Toro Z Master 8000 Series Operator'S Manual Download Page 3

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Contents

Safety ....................................................................... 4

General Safety ................................................... 4
Slope Indicator ................................................... 5
Safety and Instructional Decals .......................... 6

Product Overview ................................................... 12

Controls ........................................................... 12
Specifications .................................................. 13
Attachments/Accessories ................................. 13

Before Operation ................................................. 14

Before Operation Safety ................................... 14
Adding Fuel ...................................................... 15
Performing Daily Maintenance.......................... 15
Breaking in a New Machine .............................. 15
Raising the Mower Deck into the Service

Position ......................................................... 16

Lowering the Mower Deck to the Operating

Position ......................................................... 16

Adjusting the Fill Reduction System (FRS)

Baffles........................................................... 17

Using the Safety-Interlock System .................... 18
Unlatching the Seat .......................................... 19

During Operation ................................................. 19

After Operation .................................................... 26

After Operation Safety ...................................... 26
Clearing the Hopper Screen ............................. 26
Using the Drive-Wheel Release Valves ............. 26
Transporting the Machine ................................. 27

Maintenance ........................................................... 29

Maintenance Safety.......................................... 29

Recommended Maintenance Schedule(s) ........... 29
Lubrication .......................................................... 31

Greasing the Machine....................................... 31
Greasing the Pump-Belt Idler Arm .................... 31
Lubricating the Brake-Handle Pivot................... 32
Lubricating the Brake-Rod Bushings and

Steering-Linkage Rod Ends .......................... 33

Changing the Gearbox Oil ................................ 33
Greasing the Caster Pivots ............................... 34
Greasing the Caster-Wheel Hubs ..................... 35

Engine Maintenance ........................................... 36

Engine Safety ................................................... 36
Servicing the Air Cleaner .................................. 36
Servicing the Engine Oil.................................... 37
Servicing the Spark Plug................................... 39

Fuel System Maintenance ................................... 40

Replacing the Fuel Filter ................................... 40
Servicing the Fuel Tank..................................... 40

Electrical System Maintenance ........................... 41

Electrical System Safety ................................... 41
Servicing the Battery......................................... 41
Adjusting the Safety Switches........................... 42
Servicing the Fuses .......................................... 42
Jump-Starting the Machine............................... 43

Drive System Maintenance .................................. 44

Adjusting the Tracking ...................................... 44
Checking the Tire Pressure............................... 45
Checking the Wheel Lug Nuts........................... 45
Checking the Wheel-Hub Slotted Nuts .............. 45
Adjusting the Caster-Pivot Bearings ................. 45

Cooling System Maintenance .............................. 46

Cooling System Safety ..................................... 46
Cleaning the Engine Screen and Engine-Oil

Cooler ........................................................... 46

Servicing the Engine-Oil Cooler ........................ 47
Cleaning the Engine Cooling Fins and

Shrouds ........................................................ 47

Brake Maintenance ............................................. 47

Adjusting the Parking Brake.............................. 47

Belt Maintenance ................................................ 49

Inspecting the Belts .......................................... 49
Replacing the PTO Belts................................... 49
Replacing the Pump-Drive Belt ......................... 50
Adjusting the Belt Guides.................................. 50

Controls System Maintenance ............................. 51

Adjusting the Reverse-Stop Rod....................... 51
Adjusting the Speed-Control Lever

Tension ......................................................... 51

Adjusting the Speed-Control Linkage................ 52
Aligning the PTO-Drive Pulley........................... 52
Aligning the Pump-Drive Pulley......................... 53
Adjusting the PTO Brake Spring ....................... 54
Adjusting the Hopper Door................................ 54
Adjusting the Locking-Pin Stop on the Mower

Deck.............................................................. 55

Hydraulic System Maintenance ........................... 55

Hydraulic System Safety................................... 55
Hydraulic-Fluid Specifications .......................... 55
Checking the Hydraulic Fluid ............................ 55
Changing the Hydraulic Fluid and

Filter.............................................................. 56

Checking and Cleaning the Hydraulic

Pumps........................................................... 56

Blade Maintenance .............................................. 57

Blade Safety ..................................................... 57
Servicing the Cutting Blades ............................. 57
Leveling the Mower Deck.................................. 59
Removing the Mower Deck ............................... 59
Installing the Mower Deck................................. 61
Adjusting the Locking-Pin Stop on the Mower

Deck.............................................................. 61

Cleaning .............................................................. 62

Cleaning under the Mower Deck ....................... 62
Cleaning Debris from the Machine .................... 62

Summary of Contents for Z Master 8000 Series

Page 1: ...Form No 3436 620 Rev A Z Master 8000 Series Riding Mower with 122cm Cutting Unit Model No 74311TE Serial No 405700000 and Up Register at www Toro com Original Instructions EN 3436 620 A...

