Form No. 3356-228 Rev A Z400 Z Master® with 122 cm 7-Guage Side Discharge Mower Model No. 74418TE—Serial No. 270000001 and Up Register your product at www.Toro.
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.
Recommended Maintenance Schedule(s) ............................... 26 Lubrication................................................ 27 Greasing and Lubrication................... 27 Greasing the Mower Deck and Belt Idlers................................. 27 Lubricating the Caster Wheel Hubs ................................. 28 Engine Maintenance.................................. 29 Servicing the Air Cleaner ................... 29 Servicing the Engine Oil .................... 30 Servicing the Spark Plugs ....
Safety ◊ the type of machine is unsuitable for its task; ◊ lack of awareness of the effect of ground conditions, especially slopes; This machine meets or exceeds European Standards in effect at the time of production. However, improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means CAUTION, WARNING, or DANGER-"personal safety instruction.
• Mow only in daylight or in good artificial light. • Before attempting to start the engine, disengage all blade attachment clutches and shift into neutral. • Do not use on slopes greater than 15 degrees. • Remember there is no such thing as a safe slope. Travel on grass slopes requires particular care.
information that you must know that is not included in the CEN standard. • Watch for ditches, holes, rocks, dips, and rises that change the operating angle, as rough terrain could overturn the machine. • Engine exhaust contains carbon monoxide, which is an odorless, deadly poison that can kill you. Do not run engine indoors or in an enclosed area. • Avoid sudden starts when mowing uphill because the mower may tip backwards. • Be aware that loss of traction may occur going downhill.
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. 58-6520 1. Grease 93-7010 1. Thrown object hazard— 2. Thrown object hazard, mower—keep the deector in place. 3. Cutting/dismemberment of hand or foot—stay away from moving parts. 93-7818 1. Warning—read the Operator’s Manual for instructions on torquing the blade bolt/nut to 115-149 N•m (85-110 ft-lb).
105-6183 1. 2. 3. Read the Operator’s Manual. Use a wrench to rotate the 4. bypass valve. Rotate the bypass valve out to push the machine. Rotate the bypass valve in to drive the machine. 99-8936 1. Machine speed 2. Fast 3. Slow 4. 5. Neutral Reverse 107-1686 99-8939 3. 1. Read the Operator’s Manual. 2. Height of cut 1. Remove the ignition key and read the instructions before servicing or performing maintenance. 2. 3. 4. 99-8944 1. Explosion hazard—wear eye protection. 2.
7-1866 1. Sliding and loss of control hazard and tipping hazard, drop-offs—do not operate the machine near drop-offs, slopes greater than 15 degrees, or water; keep a safe distance from drop-offs; do not turn sharply while traveling fast, instead, slow down and turn gradually; if the roll bar is raised, wear the seat belt; if the roll bar is lowered, do not wear the seat belt. 107-3069 1. Warning—there is no rollover protection when the roll bar is down. 2.
2-9028 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 6. 2. No re, open ame, or smoking. 7. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 8. 5. Read the Operator’s Manual. 9. 10. Keep bystanders a safe distance from the battery. Wear eye protection; explosive gases can cause blindness and other injuries Battery acid can cause blindness or severe burns.
108-1054 1. Parking brake 3. Disengage 2. Engage 4. Warning—read the Operator’s Manual, do not use alcohol or drugs while operating this machine, all operators should be trained before operating the machine, wear hearing protection. 5. Return levers to the neutral 7. Cutting/dismemberment, locked position, engage the mower blade—do not carry parking brake, and remove passengers. the ignition key before leaving the machine. 6. Thrown object hazard—keep 8.
Product Overview Using the Hour Meter 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. Figure 5 1. Hour meter Using the Fuel Shutoff Valve The machine has 2 fuel tanks, one on the left side and the other on the right side. Each tank connects to a check valve and then to a tee. From there a common fuel line leads to the engine (Figure 6). Figure 3 1. 2. 3. 4. 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 • Always place gasoline containers on the ground away from your vehicle before filling. Use Unleaded Regular Gasoline suitable for automotive use (85 pump octane minimum).
• Cleans the engine while it runs • Eliminates gum-like varnish buildup in the fuel system, which causes hard starting There is no rollover protection when the roll bar is in the down position. Important: Do not use fuel additives containing methanol or ethanol. • Lower the roll bar only when absolutely necessary. Add the correct amount of gas stabilizer/conditioner to the gas. • Do not wear the seat belt when the roll bar is in the down position.
