Form No. 3360-403 Rev A Z300 Z Master® with a 34in 7-Gauge Side Discharge Mower or with a 40in 7-Gauge Side Discharge Mower Model No. 79408—Serial No. 280000001 and Up Model No. 79409—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.
Controls ............................................................. 10 Operation................................................................... 11 Adding Fuel ....................................................... 11 Checking the Engine Oil Level............................ 12 Think Safety First ............................................... 12 Operating the Parking Brake ............................... 13 Starting and Stopping the Engine ........................
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.
• Shut off fuel while storing or transporting. Do not store fuel near flames or drain indoors. • Park machine on level ground. Never allow untrained personnel to service machine. • Use jack stands to support components when required. • Carefully release pressure from components with stored energy. • Disconnect battery or remove spark plug wire before making any repairs. Disconnect the negative terminal first and the positive last. Reconnect positive first and negative last. • Use care when checking blades.
Safe Handling of Gasoline: To avoid personal injury or property damage, use extra care when handling gasoline and other fuels. They are flammable and the vapors are explosive. • Extinguish all cigarettes, cigars, pipes and other sources of ignition. • Never remove the gas cap or add fuel when the engine is running. Allow the engine to cool before refueling. • Never refuel the machine indoors.
Slope Chart 7
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. 98-5954 1-403005 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 54-9220 5. Read the Operator’s Manual. 6. Keep bystanders a safe distance from the battery. 7.
112-3830 109-2356 1. Fast 2. Slow 112-3831 3. Neutral 4.
112-3833 Product Overview Controls Become familiar with all the controls before you start the engine and operate the machine (Figure 3 and Figure 4). Figure 3 1. 2. 3. 4. Side discharge chute Height-of-cut selection pin Controls Motion control lever 5. 6. 7. 8. Fuel cap (both sides) Parking brake lever Mower deck Front caster wheel Figure 4 1. Ignition switch 2. Hour meter 3. PTO Switch 10 4. Choke lever 5.
Using the Hour Meter Operation The hour meter (Figure 5) records the number of hours the engine has operated. It operates when the engine is running. Use these times for scheduling regular maintenance. 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. 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.
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, hearing, feet, and head.
5. Move the throttle control to the fast position before starting a cold engine (Figure 11). Figure 9 1. Parking brake – Set/ON 2. Parking brake – Released/OFF Figure 11 1. Choke on 2. Choke off Starting and Stopping the Engine 3. Throttle slow 4. Throttle fast 6. Turn the ignition key to Start. When the engines starts, release the key (Figure 12). Important: Do not engage starter for more than 10 seconds at a time. If engine fails to start allow 30 second cool-down period between attempts.
3. Let the engine idle for 60 seconds. 4. Turn the ignition key to the off position and remove the key (Figure 12). 5. Close the fuel shut off valve before transporting or storing the machine (Figure 6). Important: Make sure that the fuel shut off valve is closed before transporting or storing the machine, as fuel leakage may occur. Set the parking brake before transporting. Make sure to remove the key as the fuel pump may run and cause the battery to lose charge. Figure 13 1. PTO-On (knob out) 2.
Note: If the safety system does not operate as described below, have an Authorized Service Dealer repair the safety system immediately. 2. Move the levers to the center, the un-locked position. 3. To go forward, slowly push the motion control levers forward (Figure 14). 1. Sitting on the seat, engage the parking brake and move the PTO to on. Try starting the engine; the engine should not crank. Note: The engine will kill if the traction control levers are moved with the parking brake engaged. 2.
To turn, release pressure on the motion control lever toward the direction you want to turn (Figure 14). To stop, push the motion control levers to the neutral position. Stopping the Machine To stop the machine, move the traction control levers to the center position and move them out to the locked position, disengage the power take off (PTO), and turn the ignition key to off. Set the parking brake when you leave the machine; refer to Setting the Parking Brake in Operation , page 11.
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 17 ). 4.
2 1 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. 1 • Never remove the grass deflector from the mower because the grass deflector routes material down toward the turf. If the grass deflector is ever damaged, replace it immediately. • Never put your hands or feet under the mower.
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 20). 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 • • • • Check for any loose fasteners and tighten them. Change the engine oil. Tighten the wheel lug nuts. Check the hydraulic fluid. After the first 250 hours • Change the hydraulic filters and oil. Before each use or daily • • • • • • Check the safety system. Check the engine oil level. Clean the air intake screen. Check the brake. Check the mower blades.
How to Grease 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. Wipe up any excess grease.
4. Remove then nut and bolt holding the caster wheel to the front caster fork (Figure 25). 5. Remove the seal guard from the wheel hub (Figure 25). Figure 23 Figure 25 1. Caster fork 2. Bolt 3. Seal guard 4. Caster wheel 5. Nut 6. Remove one of the spacer nuts (with wrench flats) from the axle (Figure 27). Note: Thread locking adhesive has been applied to the spacer nuts. 7. Remove the axle without removing the opposite spacer nut (Figure 27). Figure 24 8.
Figure 27 1. Spacer nut 2. Bearing seal (new seals required) 3. Bearing Figure 26 1. 1/8 inch (3 mm) of the nut past the axle 12. Install the assembled nut and axle into the wheel on the side with the bearing and a new seal (Figure 27). 13. Place the wheel with the open end facing up and fill the area inside the wheel with multi-purpose grease. 14. Install the second bearing and a new seal into the wheel (Figure 27). 15.
Engine Maintenance Servicing the Air Cleaner Important: Do not oil the foam or paper element. Note: Service the air cleaner more frequently (every few operating hours) if the operating conditions are extremely dusty or sandy. Removing the Foam and Paper Elements 1. Disengage the PTO 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.
