Form No. 3364-231 Rev A Z400 Z Master® with 122 cm TURBO FORCE® Side Discharge Mower Model No. 74450TE—Serial No. 310000001 and Up 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. injury or death if you do not follow the recommended precautions. Figure 2 This spark ignition system complies with Canadian ICES-002. 1. Safety alert symbol This manual uses 2 other words to highlight information.
Recommended Maintenance Schedule(s) ................ 27 Lubrication............................................................. 28 Greasing and Lubrication ................................... 28 Greasing the Mower Deck and Belt Idlers.............................................................. 29 Engine Maintenance............................................... 30 Servicing the Air Cleaner .................................... 30 Servicing the Engine Oil .....................................
Preparation Safety • 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.
• • • • • • • • • • • Maintenance and Storage – - stay alert for humps and hollows and other hidden hazards; Use care when pulling loads or using heavy equipment. – - Use only approved drawbar hitch points. – - Limit loads to those you can safely control. – - Do not turn sharply. Use care when reversing. Watch out for traffic when crossing or near roadways. Stop the blades rotating before crossing surfaces other than grass.
Measured vibration level for right hand = 2.4 m/s2 • Do not mow near drop-offs, ditches, steep banks or water. Wheels dropping over edges can cause rollovers, which may result in serious injury, death or drowning. • Do not mow slopes when grass is wet. Slippery conditions reduce traction and could cause sliding and loss of control. • Do not make sudden turns or rapid speed changes. • Use a walk behind mower and/or a hand trimmer near drop-offs, ditches, steep banks or water.
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. 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.
9-8944 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 4 and Figure 5). Figure 5 1. 2. 3. 4. 5. Figure 4 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 6). 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 6).
Operation DANGER 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. • Always place gasoline containers on the ground away from your vehicle before filling.
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. Important: Lower the roll bar only when absolutely necessary. Filling the Fuel Tank 2. Lower the roll bar to the down position. There are two down positions. See Figure 7 for the positions. 1. Remove the hairpin cotter pins and remove the two pins (Figure 8). Note: Do not fill the fuel tank completely full.
1 2 3 Figure 9 1. Safe Zone-use the Z Master here on slopes less than 15 degrees or flat areas. 2. Use walk behind mower and/or hand trimmer near drop-offs and water. 4 G004955 Figure 8 1. Roll bar 2. Raised position 3. Water 3. Pin 4. Hairpin cotter pin CAUTION This machine produces sound levels in excess of 85 dBA at the operators ear and can cause hearing loss through extended periods of exposure. Think Safety First Please read all safety instructions and symbols in the safety section.
Starting and Stopping the Engine Starting the Engine 1. Sit on the seat and move the motion controls to neutral locked position. Figure 10 1. Warning— wear hearing protection 2. Set the parking brake; refer to Setting the Parking Brake. 3. Move the PTO (power take off) switch to the Off position (Figure 12). Operating the Parking Brake Always set the parking brake when you stop the machine or leave it unattended. Setting the Parking Brake 1.
to remove the key as the fuel pump may run and cause the battery to lose charge. CAUTION 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. Figure 14 1. Throttle—fast 2. Throttle—slow 6. Turn the ignition key to Start. When the engines starts, release the key (Figure 15).
The Safety Interlock System 1. Sitting on the seat, engage the parking brake and move the PTO to on. Try starting the engine; the engine should not crank. CAUTION 2. Sitting on the seat, engage the parking brake and move the PTO to off. Move either motion control lever (out of neutral locked position). Try starting the engine; the engine should not crank. Repeat for other control lever.
To go straight, apply equal pressure to both motion control levers (Figure 18). Stopping the Machine To turn, move the motion control lever toward neutral in the direction you want to turn (Figure 18). To stop the machine, move the traction control levers to neutral and move to locked position, disengage the power take off (PTO), and turn the ignition key to off. The farther you move the traction control levers in either direction, the faster the machine will move in that direction.
Adjusting the Anti-Scalp Rollers Whenever you change the height-of-cut, adjust the height of the anti-scalp rollers. 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. 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 ). Figure 21 1.
Figure 24 Figure 22 1. Cam lock 2. Lever 3. Rotate cam to increase or decrease locking pressure 4. Slot Position C This is the full open position. The suggested use for this position is as follows. Positioning the Flow Baffle • Use in tall, dense grass mowing conditions. The following figures are only recommendations for use. Adjustments will vary by grass type, moisture content, and height of grass. • Use in wet conditions. • Lowers the engine power consumption.
