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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.

1-403005

54-9220

66-1340

68-8340

98-5954

Battery Symbols

Some or all of these symbols are on your battery

1. Explosion hazard

6. Keep bystanders a safe

distance from the battery.

2. No re, open ame, or

smoking.

7. Wear eye protection;

explosive gases can cause

blindness and other injuries

3. Caustic liquid/chemical

burn hazard

8. Battery acid can cause

blindness or severe burns.

4. Wear eye protection

9. Flush eyes immediately

with water and get medical

help fast.

5. Read the

Operator’s

Manual.

10. Contains lead; do not

discard.

Manufacturer’s Mark

1. Indicates the blade is identied as a part from the original

machine manufacturer.

Содержание 74408

Страница 1: ...0 Z Master with a 40in 7 Gauge Side Discharge Mower Model No 74408 Serial No 270000001 and Up Model No 74408CP Serial No 270000001 and Up Model No 74409 Serial No 270000001 and Up Model No 74409CP Serial No 270000001 and Up Register your product at www Toro com Original Instructions EN ...

Страница 2: ...ontact Toro directly at www Toro com for product and accessory information help ﬁnding a dealer or to register your product Whenever you need service genuine Toro parts or additional information contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready Figure 1 identiﬁes the location of the model and serial numbers on the product Writ...

Страница 3: ...ng the Engine Oil 27 Servicing the Spark Plugs 29 Fuel System Maintenance 30 Draining the Fuel Tank 30 Replacing the Fuel Filter 30 Electrical System Maintenance 31 Servicing the Battery 31 Servicing the Fuses 32 Drive System Maintenance 33 Checking the Tire Pressure 33 Adjusting the Caster Pivot Bearing 33 Cooling System Maintenance 34 Cleaning the Air Intake Screen 34 Cleaning the Cooling System...

Страница 4: ...cessories and attachments approved by the manufacturer Wear appropriate clothing including hard hat safety glasses and hearing protection Long hair loose clothing or jewelry may get tangled in moving parts Inspect the area where the equipment is to be used and remove all objects such as rocks toys and wire which can be thrown by the machine Use extra care when handling gasoline and other fuels The...

Страница 5: ... wheels may cause drive wheels to slip and cause loss of braking and steering Always avoid sudden starting or stopping on a slope If tires lose traction disengage the blades and proceed slowly off the slope Follow the manufacturer s recommendations for wheel weights or counterweights to improve stability Use extreme care with grass catchers or other attachments These can change the stability of th...

Страница 6: ...hine onto a trailer or truck use a single full width ramp only The ramp angle should not exceed 15 degrees 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 ...

Страница 7: ...Slope Chart 7 ...

Страница 8: ...ion hazard 6 Keep bystanders a safe distance from the battery 2 No re open ame or smoking 7 Wear eye protection explosive gases can cause blindness and other injuries 3 Caustic liquid chemical burn hazard 8 Battery acid can cause blindness or severe burns 4 Wear eye protection 9 Flush eyes immediately with water and get medical help fast 5 Read the Operator s Manual 10 Contains lead do not discard...

Страница 9: ...109 2356 1 Fast 3 Neutral 2 Slow 4 Reverse 109 2463 109 2467 109 2490 109 2539 112 3830 112 3831 112 3832 112 3834 112 3836 9 ...

Страница 10: ...112 3833 10 ...

Страница 11: ... Throttle control 3 PTO Switch 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...

Страница 12: ...ystem in place and in proper working condition 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 Do not ﬁll gasoline containers inside a vehicle or on a truck o...

Страница 13: ...fore you start the engine and use the machine check the oil level in the engine crankcase refer to Checking Oil Level in Engine Maintenance page 26 Think Safety First Please read all safety instructions and symbols in the safety section Knowing this information could help you or bystanders avoid injury Operating on wet grass or steep slopes can cause sliding and loss of control Wheels dropping ove...

