Toro Z355 Z-Master Operator'S Manual Download Page 56

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Troubleshooting

PROBLEM

POSSIBLE CAUSES

CORRECTIVE ACTION

Starter does not crank

1. Power take off (PTO) is

ENGAGED.

1. Move power take off (PTO) to

DISENGAGED.

2. Parking brake is not on.

2. Set parking brake.

3. Motion control levers are not in

neutral

3. Move motion control levers into

neutral

neutral.

4. Battery is dead.

neutral.

4. Charge the battery.

5. Electrical connections are

corroded or loose.

5. Check electrical connections

for good contact.

6. Fuse is blown.

6. Replace fuse.

7. Relay or switch is defective.

7. Contact Authorized Service

Dealer.

Engine will not start, starts hard, or

f il t k

1. Fuel tank is empty.

1. Fill fuel tank with gasoline.

fails to keep running.

2. Choke is not ON.

2. Move choke lever to ON.

3. Air cleaner is dirty.

3. Clean or replace air cleaner

element.

4. Spark plug wires is loose or

disconnected.

4. Install wires on spark plug.

5. Spark plugs are pitted, fouled,

or gap is incorrect.

5. Install new, correctly gapped

spark plugs.

6. Dirt in fuel filter.

6. Replace fuel filter.

7. Dirt, water, or stale fuel is in

fuel system.

8. Fuel shut off valve is “off”.

7. Contact Authorized Service

Dealer.

8. Turn shut off valve to “on”.

Engine loses power.

1. Engine load is excessive.

1. Reduce ground speed.

2. Air cleaner is dirty.

2. Clean air cleaner element.

3. Oil level in crankcase is low.

3. Add oil to crankcase.

4. Cooling fins and air passages

under engine blower housing

are plugged.

4. Remove obstruction from

cooling fins and air passages.

5. Spark plugs are pitted, fouled,

or gap is incorrect.

5. Install new, correctly gapped

spark plugs.

6. Dirt in fuel filter.

6. Replace fuel filter.

7. Dirt, water, or stale fuel is in

fuel system.

7. Contact Authorized Service

Dealer.

Engine overheats.

1. Engine load is excessive.

1. Reduce ground speed.

2. Oil level in crankcase is low.

2. Add oil to crankcase.

3. Cooling fins and air passages

under engine blower housing

are plugged.

3. Remove obstruction from

cooling fins and air passages.

Summary of Contents for Z355 Z-Master

Page 1: ...Operator s Manual Original Instructions EN Register your product at www Toro com Form No 3329 833 Rev A Z355 Z Master with 48 in Mower and Bagger Model No 74805 Serial No 240000001 and Up ...

Page 2: ...Rear Tail Wheel 13 Removing the Deck Banding 13 Checking the Tire Pressure 13 Activating the Battery 13 Checking the Hydraulic Fluid 14 Check Engine Oil Level 14 Removing the Machine from the Crate 14 Page Operation 14 Think Safety First 14 Controls 15 Operating the Parking Brake 16 Starting and Stopping the Engine 16 Operating the Power Take Off PTO 17 The Safety Interlock System 17 Driving Forwa...

Page 3: ...to identify the level of hazard However regardless of the hazard be extremely careful Danger signals an extreme hazard that will cause serious injury or death if you do not follow the recommended precautions Warning signals a hazard that may cause serious injury or death if you do not follow the recommended precautions Caution signals a hazard that may cause minor or moderate injury if you do not ...

Page 4: ...e in an enclosed area Only operate in good light keeping away from holes and hidden hazards Be sure all drives are in neutral and parking brake is engaged before starting engine Start the engine only from the operator s position Never raise a deck with the blades running Never operate without the PTO shield or other guards securely in place Be sure all interlocks are functioning properly Never ope...

