 2. While seated in the seat, release the pressure on the traction control levers and place in neutral. 3. Place the throttle in the fast position. Note: Engaging the PTO with the throttle at the half or less position will cause excessive wear to the drive belts. 4. Pull out on the power take off (PTO) switch to engage it (Figure 16). Figure 15 1. Off 2. Run 3. Start 7.
• You are sitting on the seat. • The parking brake is engaged. Machine can spin very rapidly. Operator may lose control of machine and cause personal injury or damage to machine. • The power take off (PTO) is disengaged. • The motion control levers are in the neutral locked position • Use caution when making turns.
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 45 ). 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. Before each use or daily • • • • • Check the safety system. Check the engine oil level. Clean the engine air intake screen from grass and debris. Check the mower blades. Clean the mower deck. Every 25 hours • • • • • Grease the mower deck and spindles.
How to Grease Where to Add Light Oil or Spray Lubrication 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. 3. Clean the grease fittings with a rag. Make sure to scrape any paint off the front of the fitting(s). 4. Connect a grease gun to the fitting. Pump grease into the fittings until grease begins to ooze out of the bearings. 5.
Engine Maintenance Servicing the Air Cleaner Note: Service the filter more frequently if operating conditions are extremely dusty or sandy. Removing the Filters 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. 3. Release the latches on the air cleaner and pull the air cleaner cover off of the air cleaner body (Figure 27).
1. If installing a new filter, check it for shipping damage. Do not use a damaged filter. 2. Carefully slide the air filter into the body (Figure 27). Note: Ensure that it is fully seated by pushing on the outer rim of the filter while installing it. Important: Do not press on the soft inside area of the filter. 3. Install the air cleaner cover with the side indicated as UP facing up and secure the latches (Figure 27). Figure 29 2. Filler tube 1. Oil dipstick Servicing the Engine Oil 5.
3. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Figure 31). 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 31). 5. Fill the crankcase with the proper type of new oil; refer to Servicing the Engine Oil. 6. Run the engine for about 3 minutes, stop the engine, and check for oil leaks around the oil filter. 7.
Checking the Spark Plugs Fuel System Maintenance Service Interval: Every 100 hours 1. Look at the center of the spark plugs (Figure 33). If you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means that the air cleaner is dirty. Replacing the Fuel Filter Service Interval: Every 200 hours—Replace the fuel filter 2. If needed, clean the spark plug with a wire brush to remove carbon deposits.
Servicing the Fuel Tank Electrical 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. Servicing the Battery Warning • Drain gasoline from the fuel tank when the engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills.
6. Remove both wing nuts (1/4 inch) securing the battery clamp (Figure 35). Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. 7. Remove the battery. Installing the Battery 1. Position battery in the tray with the terminal posts toward the engine (Figure 35). • Always Disconnect the negative (black) battery cable before disconnecting the positive (red) cable. 2.
Figure 36 1. Positive Battery Post 2. Negative Battery Post 3. Red (+) Charger Lead 4. Black (-) Charger Lead Figure 37 1. Main, 30 amp 2. Charge circuit, 25 amp 3. For optional head light kit, 10 amp 3. Install the battery in the machine and connect the battery cables; refer to Installing the Battery. Note: Do not run the machine with the battery disconnected, electrical damage may occur. Servicing the Fuses The electrical system is protected by fuses.
Drive System Maintenance Check the pressure at the valve stem (Figure 39). 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. 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.
Figure 40 1. Slotted Nut 2. Two threads or less showing 3. Hole in threaded shaft 4. Washer (if needed) 5. Check the distance from bottom of slot in nut to inside edge of hole. Two threads or less should be showing (Figure 40). Figure 41 6. If more than two threads are showing remove nut and install washer between hub and nut. 1. Spring Washers 2. Lock Nut 7. Torque the slotted nut to 125 ft-lb. (170 N•m) (Figure 40). 8.
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 Belt Maintenance Adjusting the Parking Brake Inspecting the Belts Check the parking brake for proper adjustment. Service Interval: Every 100 hours 1. Disengage the brake lever (lever down). Check belts for cracks, frayed edges, burn marks or any other damage. Replace damaged belts. 2. Measure the length of the spring; the measurement should be 2-3/4 inch (74 mm) between the washers (Figure 43).
Replacing the Pump Drive Belt Service Interval: Every 50 hours 1. Remove the mower belt first; refer to Replacing the Mower Belt. 2. Remove the bolt from the clutch stop and unplug the clutch electrical wire (Figure 46). 3. Pull the spring loaded idler to the side. Figure 44 1. Fixed idler arm 2. Square hole 3. Fixed Idler pulley 4. Remove the traction belt from the engine and the hydraulic pump pulleys (Figure 46). 4. Mower belt 5. Belt guide 6. Spring-loaded idler pulley 5.
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. Figure 47 1. Push arm 2. 15–1/8 inch (384 mm) 3.
Hydraulic System Maintenance Servicing the Hydraulic System Checking the Hydraulic Fluid Service Interval: After the first 8 hours Every 25 hours Fluid Type: Mobil 1 15W-50 synthetic motor oil or equivalent synthetic oil. Hydraulic System Oil Capacity: 67 ounces (2.0 l) Important: Use oil specified or equivalent. Other fluids could cause system damage. 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.
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 51). Figure 50 1. Cap 2. Baffle 3. Cold fluid level-full 4. Hot fluid 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 52 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 Operation , page 12.
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 57). 2. Measure the right blade at the A location, from a level surface to the cutting edge of the blade tip (Figure 57). Figure 55 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 56). Figure 57 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 58). 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 58).
to the cutting edge, position A, of the blades (Figure 60). 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 63). Sharpening the Blades Figure 60 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 Important: The grass deflector must be able to lower down into position. Lift the deflector up to test that it lowers into the full down position. 1. Install the blade onto the spindle shaft (Figure 63). Important: The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting. 2. Install the spring disk and blade bolt. The spring disk cone must be installed toward the bolt head (Figure 63).
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.
B. Run the engine to distribute conditioned fuel through the fuel system (5 minutes). C. Stop the engine, allow it to cool, and drain the fuel tank; refer to Servicing the Fuel Tank in Fuel System Maintenance , page 29. 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.
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.
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The Toro Total Coverage Guarantee Landscape Contractor Equipment (LCE) A Limited Warranty Conditions and Products Covered Owner Responsibilities The Toro® Company and its afliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair the listed Toro Products if defective in materials or workmanship.