Page 2: ...gister 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 p...

Page 3: ...Maintenance 40 Replacing the Fuel Filter 40 Servicing the Fuel Tank 40 Electrical System Maintenance 41 Electrical System Safety 41 Servicing the Battery 41 Adjusting the Safety Switches 42 Servicing...

Page 4: ...e Allow only people who are responsible trained familiar with the instructions and physically capable to operate or service the machine Always keep the roll bar in the fully raised and locked position...

Page 5: ...ees 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 recommend...

Page 6: ...Flush eyes immediately with water and get medical help fast 5 Read the Operator s Manual 10 Contains lead do not discard decaloemmarkt Manufacturer s Mark 1 This mark indicates that the blade is ident...

Page 7: ...arking brake 2 Battery 6 Neutral 3 Hour meter 7 Operator presence switch 4 PTO decal116 8934 116 8934 1 Warning disengage the blade clutch shut off the engine and remove the key before making adjustme...

Page 8: ...do not operate the machine with mower hopper in the raised position decal116 8946 116 8946 1 Rotate counterclockwise to release 3 Unlock to push the machine 2 Rotate clockwise to lock 4 Read the Opera...

Page 9: ...efer to the Operator s Manual for adjustment procedure When PTO is engaged the idler arm position must be in hatched area or an adjustment is required decal130 2880 130 2880 1 Engine temperature 7 Ret...

Page 10: ...ds in place Shut off the engine and remove the key before adjusting servicing or cleaning the machine 2 Sliding tipping hazard Do not use the machine near drop offs with slopes greater than 15 degrees...

Page 11: ...Check the gearbox oil every 100 hours use only Mobil 1 75W 90 gear oil 4 Check the hydraulic fluid level every 40 hours only use recommended hydraulic fluid 11 Grease the front caster pivots every 500...

Page 12: ...y Switch The key switch used to start and shut off the engine has 3 positions OFF RUN and START Refer to Starting the Engine page 22 Throttle Control The throttle controls the engine speed and it has...

Page 13: ...motion control levers to drive the machine forward reverse and turn either direction Figure 4 Parking Brake Lever Whenever you shut off the engine engage the parking brake to prevent accidental moveme...

Page 14: ...fire or explosion from fuel can burn you and others and can damage property To prevent a static charge from igniting the fuel place the container and or machine directly on the ground before filling...

Page 15: ...stabilizer manufacturer Cleans the engine while it runs Eliminates gum like varnish buildup in the fuel system which causes hard starting Important Do not use fuel additives containing methanol or eth...

Page 16: ...Figure 9 1 Secure the mower deck in the raised position by securing the mower deck latch onto the hook 3 Deck lift handle 2 Hook WARNING Engaging the PTO with a deck in the raised position can result...

Page 17: ...he PTO and engage the parking brake 2 Shut off the engine remove the key and wait for all moving parts to stop before leaving the operating position 3 Loosen the bolts attached to the rubber guard Fig...

Page 18: ...y 2 Hopper up 4 Low voltage indicator light Testing the Safety Interlock System Service Interval Before each use or daily Test the safety interlock system before you use the machine each time If the s...

Page 19: ...you before moving the machine in reverse Use extreme care when approaching blind corners shrubs trees or other objects that may block your view Stop the blades whenever you are not mowing If the machi...

Page 20: ...ir or alter them There is no rollover protection when the roll bar is down Wheels dropping over edges over steep banks or into water can cause a rollover which may result in serious injury or death Do...

Page 21: ...he ground while operating on slopes Raising the deck while operating on slopes can cause the machine to become unstable g233738 Figure 16 1 Safe Zone use the machine here on slopes less than 15 or fla...

Page 22: ...l between FAST and SLOW positions Figure 21 Always use the FAST position when engaging the PTO g232776 Figure 21 Operating the Choke Use the choke to start a cold engine 1 Pull up the choke knob to en...

Page 23: ...ow these instructions can burn out the starter motor Note You may need multiple attempts to start the engine the first time after adding fuel to an empty fuel system 7 If the choke is in the CLOSED ON...