Page 5: ...en or rolls into ponds or water Check carefully for overhead clearances i e branches doorways electrical wires before driving under any objects and do not contact them Maintenance and storage Disengage drives lower implement set parking brake stop engine and remove key or disconnect spark plug wire Wait for all movement to stop before adjusting cleaning or repairing Clean grass and debris from cut...

Page 6: ...6 ...

Page 7: ...7 Slope Chart ...

Page 8: ...8 ...

Page 9: ...cals 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 523552 43 8480 55 4300 68 8340 79 0360 80 8760 93 9198 98 4361 1 Entanglement belt 100 5809 ...

Page 10: ...o fire open flames or smoking 3 Caustic liquid chemical burn hazard 4 Wear eye protection 5 Read the Operator s Manual 6 Keep bystanders a safe distance from the battery 104 7807 104 8172 98 1313 1 Fast forward 2 Slow forward 3 Neutral 4 Slow reverse 5 Fast reverse 6 Continuous variable setting ...

Page 11: ...ection explosive gases can cause blindness and other injuries 4 No sparks flame or smoking 5 Sulfuric acid can cause blindness or severe burns 6 Flush eyes immediately with water and get medical help fast 7 Maximum fill line 8 Minimum fill line 9 Instructions for activating the battery ...

Page 12: ...possible then refuel such equipment on a truck or trailer from a portable container rather than from a gasoline dispenser nozzle If a gasoline dispenser nozzle must be used keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete Gasoline is harmful or fatal if swallowed Long term exposure to vapors can cause serious injury and illness Av...

Page 13: ...lt head 4 Washer 5 Locknut 6 Crate bracket 7 Spacer 8 Shim Washers Removing the Deck Banding Remove any tie down banding that holds deck in place Checking the Tire Pressure Check the air pressure in all tires refer to Tire Pressure page 45 Activating the Battery Bulk electrolyte with 1 265 specific gravity must be purchased from a local battery supply outlet Danger Battery electrolyte contains sul...

Page 14: ... Note Do not run the machine with the battery disconnected electrical damage may occur Checking the Hydraulic Fluid Check the hydraulic fluid level before the engine is first started Refer to Checking the Hydraulic Fluid on page 45 Check Engine Oil Level Before you start the engine and use the machine check the oil level in the engine crankcase refer to Checking the Engine Oil Level page 36 Removi...

Page 15: ...aring protection when operating this machine Caution Figure 5 1 Warning wearhearing protection Controls Become familiar with all the controls before you start the engine and operate the machine Fig 6 1 2 5 10 3 8 9 7 4 6 m 5287 11 Figure 6 1 Motion control lever 2 Parking brake 3 Ignition switch 4 Throttle 5 Power take off PTO 6 Hourmeter 7 Choke 8 Drink holder 9 Fuel cap 10 Hydro reservoir cap 11...

Page 16: ...efore starting a cold engine Note A warm or hot engine may not require choking After engine starts move choke control to the off position 6 Turn ignition key to the start position to energize starter When engine starts release key Note If starter does not crank move the motion control levers slightly forward or backward to locate neutral Important Do not engage starter for more than 10 seconds at ...

Page 17: ...rlock switches daily and replace any damaged switches before operating the machine Caution Understanding the Safety Interlock System The safety interlock system is designed to prevent the engine from starting unless The parking brake is set The power take off PTO is disengaged or off The motion control levers are in neutral position The safety interlock system also is designed to stop the engine w...

Page 18: ...e motion control lever toward neutral on the side you want to turn toward Fig 14 The farther you move the motion control levers in either direction the faster the machine will move in that direction To slow or stop move the motion control levers to neutral m 3288 3 4 2 3 1 2 5 5 4 5 5 1 Figure 14 1 Motion control lever neutral position 2 Forward 3 Backward 4 Slow 5 Fast Driving Backward 1 Release ...

Page 19: ...t of Cut The height of cut can be adjusted from 1 to 4 1 2 inch in 1 2 inch increments by relocating four hairpin cotter pins in different hole locations Note Fine adjustment can be done by removing washers 1 To adjust remove hairpin cotter from height of cut post Fig 17 2 Select hole in height of cut post corresponding to the height of cut desired Lift on side of deck to align holes and insert ha...