Installing the Foam and Paper Elements Important: To prevent engine damage, always operate the engine with the complete foam and paper air cleaner assembly installed. 1. Carefully slide the foam element onto the paper air cleaner element (Figure 28). 2. Place the air cleaner assembly onto the air cleaner base and secure it with the 2 wing nuts (Figure 28). Figure 30 3. Place the air cleaner cover into position and tighten the cover knob (Figure 28). 2. Filler tube 1.
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. 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 34). 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. Draining the Fuel Tank 2. If needed, clean the spark plug with a wire brush to remove carbon deposits. In certain conditions, gasoline is extremely flammable and highly explosive.
Electrical System Maintenance 3. Close the fuel shut-off valve located under the front of the fuel tank. 4. Squeeze the ends of the hose clamps together and slide them away from the filter (Figure 35). Servicing the Battery 5. Remove the filter from the fuel lines. 6. Install a new filter and move the hose clamps close to the filter (Figure 35). Warning Important: Install the filter so the direction of the flow arrow is consistent with the flow of fuel; from the gas tank to the engine.
Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. • Always Disconnect the negative (black) battery cable before disconnecting the positive (red) cable. • Always Reconnect the positive (red) battery cable before reconnecting the negative (black) cable. 1. Disengage the PTO, move the motion control levers to the neutral locked position, and set the parking brake. 2.
Charging the Battery 2. To replace the fuses, pull out on the fuse to remove it. 3. Install a new fuse (Figure 38). Charging the battery produces gasses that can explode. Never smoke near the battery and keep sparks and flames away from battery. Important: Always keep the battery fully charged (1.265 specific gravity). This is especially important to prevent battery damage when the temperature is below 32°F (0°C). 1. Charge battery for 10 to 15 minutes at 25 to 30 amps or 30 minutes at 4-6 amps. 2.
Drive System Maintenance Checking the Tire Pressure Service Interval: Every 50 hours or monthly, whichever occurs first. Check the pressure at the valve stem after every 50 operating hours or monthly, whichever occurs first (Figure 39). Maintain the air pressure in the 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.
Cooling System Maintenance Brake Maintenance Cleaning the Air Intake Screen Before each use, check the brakes on both a level surface and slope. Servicing the Brakes 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.
Belt Maintenance Inspecting the Belts Service Interval: Every 100 hours—Inspect all belts for cracks and wear. Check belts for cracks, frayed edges, burn marks or any other damage. Replace damaged belts. Replacing the Mower Belt The signs of a worn mower belt are squealing while the belt is rotating, blades slipping while you are cutting grass, frayed belt edges, burn marks, and cracks. Replace the mower belt if you detect any of these signs. Figure 43 40 inch Mower 1. Fixed idler pulley 2.
Controls System Maintenance Note: Non-commercial owners will need to loosen the seat retainer clip that holds the seat in place. 2. Check the belt for wear and replace it if needed. 3. To replace the belt, remove the bolt from the clutch stop and unplug the clutch electrical wire (Figure 45). Adjusting the Control Handle Neutral Position 4. Pull on the idler pulley to relieve the belt tension on the idler pulley (Figure 45). 1.
Figure 48 1. Control lever 2. Stop Figure 47 5. If the ends of the levers hit against each other, adjust the levers by rotating them out to the neutral locked position and carefully bend them outward. Repeat this step as needed. Adjusting the Tracking 1. If the machine turns right or left when the handles are pushed forward together, adjust the stop on the side opposite that the machine turns. 2. Loosen the bolt located in front of the control lever. 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. Figure 49 Important: Use oil specified or equivalent. Other fluids could cause system damage. 1. Cap 2. Baffle Note: There are two ways of checking the hydraulic oil; when the oil is warm or when the oil is cold. The tank has two levels depending if the oil is warm or cold (Figure 49).
changing filter), unless it is felt the oil has been contaminated or been extremely hot. Changing the oil unnecessarily could damage the hydraulic system by introducing contaminates into the system. 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.
Mower Deck Maintenance Note: The mower deck cutting height can be adjusted. Loosen the height of cut bracket and adjust it forward or backward to get the correct height. Tighten the bracket after the adjustment is made. Leveling the Mower Important: There are only three measuring positions needed to level the mower. 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.
Figure 52 Left side shown 1. Pivot bracket 2. Bolt installed in the middle of the slot 3. Rear pivot bracket 4. Front pivot bracket Servicing the Cutting Blades 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. Maintain sharp blades throughout the cutting season because sharp blades cut cleanly without tearing or shredding the grass blades.
Inspecting the Blades 2 A Service Interval: Before each use or daily 1. Inspect the cutting edges (Figure 53). If the edges are not sharp or have nicks, remove and sharpen the blades. Refer to Sharpening the Blades. A 2. Inspect the blades, especially the curved area (Figure 53). If you notice any damage, wear, or a slot forming in this area (Figure 53), immediately install a new blade. 1 G004621 Figure 54 34 inch Mower 1. Measure here from blade to hard surface 2. Position A Figure 53 1.
A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders. • Always replace bent or damaged blade with a new blade. Figure 56 1. Sharpen at original angle • Never file or create sharp notches in the edges or surfaces of blade. 2. Check the balance of the blade by putting it on a blade balancer (Figure 57). If the blade stays in a horizontal position, the blade is balanced and can be used.
Figure 58 1. Sail Area of Blade 2. Blade 3. Spring Disk 4. Blade Bolt 5. Cone Towards Bolt Head Replacing the Grass Deflector Figure 59 1. 2. 3. 4. 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. • Make sure the grass deflector is in the down position. 1.
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 1.
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. 12. Check and tighten all bolts, nuts, and screws. Repair or replace any part that is damaged. 13. Paint all scratched or bare metal surfaces. Paint is available from your Authorized Service Dealer. 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.
Notes: 50
Notes: 51
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.