Page 24: ...pull the speed control lever back to the NEUTRAL position Driving Backward 1 To move rearward in a straight line pull both steering levers rearward equally To turn left or right release pressure on th...

Page 25: ...te fall when grass grows more slowly Alternating the Mowing Direction Alternate the mowing direction to keep the grass standing straight This also helps disperse clippings which enhances decomposition...

Page 26: ...movable screen 4 Handles Using the Drive Wheel Release Valves WARNING Hands may become entangled in the rotating drive components below the engine deck which could result in serious injury Shut off th...

Page 27: ...lecting a Trailer WARNING Loading a machine onto a trailer or truck increases the possibility of tip over and could cause serious injury or death Figure 27 Use only a full width ramp do not use indivi...

Page 28: ...connect the trailer brakes and lights 3 Lower the ramp ensuring that the angle between the ramp and the ground does not exceed 15 degrees Figure 27 4 Back the machine up the ramp Figure 28 g233949 Fig...

Page 29: ...inal first and the positive last Connect the positive terminal first and the negative last To ensure optimum performance use only genuine Toro replacement parts and accessories Replacement parts and a...

Page 30: ...djust the caster pivot bearings Check the parking brake adjustment Change the hydraulic filter and reservoir hydraulic fluid when using Toro HYPR OIL 500 hydraulic fluid more often in dirty or dusty c...

Page 31: ...ff 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 Note Scrape any paint off the front of the fitting s 4 C...

Page 32: ...Lubricate the pump belt idler arm Figure 32 8 Install the plate and the air cleaner Lubricating the Brake Handle Pivot Service Interval Every 160 hours 1 Park the machine on a level surface disengage...

Page 33: ...earbox housings and add oil as needed 1 Park the machine on a level surface disengage the PTO and engage the parking brake 2 Shut off the engine remove the key and wait for all moving parts to stop be...

Page 34: ...pack the caster wheel bearings more often in dirty or dusty conditions 1 Park the machine on a level surface disengage the blade control switch and engage the parking brake 2 Shut off the engine remov...

Page 35: ...compound to 1 spacer nut and thread it onto the axle with the wrench flats facing outward Note Do not thread the spacer nut all of the way onto the end of the axle Leave approximately 3 mm 1 8 inch fr...

Page 36: ...nd wait for all moving parts to stop before leaving the operating position 3 Release the latches on the air cleaner and pull the air inlet cover off the air cleaner body Figure 37 4 Clean the air inle...

Page 37: ...a level surface move the speed control lever to the NEUTRAL position disengage the PTO and engage the parking brake 2 Shut off the engine remove the key and wait for all moving parts to stop before le...

Page 38: ...32754 Figure 41 5 Slowly pour approximately 80 of the specified oil into the filler tube and slowly add the additional oil to bring it to the full mark on the dipstick Figure 40 6 Start the engine and...

Page 39: ...rating position 3 Clean the area around the base of the plug s to keep dirt and debris out of the engine 4 Locate and remove the spark plug s as shown in Figure 43 g027478 Figure 43 Checking the Spark...

Page 40: ...the blade control switch PTO and engage the parking brake 2 Shut off the engine remove the key and wait for all moving parts to stop before leaving the operating position 3 Allow the machine to cool...

Page 41: ...PTO and engage the parking brake 2 Shut off the engine remove the key and wait for all moving parts to stop before leaving the operating position 3 Disconnect the negative battery cable black from th...

Page 42: ...the red terminal boot onto the positive red battery post 6 Install the clamp and secure it with the wing nuts and J hooks Figure 47 Adjusting the Safety Switches Adjust all safety switches so that the...

Page 43: ...battery terminal polarity and jumper cable polarity when hooking up the batteries WARNING Batteries contain acid and produce explosive gases Shield your eyes and face from the batteries at all times...

Page 44: ...ring hydraulic fluid up to operating temperature 2 Park the machine on a level surface move the speed control lever to the NEUTRAL position disengage the blade control switch PTO and engage the parkin...

Page 45: ...re that the torque of the slotted nut is 373 to 475 N m 275 to 350 ft lb Adjusting the Caster Pivot Bearings Service Interval Every 500 hours Yearly whichever comes first 1 Park the machine on a level...

Page 46: ...oving the radiator cap Use a rag when opening the radiator cap and open the cap slowly to allow steam to escape Cleaning the Engine Screen and Engine Oil Cooler Service Interval Before each use or dai...

