Form No. 3361-219 Rev A Z400 Z Master® with 122 cm TURBO FORCE® Side Discharge Mower Model No. 74450TE—Serial No. 290000001 and Up Register at www.Toro.com.
This spark ignition system complies with Canadian ICES-002. Figure 2 Introduction 1. Safety alert symbol Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage. You are responsible for operating the product properly and safely. This manual uses 2 other words to highlight information. Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention.
Safety Greasing the Mower Deck and Belt Idlers.............................................................. 28 Engine Maintenance............................................... 29 Servicing the Air Cleaner .................................... 29 Servicing the Engine Oil ..................................... 29 Servicing the Spark Plugs.................................... 31 Fuel System Maintenance ....................................... 32 Replacing the Fuel Filter .....................................
Preparation • While mowing, always wear substantial footwear and long trousers. Do not operate the equipment when barefoot or wearing open sandals. • Thoroughly inspect the area where the equipment is to be used and remove all objects which may be thrown by the machine. • Warning–Fuel is highly flammable. – Store fuel in containers specifically designed for this purpose. – Refuel outdoors only and do not smoke while refuelling. – Add fuel before starting the engine.
• Do not make sudden turns or rapid speed changes. • Allow the engine to cool before storing in any enclosure. • To reduce the fire hazard, keep the engine, silencer, battery compartment and fuel storage area free of grass, leaves, or excessive grease. • Check the grass catcher frequently for wear or deterioration. • Replace worn or damaged parts for safety. • If the fuel tank has to be drained, this should be done outdoors.
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 99-8936 1. Machine speed 2. Fast 3. Slow 4. Neutral 5. Reverse 93-7010 1. Thrown object hazard— 2. Thrown object hazard, mower—keep the deflector in place. 3. Cutting/dismemberment of hand or foot—stay away from moving parts. 93-7818 99-8939 1.
99-8944 1. Explosion hazard—wear eye protection. 2. Caustic liquid/chemical burn hazard—to perform first aid, flush with water. 3. Fire hazard—no fire, open flames, or smoking. 4. Poison hazard—keep children away from the battery. 107-2131 1. Hydraulic oil level 2. Warning—do not touch the hot surface. 106-5517 1. Warning—do not touch the hot surface. 107-2132 1. Warning—engage the parking brake and chock the wheels when parking on a hill. 105-6183 3. Rotate the bypass valve 1.
110-2067 108-1052 1. Height of cut adjustment 110-2068 1. Read the Operator’s Manual. 112-8651 108-1053 1. 2. 3. 4. 5. 6. 1. Height-of-cut Interval Power Take-off (PTO) Parking brake Neutral Operator presence switch Battery 109-7949 112-9028 1. Warning—stay away from moving parts; keep all guards in place.
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 117-3822 5. Tire pressure 1. Read the Operator’s Manual before servicing or performing maintenance. 2. Time interval 6. Grease here 3. Engine oil 7. Check and perform any maintenance necessary 4. Hydraulic oil level 5. Read the Operator’s Manual. 6. Keep bystanders a safe distance from the battery. 7.
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. 117-0904 1. Fast 2. Continuous variable setting Product Overview 3. Slow Controls Become familiar with all the controls before you start the engine and operate the machine (Figure 3 and Figure 4). Figure 4 1. 2. 3. 4. 5. 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.
Hour Meter Fuel Shut-off Valve The hour meter 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). Close the fuel shut-off valve (near the engine) when transporting or storing the mower. 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).
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 10 1. Parking brake-ON 2. Parking brake-OFF Starting and Stopping the Engine Figure 9 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 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 12 1. Choke—on 5. Close the fuel shut off valve before transporting or storing the machine. 2.
Figure 16 1. Triangles light up when the interlock components are in the correct position Figure 15 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 15).
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 17).
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 19 , Figure 20 and Figure 50 ). Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes.
Figure 20 1. Anti-scalp roller 2. Bushing Figure 21 3. Bolt 4. Flange Nut 1. Cam lock 2. Lever Adjusting the Flow Baffle 3. Rotate cam to increase or decrease locking pressure 4. Slot Positioning the Flow Baffle The mower discharge flow can be adjusted for different types of mowing conditions. Position the cam lock and baffle to give the best quality of cut. The following figures are only recommendations for use. Adjustments will vary by grass type, moisture content, and height of grass. 1.
Slide the seat to the desired position and release lever to lock in position. Figure 25 1. Adjustment lever Figure 23 Position C Unlatching the Seat 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.
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.
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 28). 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.
Mowing Direction shredding the grass blades. Tearing and shredding turns grass brown at the edges, which slows growth and increases the chance of disease. Check the cutter blades daily for sharpness, and for any wear or damage. File down any nicks and sharpen the blades as necessary. If a blade is damaged or worn, replace it immediately with a genuine TORO replacement blade. Alternate mowing direction to keep the grass standing straight.