1. Place your foot onto lift assist lever. 2. Press on the lift assist lever while pulling up on the height-of-cut lever (Figure 26). Figure 28 Figure 26 1. Seat latch 2. Fuel cap Positioning the Seat 3. Seat Pushing the Machine by Hand The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable. Important: Always push the machine by hand. Never tow the machine because hydraulic damage may occur.
• Lock the brake and block the wheels. • Securely fasten the machine to the trailer or truck with straps, chains, cable, or ropes. • Secure a trailer to the towing vehicle with safety chains. WARNING 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. Figure 29 1. Side console controls 2. By-pass valve 3. Hydraulic pumps Do not drive machine on a public street or roadway.
mower free from uncut grass, which allows air to be drawn into the mower. WARNING 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. • Use only a single, full width ramp; Do Not use individual ramps for each side of the unit. • If individual ramps must be used, use enough ramps to create an unbroken ramp surface wider than the unit.
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. Keep the Underside of the Mower Clean Clean clippings and dirt from the underside of the mower after each use. If grass and dirt build up inside the mower, cutting quality will eventually become unsatisfactory.
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. 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 34). 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 37). 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 36) so that dirt cannot fall into the filler hole and damage the engine. Figure 36 2. Filler tube 1. Oil dipstick 5. Unscrew the oil dipstick and wipe the end clean (Figure 36). Figure 37 1.
Figure 39 Figure 38 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 38). 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 40). 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 DANGER 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.
5. Slide the red terminal boot onto the positive (red) battery post. 6. Secure battery with J-bolts, hold down clamp and 2 washers (1/4 inch), and 2 wing nuts (1/4 inch) (Figure 42). 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. Unlatch the seat and tilt the seat up. 4.
Drive System Maintenance 1. Raise the seat to gain access to the fuse holder (Figure 44). 2. To replace the fuses, pull out on the fuse to remove it. Adjusting the Tracking 3. Install a new fuse (Figure 44). 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.
Check the tires when they are cold to get the most accurate pressure reading. Note: The front tires are semi-pneumatic tires and do not require air pressure maintenance. Figure 47 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 47). Figure 46 6. If more than two threads are showing remove nut and install washer between hub and nut.
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. Cleaning the Cooling System Figure 48 1. Spring Washers 2.
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: Service Interval: Every 100 hours—Inspect the belts for cracks and wear. A. Loosen the jam nut directly below the yoke. B. Turn the bottom adjusting nuts until the correct measurement is obtained (Figure 50).
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. 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.
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. Place a drain pan under filter, remove the old filter and wipe the filter adapter gasket surface clean (Figure 58). 3. Cold fluid level-full 4.
WARNING 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. • Use cardboard or paper to find hydraulic leaks.
Setting the Left-hand Hydraulic Pump Neutral Position 3. Adjust the pump rod length by rotating double nuts on the rod, in the appropriate direction, until the wheel is still or slightly creeps in reverse (Figure 61). 1. Start the engine, open the throttle 1/2 way and release parking brake. Refer to Starting and Stopping the Engine in Operation (page 14). 4. Move the motion control lever forward and reverse, then back to neutral. The wheel must stop turning or slightly creep in reverse.
Mower Deck Maintenance 9. Install the seat rod and lower the seat into position. 10. Remove the jack stands. Leveling the Mower at Three Positions Important: There are only three measuring positions needed to level the mower. Preparing the Machine 1. Position mower on a flat surface. 2. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
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). DANGER 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. • Inspect the blade periodically for wear or damage. • Replace a worn or damaged blade. 3.
to the cutting edge, position A, of the blades (Figure 67). Note this dimension. 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 WARNING When sharpening blade, pieces of blade could be thrown and cause serious injury. Wear proper eye protection when sharpening blade. 1. Use a file to sharpen the cutting edge at both ends of the blade (Figure 68). Maintain the original angle.
Figure 71 Figure 70 1. Sail Area of Blade 2. Blade 3. Spring Disk 1. Bolt 2. Spacer 3. Locknut 4. Blade Bolt 5. Cone Towards Bolt Head 4. Spring Replacing the Grass Deflector WARNING An uncovered discharge opening could allow the lawn mower to throw objects in the operator’s or bystander’s direction and result in serious injury. Also, contact with the blade could occur. • Never operate the lawn mower unless you install a cover plate, a mulch plate, or a grass chute and catcher.
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: 57
Notes: 58
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.
The Toro Total Warranty Conditions and Products Covered 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. 2. Bring the product and your proof of purchase (sales receipt) to the Service Dealer. 3.