Страница 14: ...e 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 Releasing the Parking Brake Push forward and down on the parking brake lever to release the parking brake Figure 9 Figure 9 1 Parking brake Set ON 2 Parking brake Released O...

Страница 15: ...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 Chi...

Страница 16: ...1 Sitting on the seat engage the parking brake and move the PTO to on Try starting the engine the engine should not crank 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 3 Sitting on the seat engage the parking brake move the PTO ...

Страница 17: ...rol levers in either direction the faster the machine will move in that direction To stop pull the motion control levers to the center position Figure 14 1 Motion control lever neutral lock position 3 Forward 2 Center un lock position 4 Backward Driving Backward 1 Move the levers to the center un locked position 2 To go backward slowly pull the motion control levers rearward Figure 14 To go straig...

Страница 18: ...ut lever to the transport position also the 5 inch 127 mm cutting height position Figure 15 2 To adjust remove the clevis pin from the height of cut bracket Figure 15 3 Select a hole in the height of cut bracket corresponding to the height of cut desired and insert the clevis pin Figure 15 4 Move the lever to the selected height Figure 15 1 Height of cut holes 2 Clevis Pin Using the Lift Assist Pe...

Страница 19: ...racket 5 Spacer 3 Flange Nut 6 Bushing Positioning the Seat The seat can move forward and backward Position the seat where you have the best control of the machine and are most comfortable 1 Raise the seat and loosen the adjustment bolts Figure 18 2 Move the seat to the desired position and tighten the bolts Figure 18 1 Adjustment bolts 2 Seat Pushing the Machine by Hand Important Always push the ...

Страница 20: ...r hands or feet under the mower Never try to clear the discharge area or mower blades unless you move the power take off PTO to the off position rotate the ignition key to off and remove the key Make sure the grass deﬂector is in the down position Transporting Machines Use a heavy duty trailer or truck to transport the machine Ensure that the trailer or truck has all necessary lighting and marking...

Страница 21: ...e of the slope and the ramp extends up the slope This will minimize the ramp angle The trailer or truck should be as level as possible Important Do Not attempt to turn the unit while on the ramp you may lose control and drive off the side Avoid sudden acceleration when driving up a ramp and sudden deceleration when backing down a ramp Both maneuvers can cause the unit to tip backward Loading a uni...

Страница 22: ...s frequently If you cannot mow for an extended period ﬁrst mow at a high cutting height then mow again two days later at a lower height setting Cutting Speed To improve cut quality use a slower ground speed in certain conditions Avoid Cutting Too Low If the cutting width of the mower is wider than the mower you previously used raise the cutting height to ensure that uneven turf is not cut too shor...

Страница 23: ...ine oil Check the spark plugs Check and clean engine cooling ns and shrouds Inspect the belts for cracks and wear Every 150 hours Lubricate the machine with light oil Refer to Lubrication Every 200 hours Replace the paper air cleaner element Replace the oil lter Replace the fuel lter Every 500 hours Adjust the caster pivot bearing Yearly Grease the front caster pivots more often in dirty or dusty ...

Страница 24: ...excess grease Greasing the Front Caster Pivots Lubricate the front caster pivots once a year 1 Remove the dust cap and adjust the caster pivots Keep the dust cap off until greasing is done Refer to Adjusting the Caster Pivot Bearing in Drive System Maintenance page 33 2 Remove the hex plug Thread a grease zerk into the hole 3 Pump grease into the zerk until it oozes out around the top bearing 4 Re...

Страница 25: ...emove the seal guard from the wheel hub Figure 25 Figure 25 1 Caster fork 4 Caster wheel 2 Bolt 5 Nut 3 Seal guard 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 8 Remove the seals and inspect the bearings for wear or damage Replace the bea...