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 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 30). Grease more frequently when operating conditions are extremely dusty or sandy. Grease Type: General-purpose grease. Figure 29 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. 14. Reinstall the seal guards over the wheel hub and insert wheel into caster fork. Reinstall caster bolt and tighten nut fully. Every 50 hours—Grease the pump drive belt idler arm. Grease with No. 2 general purpose lithium base or molybdenum base grease. Important: Make sure cutting unit spindles are full of grease weekly.
Engine Maintenance Installing the Air Filter Important: To prevent engine damage, always operate the engine with the air filter and cover installed. 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 32). Servicing the Air Cleaner Service Interval: Every 200 hours—Replace the air filter (more often in dirty or dusty conditions).
2. Disengage the PTO, turn the ignition key to off, and remove the key. 8. Remove the drain hose (Figure 35). Note: Dispose of the used oil at a recycling center. 3. Wait for all moving parts to stop before leaving the operating position and then chock or block tires. 4. Clean around the oil dipstick (Figure 34) so that dirt cannot fall into the filler hole and damage the engine. Figure 34 2. Filler tube 1. Oil dipstick 5. Unscrew the oil dipstick and wipe the end clean (Figure 34). Figure 35 1.
Figure 37 Figure 36 1. Oil filter 1. Spark-plug wire/spark plug 2. Adapter 4. Clean around the spark plugs to prevent dirt from falling into the engine and potentially causing damage. 3. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Figure 36). 5. Remove the spark plugs and the metal washers. 4.
Installing the Spark Plugs Fuel System Maintenance 1. Install the spark plugs and the metal washer. Ensure that the air gap is set correctly. 2. Tighten the spark plugs to 16 ft-lb (22 N-m). Replacing the Fuel Filter 3. Connect the wires to the spark plugs (Figure 38). Service Interval: Every 200 hours/Yearly (whichever comes first)—Replace the fuel filter. Never install a dirty filter if it is removed from the fuel line. 1.
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 40). 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 40). • Always Disconnect the negative (black) battery cable before disconnecting the positive (red) cable. 2.
Figure 41 1. Positive Battery Post 2. Negative Battery Post 3. Red (+) Charger Lead 4. Black (-) Charger Lead Figure 42 1. Accessory—15 amp 2. Clutch—10 amp 3. Install the battery in the machine and connect the battery cables; refer to Installing the Battery. 3. Charge circuit—25 amp 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 Maintain the air pressure in the rear tires at 13 psi (90 kPa). Uneven tire pressure can cause an uneven cut. Check the tires when they are cold to get the most accurate pressure reading. Adjusting the Tracking Note: The front tires are semi-pneumatic tires and do not require air pressure maintenance. 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 45 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 45). Figure 46 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 45). 8.
Cooling System Maintenance Cleaning the Air Intake Screen Service Interval: Before each use or daily 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—Inspect the belts for cracks and wear. 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 48). Check belts for cracks, frayed edges, burn marks or any other damage. Replace damaged belts.
Replacing the Pump Drive Belt 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 51). 3. Pull the spring loaded idler to the side. 4. Remove the traction belt from the engine and the hydraulic pump pulleys (Figure 51). Figure 49 1. Fixed idler arm 2. Square hole 3. Fixed Idler pulley 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 52 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 50 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 56). Figure 55 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 57 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 62). 2. Measure the right blade at the A location, from a level surface to the cutting edge of the blade tip (Figure 62). Figure 60 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 61). Figure 62 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 63). 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 63).
to the cutting edge, position A, of the blades (Figure 65). 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 68). Sharpening the Blades Figure 65 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 68). Note: Make sure the L end of the spring is installed behind the deck edge before installing the bolt as shown in Figure 69. 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.
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International Distributor List Distributor: Atlantis Su ve Sulama Sisstemleri Lt Balama Prima Engineering Equip B-Ray Corporation Casco Sales Company Ceres S.A CSSC Turf Equipment (pvt) Ltd Cyril Johnston & Co Equiver Femco S.A. G.Y.K. Company ltd. Geomechaniki of Athens Guandong Golden Star Hako Ground and Garden Hako Ground and Garden Hayter Limited (U.K.) Hydroturf Int. Co Dubai Hydroturf Egypt LLC Ibea S.p.A. Irriamc Irrigation Products Int'l Pvt Ltd Jean Heybroek b.v. Lely (U.K.) Limited Maquiver S.A.
The Toro Warranty Conditions and Products Covered Instructions for Obtaining Warranty Service The Toro® Company and its afliate, Toro Warranty Company, pursuant to an agreement between them, jointly promises to the original purchaser* to repair any Toro Product used for normal residential purposes* if defective in materials or workmanship.