Think Safety First 5. To raise the roll bar, remove the hairpin cotter pins and remove the two pins (Figure 8). 6. Raise the roll bar to the upright position and install the two pins and secure them with the hairpin cotter pins (Figure 8). Please read all safety instructions and symbols in the safety section. Knowing this information could help you or bystanders avoid injury. Important: Always use the seat belt with the roll bar in the raised position.
Setting the Parking Brake 1. Move the motion control levers (Figure 18) out to the neutral lock position. 2. Pull up and back on the parking brake lever to set the parking brake (Figure 12). The parking brake lever should stay firmly in the engaged position. Parking brake may not hold machine parked on a slope and could cause personal injury or property damage. Do not park on slopes unless wheels are chocked or blocked Figure 10 1. Safe Zone-use the Z Master 3.
Figure 15 1. Throttle—fast 2. Throttle—slow 6. Turn the ignition key to Start. When the engines starts, release the key (Figure 16). Figure 13 1. PTO—on 2. PTO—off 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. Failure to follow these instructions can burn out starter motor. 4. Move the choke control to the on position before starting a cold engine (Figure 14).
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. Children or bystanders may be injured if they move or attempt to operate the tractor while it is unattended. Figure 17 Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes.
engaged or if you rise from the seat when the PTO is engaged. Machine can spin very rapidly. Operator may lose control of machine and cause personal injury or damage to machine. Testing the Safety Interlock System 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. • Use caution when making turns. • Slow the machine down before making sharp turns. 1.
page 14. Remember to remove the key from the ignition switch. 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.
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 50 ). Note: The two middle rollers will not have a spacer (Figure 21). 4.
Figure 23 1. Seat latch 2. Fuel cap 3. Figure 24 Seat 1. 2. Side console controls By-pass valve 3. Hydraulic pumps Using the Side Discharge Pushing the Machine by Hand The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. Important: Always push the machine by hand. Never tow the machine because hydraulic damage may occur.
Please carefully read all the safety instructions. Knowing this information could help you, your family, pets or bystanders avoid injury. ramp. Both maneuvers can cause the unit to tip backward. 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. • Secure a trailer to the towing vehicle with safety chains.
Operating Tips Long Grass Fast Throttle Setting If the grass is ever allowed to grow slightly longer than normal, or if it contains a high degree of moisture, raise the cutting height higher than usual and cut the grass at this setting. Then cut the grass again using the lower, normal setting. For best mowing and maximum air circulation, operate the engine at the fast throttle position.
Maintenance Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the rst 8 operating hours • Change the engine oil. • Check the hydraulic uid. After the rst 25 operating hours • Change the hydraulic lter and oil. Before each use or daily • • • • • Check the safety system. Check the engine oil level. Clean the air intake screen. Check the mower blades. Clean the mower deck. Every 25 hours • • • • • • Grease the mower deck and spindles.
Lubrication Greasing and Lubrication Lubricate the machine when shown on the Check Service Reference Aid decal (Figure 26). Grease more frequently when operating conditions are extremely dusty or sandy. Grease Type: General-purpose grease. 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. Figure 26 3.
4. Grease the three spindle bearings under the pulleys until grease comes out the lower seals (Figure 27). 5. Grease the idler arm on the mower deck (Figure 27). 6. Grease the fittings on the push arms (Figure 27). Figure 28 1. Caster fork 2. Bolt 3. Seal guard 4. 5. Caster wheel Nut 6. Remove one of the spacer nuts (with wrench flats) from the axle (Figure 30). Note: Thread locking adhesive has been applied to the spacer nuts. Figure 27 7.
Figure 30 1. 2. 3. Figure 29 Spacer nut Bearing seal (new seals required) Bearing 4. 5. Caster wheel Nut and axle assembled Engine Maintenance 1. 1/8 inch (3 mm) of the nut past the axle Servicing the Air Cleaner 12. Install the assembled nut and axle into the wheel on the side with the bearing and a new seal (Figure 30). Service Interval/Specication Foam element: Clean it after every 25 operating hours. 13.
5. Remove the 2 wing nuts and remove the air cleaner assembly (Figure 31). 2. Inspect the element for tears, an oily film, or damage to the rubber seal. 6. Carefully pull the foam element off the paper element (Figure 31). 3. Replace the paper element if it is damaged. 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.