Страница 26: ...any side to side play between the caster fork If the wheel spins freely adjust the torque on the spacer nut until there is a slight amount of drag Figure 27 1 Spacer nut 4 Caster wheel 2 Bearing seal new seals required 5 Nut and axle assembled 3 Bearing Engine Maintenance Servicing the Air Cleaner Service Interval Speci cation Foam element Clean it after every 25 operating hours Paper element Chec...

Страница 27: ... 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 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 3 Place the air cleaner cover into po...

Страница 28: ... 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 4 Stop the engine remove the key and wait for all moving parts to stop before leaving the operating position 5 Slide the drain hose over the oil drain valve 6 Place a pan below the drain hose Rotate oil drain valve to allow oil to drain...

Страница 29: ...nstalling the spark plugs and a gapping tool feeler gauge to check and adjust the air gap Install a new spark plugs if necessary Type Champion RCJ8Y or equivalent Air Gap 0 030 inch 0 75 mm Removing the Spark Plugs 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 Disconnect the wires from th...

Страница 30: ...rts to stop before leaving the operating position 4 Close the fuel shut off valve located under the front of the fuel tank 5 Loosen the hose clamp at the fuel ﬁlter and slide it up the fuel line away from the fuel ﬁlter Figure 35 6 Pull the fuel line off of the fuel ﬁlter Figure 35 7 Open the fuel shut off valve Allow gasoline to drain into a gas can or drain pan Note Now is the best time to insta...

Страница 31: ...terminals to touch any metal parts of the machine Do not allow metal tools to short between the battery terminals and metal parts of the machine 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 A...

Страница 32: ...J bolts hold down clamp and 2 washers 1 4 inch and 2 wing nuts 1 4 inch Figure 36 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 Char...

Страница 33: ...pressure can cause uneven cut 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 39 Adjusting the Caster Pivot Bearing Check after every 500 operating hours or at storage which ever comes ﬁrst 1 Disengage the PTO move the motion control levers to the neutral locked position an...

Страница 34: ... 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 Remove the air intake screen recoil starter and fan housing Figure 41 4 Clean the debris and grass from the engine parts 5 Install air intake screen recoil starter and fan housing Figure 41 Figure 41 1 Air intake screen 4 Bolt 2 Fan housing 5 Nut 3 Recoil starte...

Страница 35: ... 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 Remove 2 bolts and washers in each belt cover and remove the belt covers over the outside spindles Figure 44 4 Pull on the idler arm to relieve the belt tension on the left spindle pulley Figure 42 or Figure 43 5 Remove the old belt 6 Ins...

Страница 36: ... belt around the engine and the hydraulic pump pulleys Figure 45 6 Pull the spring loaded idler to the side and align the belt 7 Release the pressure on the spring loaded idler Figure 45 Figure 45 1 Belt 3 Engine pulley 2 Transmission pump pulleys 4 Spring loaded idler pulley Controls System Maintenance Adjusting the Control Handle Neutral Position 1 Disengage the PTO move the motion control lever...

Страница 37: ...s 2 Loosen the bolt located in front of the control lever 3 Move the stop until the machine drives straight Figure 48 4 Tighten the bolt located in front of the control lever Figure 48 Figure 48 1 Control lever 3 Bolt in front of the control lever 2 Stop Hydraulic System Maintenance Servicing the Hydraulic System Checking the Hydraulic Fluid Fluid Type Mobil 1 15W 50 synthetic motor oil or equival...

Страница 38: ...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 Safely relieve all pressure in the hydraulic system before performing any work on the hydraulic system Make sure all hydraulic ﬂuid hoses and lines are in good co...

Страница 39: ...oth forward and reverse directions 5 to 6 times Stop the engine and check the oil level and add oil as required to the hot line 13 Repeat items 11 and 12 as necessary until all the air is completely purged from the system When the transaxle operates at normal noise levels and moves smoothly forward and reverse at normal speeds then the transaxle is purged Important Do not change hydraulic system o...