Page 47: ...n the debris and grass from the engine parts 5 Install air intake screen and fan housing Brake Maintenance Adjusting the Parking Brake Service Interval After the first 100 hours Every 500 hours therea...

Page 48: ...e vertical spring assembly Figure 59 Note The linkage should measure 22 7 to 23 3 cm 8 92 to 9 16 inches g020525 Figure 59 1 22 7 to 23 3 cm 8 92 to 9 16 inches 2 Nuts 9 Engage and disengage the brake...

Page 49: ...e engine remove the key and wait for all moving parts to stop before leaving the operating position 3 With the engine off engage the PTO lever then remove the hairpin cotter and clevis pin at the bott...

Page 50: ...ute the new belt onto the sheaves as shown in the decal located on the back of the left drive shield Figure 62 g006838 Figure 62 1 Pump drive belt 4 Pump 2 Pump 5 Idler 3 Idler 6 Engine 7 Install the...

Page 51: ...d by rotating the rod g020490 Figure 64 1 Parking brake 4 Speed control lever 2 Nut 5 Clevis pin and stop rod 3 Steering lever E Engage the parking brake and check the steering levers F Repeat steps C...

Page 52: ...rt the engine 7 Run the machine at least 5 minutes with the speed control lever at full forward speed to bring the hydraulic system fluid up to operating temperature 8 Return the speed control lever t...

Page 53: ...hten the 4 engine mounting bolts and 4 jackshaft mounting bolts Check the alignment after tightening 10 Install the pump belt tension spring 11 Swing the fuel tank in and install the tank mounting nut...

Page 54: ...48 Figure 68 1 Tighten the jam nuts here 2 PTO brake spring assembly Adjusting the Hopper Door 1 Park the machine on a level surface move the speed control lever to the NEUTRAL position disengage the...

Page 55: ...raulic system Keep your body and hands away from pinhole leaks or nozzles that eject high pressure hydraulic fluid Use cardboard or paper to find hydraulic leaks Safely relieve all pressure in the hyd...

Page 56: ...d the filter Important Ensure that no dirt or contamination enter the hydraulic system 4 Unscrew and remove the filter and allow the fluid to drain from the reservoir Important Do not change the hydra...

Page 57: ...nspecting the Blades Service Interval Before each use or daily 1 Inspect the cutting edges Figure 72 2 If the edges are not sharp or have nicks remove and sharpen the blade refer to Sharpening the Bla...

Page 58: ...position the blade is balanced and can be used Note If the blade is not balanced file some metal off the end of the sail area only Figure 75 g000553 Figure 76 1 Blade 2 Balancer 3 Repeat this procedu...

Page 59: ...hout an approved Toro front mount attachment increases the possibility of operator entanglement in the drive wheels or forward tip over Entanglement or tip over could cause serious injury or death Whe...

Page 60: ...wer Deck to the Operating Position page 16 Note The mower deck becomes heavier when you remove the springs from the anchors Lower the mower deck carefully 7 Remove the lynch pins at the front of the p...

Page 61: ...tion of the rubber guard and secure it with the attached bolts Figure 80 9 Release the mower deck locking pins on each side raise the mower deck to the service position and secure the deck latch onto...

Page 62: ...wer deck to the operating position Refer to Lowering the Mower Deck to the Operating Position page 16 Cleaning Debris from the Machine Service Interval Before each use or daily 1 Park the machine on a...

Page 63: ...nderside of the mower then wash the mower with a garden hose Note Run the machine with the blade control switch PTO engaged and the engine at high idle for 2 to 5 minutes after washing 12 Check the co...

Page 64: ...ns are corroded loose or damaged 9 Check the electrical connections for good contact Clean the connector terminals thoroughly with electrical contact cleaner apply dielectric grease and make the appro...

Page 65: ...opriate pulley 5 The engine pulley is damaged 5 Contact an Authorized Service Dealer 6 The blade spindle is bent 6 Contact an Authorized Service Dealer The machine vibrates abnormally 7 The motor moun...

Page 66: ...Schematics g020385 Wire Diagram Rev A 66...

Page 67: ...g020536 Hydraulic Diagram Rev A 67...

Page 68: ...for marketing purposes Retention of your Personal Information Toro will keep your personal information as long as it is relevant for the above purposes and in accordance with legal requirements For mo...

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