Important: Do not overfill the crankcase with oil and run the engine; engine damage can result. Changing the Oil 1. Start the engine and let it run five minutes. This warms the oil so it drains better. 2. Park the machine so that the drain side is slightly lower than the opposite side to assure the oil drains completely. 3. Disengage the PTO and set the parking brake. Figure 32 4. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
10. Check the oil level; refer to Checking the Engine Oil Level. 11. Slowly add the additional oil to bring it to the Full mark. Changing the Oil Filter Ensure that the air gap between the center and side electrodes is correct before installing the spark plug. Use a spark plug wrench for removing and installing the spark plugs and a gapping tool/feeler gauge to check and adjust the air gap. Install new spark plugs if necessary. Replace the oil filter every 200 operating hours or every other oil change.
4. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 5. Close the fuel shutoff valve (Figure 38). Figure 37 1. Center electrode insulator 2. Side electrode 3. Air gap (not to scale) Important: Always replace the spark plugs when it has a black coating, worn electrodes, an oily film, or cracks. 3. Check the gap between the center and side electrodes (Figure 37). Bend the side electrode (Figure 37) if the gap is not correct. Figure 38 1. 2.
Removing the Battery 2. Disengage the power takeoff (PTO), set the parking brake, stop the engine, and remove the key. 3. Close the fuel shutoff valve (Figure 38). Battery terminals or metal tools could short against metal machine components causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. 4. Loosen the hose clamp at the fuel filter and slide it up the fuel line away from the fuel filter (Figure 38).
Charging the Battery 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 Fuse: • Main, F1-30 amp, blade-type • Charge circuit, F2-25 amp, blade-type • Optional head light kit, 10 amp, blade-type Adjusting the Tracking 1. Raise the seat to gain access to the fuse holder (Figure 41). Note: Determine the left and right sides of the machine from the normal operating position. 2. To replace the fuses, pull out on the fuse to remove it. The machine has a knob for adjusting the tracking located under the seat. 3. Install a new fuse (Figure 41).
Checking the Tire Pressure Check the pressure at the valve stem after every 50 operating hours or monthly, whichever occurs first (Figure 43). 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. Figure 44 1. 2. Slotted Nut Two threads or less showing 3. 4. Hole in threaded shaft Washer (if needed) 5.
4. Clean the debris and grass from the engine parts. 5. Install air intake screen, recoil starter and fan housing (Figure 46). Figure 45 1. Spring Washers 2. Lock Nut 3. Dust Cap Figure 46 Cooling System Maintenance 1. Guard 2. Air intake screen 3. 4.
Figure 47 1. Brake linkage 2. Yoke 3. Hair pin and cotter pin 6. Adjust the yoke clockwise to shorten the distance; counterclockwise to lengthen distance (Figure 47). 7. Measure the distance vertically between the front of the brake bar and the crown of the tire; the measurement should be 7/8 inch to 1 inch. (Figure 48). Figure 48 8. Repeat steps through if additional adjustment is needed. 9. Engage the parking brake, with the lever up and ensure the brake bar engages the tire (Figure 48). 1. 2.
Note: Do not increase the belt tension beyond the point where the fixed idler arm stops. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the belt covers over the outside spindles. 4. Loosen the fixed idler arm and adjust it to relieve the belt tension on the fixed idler pulley (Figure 49). 9. While holding the belt in tension, tighten the 2 bolts that secure the fixed idler arm. 10.
Adjusting the Push Arms 3. Tilt the seat forward. 4. Begin with either the left or right motion control lever. If needed, adjust the push arms to increase or decrease the mower belt tension. 1. Loosen the jam nut and rotate the ball joint counterclockwise, one turn at a time (Figure 52). 5. Move lever to the neutral position but not locked (Figure 53). Figure 52 3. 1. Push arm 4. 2. 13-1/2 inch (343 mm) nominal at 15 degree twist Jam nut Ball joint Figure 53 1. 2. 2. Adjust each side the same amount.
Hydraulic System Maintenance Servicing the Hydraulic System Checking the Hydraulic Fluid Fluid Type: Mobil 1 15W-50 synthetic motor oil or equivalent synthetic oil. Important: Use oil specified or equivalent. Other fluids could cause system damage. Hydraulic System Oil Capacity: 67 ounces (2.0 l) Check the hydraulic fluid level: • Before the engine is first started. • After the first 8 operating hours. • After every 25 operating hours. Figure 54 1. 2. 3. 4. 5.