Страница 40: ...in the mower deck bracket Figure 51 10 Adjust the discharge side front bolt so it is in the middle of the slot located in the pivot bracket Figure 52 11 Raise the mower deck and remove the blocks holding up the mower deck 12 Adjust the left front bolt in the pivot bracket so the chain has no slack in it 13 Inspect the four chains The chains need to have tension Note When properly adjusted the fron...

Страница 41: ... bracket and adjust it forward or backward to get the correct height Tighten the bracket after the adjustment is made Servicing the Cutting Blades Maintain sharp blades throughout the cutting season because sharp blades cut cleanly without tearing or shredding the grass blades Tearing and shredding turns grass brown at the edges which slows growth and increases the chance of disease Check the cutt...

Страница 42: ... Refer to Sharpening the Blades 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 Figure 53 1 Cutting Edge 3 Wear slot Forming 2 Curved Area Checking for Bent Blades 1 Disengage the PTO move the motion control levers to the neutral locked position and set the parking brake 2 Stop the engi...

Страница 43: ... machine use genuine Toro replacement blades Replacement blades made by other manufacturers may result in nonconformance with safety standards 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 58 Sharpening th...

Страница 44: ...ction 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 Remove the locknut bolt spring and spacer holding the deﬂector to the pivot brackets Figure 59 Remove the damaged or worn grass deﬂector 2 Place the spacer and sprin...

Страница 45: ...al 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 Raise the mower to the transport position 4 Lift the front of the machine and support the machine using jack stands Waste Disposal Engine oil batteries hydraulic oil and engine coolant are pollutants to the environment Dispose of these accordin...

Страница 46: ... hose Note Run the machine with the PTO engaged and the engine at high idle for 2 to 5 minutes after washing 10 Check the condition of the blades refer to Servicing the Cutting Blades in Mower Deck Maintenance page 39 11 Prepare the machine for storage when non use occurs over 30 days Prepare the machine for storage as follows A Add a petroleum based stabilizer conditioner to fuel in the tank Foll...

Страница 47: ...d or fails to keep running 4 Dirt water or stale fuel is in the fuel system 4 Contact an Authorized Service Dealer 1 Engine load is excessive 1 Reduce the ground speed 2 Air cleaner is dirty 2 Clean the air cleaner element 3 Oil level in the crankcase is low 3 Add oil to the crankcase 4 Cooling ns and air passages above the engine are plugged 4 Remove the obstruction from the cooling ns and air pa...

Страница 48: ...unting bolts are loose 3 Tighten the engine mounting bolts 4 Loose engine pulley idler pulley or blade pulley 4 Tighten the appropriate pulley 5 Engine pulley is damaged 5 Contact an Authorized Service Dealer 6 Blade spindle is bent 6 Contact an Authorized Service Dealer Abnormal vibration 7 Motor mount is loose or worn 7 Contact an Authorized Service Dealer 1 Blade s not sharp 1 Sharpen the blade...

Страница 49: ...rive belt and check adjusting shafts and belt guides for correct position 3 Deck belt is worn loose or broken 3 Install a new deck belt 4 Deck belt is off pulley 4 Install the deck pulley and check the idler pulley idler arm and spring for correct position and function Blades do not rotate 5 Broken or missing idler spring 5 Replace the spring 49 ...

Страница 50: ...Schematics Wire Diagram Rev A 50 ...

Страница 51: ...cheduled for replacement as required maintenance in the written instructions must be warranted for the warranty period of two years If any such part fails during the period of warranty coverage it must be repaired or replaced by The Toro Company Any such part repaired or replaced under the warranty must be warranted for a time not less than the remaining warranty period B Any warranted part that i...

Страница 52: ... maintenance service or parts such as lters fuel lubricants tune up parts blade sharpening brake and clutch adjustments Any product or part which has been altered or misused or required replacement or repair due to normal wear accidents or lack of proper maintenance Repairs necessary due to improper fuel contaminants in the fuel system or failure to properly prepare the fuel system prior to any pe...

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