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. Bafe 3. 4. Cold uid level-full Hot uid 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 lter 2. Gasket 3. Adapter • Use cardboard or paper to find hydraulic leaks.
Engine must be running so motion control adjustment can be performed. Contact with moving parts or hot surfaces may cause personal injury. Keep hands, feet, face, clothing and other body parts away from rotating parts, muffler and other hot surfaces. 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. Figure 58 3.
Mower Deck Maintenance Leveling the Mower at Three Positions Important: There are only three measuring positions needed to level the mower. Preparing the Machine 1. Position mower on a flat surface. 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. 4. Check tire pressure of all four tires. If needed, adjust to 13 psi (90 kPa) 5.
Figure 60 1. Measure here from blade to hard surface 2. Figure 61 Measure at B and C 1. 2. 3. 4. 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). Rear chain Rear support arm Bolt Jam Nut 5. Adjustment bolt 6. Front swivel 7. Front support arm Adjusting the Front-to-Rear Mower Pitch 8.
4. Measure the right blade at the B location, from a level surface to the cutting edge of the blade tip (Figure 62). 5. Record this measurement. 6. The mower blade should be a 1/4 to 3/8 inch (6 to 10 mm) lower at position A than at position B (Figure 62). If it is not correct, proceed to the following steps. Note: Both of the front swivels need to be adjusted the same amount to maintain equal chain tension. 7.
Before Inspecting or Servicing the Blades 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Park the machine on a level surface, disengage the blade control (PTO), and set the parking brake. Turn the ignition key to Off. Remove the key. 3. Rotate the blades until the ends face forward and backward (Figure 65). Measure from a level surface to the cutting edge, position A, of the blades (Figure 65). Note this dimension.
Removing the Blades (Figure 68). Repeat this procedure until the blade is balanced. Blades must be replaced if a solid object is hit, if the blade is out of balance or is bent. To ensure optimum performance and continued safety conformance of the machine, use genuine Toro replacement blades. Replacement blades made by other manufacturers may result in nonconformance with safety standards. Figure 67 1. Blade Contact with a sharp blade can cause serious injury. 2. Balancer Installing the Blades 1.
Replacing the Grass Deector 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. Figure 69 1. Remove the locknut, bolt, spring and spacer holding the deflector to the pivot brackets (Figure 69).
Storage A. Add a petroleum based stabilizer/conditioner to fuel in the tank. Follow mixing instructions from the stabilizer manufacturer. Do not use an alcohol based stabilizer (ethanol or methanol). 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.
Troubleshooting Problem Starter does not crank Possible Cause Corrective Action 1. Blade control (PTO) is engaged. 2. Parking brake is not on. 3. Operator is not seated. 4. Battery is dead. 5. Electrical connections are corroded or loose. 1. Move the blade control (PTO) to disengaged. 2. Set the parking brake. 3. Sit on the seat. 4. Charge the battery. 5. Check the electrical connections for good contact. 6. Replace the fuse. 7. Contact an Authorized Service Dealer. 6. Fuse is blown. 7.
Problem Machine does not drive. Abnormal vibration. Possible Cause 1. By pass valve is not closed tight. 2. Drive or pump belt is worn, loose or broken. 3. Drive or pump belt is off a pulley. 4. Broken or missing idler spring. 5. Hydraulic uid level is low or too hot. 1. Tighten the by pass valve. 2. Change the belt. 1. Cutting blade(s) is/are bent or unbalanced. 2. Blade mounting bolt is loose. 3. Engine mounting bolts are loose. 4. Loose engine pulley, idler pulley, or blade pulley. 5.
Problem Blades do not rotate. Possible Cause 1. Drive belt is worn, loose or broken. 2. Drive belt is off pulley. 3. Deck belt is worn, loose or broken. 4. Deck belt is off pulley. 5. Broken or missing idler spring. 55 Corrective Action 1. Check the belt tension. 2. Install the drive belt and check adjusting shafts and belt guides for correct position. 3. Install a new deck belt. 4. Install the deck pulley and check the idler pulley, idler arm and spring for correct position and function. 5.
Schematics Wire Diagram (Rev.