Page 20: ... pins into released position and lift on side of carrier frame near latch pin until latch pin engages Fig 18 Repeat on the other side Dumping the Hopper The hopper is equipped with a sensor that checks for a full condition When the alarm buzzer sounds the PTO must be moved to the off position immediately and the hopper needs to be emptied Important The hopper is interlocked with the PTO and the en...

Page 21: ...take off PTO set the parking brake and turn the ignition key to off Remove the key 2 Remove plenum from traction unit Refer to Installing and Removing the Plenum on page 26 3 Raise seat to gain access to plenum cable Remove washer and nut from plenum cable end Fig 22 3 1 4 m 4851 5 7 2 2 6 8 Figure 22 1 Bracket 2 Plenum cable 3 Washer 4 Nut 5 Plenum 6 Plenum cable guide 7 Plenum latches 8 Blower h...

Page 22: ... from push arms at traction unit pivot brackets Fig 26 Note Save all hardware for use when installing mower Items 3 and 4 are part of traction unit 2 4 3 m 4870 1 Figure 26 1 Pivot bracket 2 Push arm 3 Pivot pin assembly flat 4 Hairpin cotter Note Drive shaft remains with traction unit 14 Drive roll pin through hole in PTO drive shaft to separate from gearbox shaft Fig 27 1 2 4 3 M 4532 Figure 27 ...

Page 23: ...3 8 x 1 5 8 inch 5 Locknut 3 8 inch 2 Position carrier frame in front of traction unit and place push arms into clevises Fig 30 m 4870 2 4 3 1 Figure 30 1 Clevis 2 Push arm 3 Pivot pin assembly flat 4 Hairpin cotter 3 Install push arms with pivot pin assemblies aligned with flat against frame and secure with hairpin cotters Fig 30 Note Pivot pin assemblies and hairpin cotters are part of traction ...

Page 24: ... Latch pins should lock 12 Select hole in height of cut post corresponding to the height of cut desired Lift on side and front to align holes and hairpin cotter Fig 34 2 1 3 m 4856 Figure 34 1 Carrier frame 2 Hairpin cotter 3 Height of cut post Note All four hairpin cotters should be in the same hole location for a level cut 13 Tilt carrier frame into its upright position Refer to Tilting the Mowe...

Page 25: ...e removed when mulching Fig 39 Operating with Mulching Baffle When operating the mower with the mulching baffle installed you must disengage the blower drive belt 1 Stop the engine remove the key 2 Remove hairpin cotter and clevis pin from idler arm Fig 38 3 Pull up on the spring loaded idler arm behind blower on lefthand side of unit to relax pressure on blower belt Fig 38 4 Align hole in idler a...

Page 26: ...d blower on lefthand side of unit to relax pressure on clevis pin Fig 40 4 Remove hairpin cotter and clevis pin from slot in frame and allow idler down to tension belt Fig 40 5 Install hairpin cotter and clevis pin in outer hole of idler arm for storage Fig 40 1 2 3 4 m 3548 Figure 40 1 Idler arm 2 Frame slot 3 Clevis pin 4 Hairpin cotter Installing and Removing the Plenum To avoid damage to the p...

Page 27: ...law Please carefully read all of the safety instructions Knowing this information could help you your family pets or bystanders avoid injury 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 Driving on street or roadway without turn signals ligh...

Page 28: ...en cutting grass longer than 6 inches 15 cm tall you may want to cut the lawn twice to ensure an acceptable quality of cut Cut 1 3 of the Grass Blade It is best to cut only about 1 3 of the grass blade Cutting more than that is not recommended unless grass is sparse or it is late fall when grass grows more slowly Mowing Direction Alternate mowing direction to keep the grass standing straight This ...

Page 29: ...rp blade throughout the cutting season because a sharp blade cuts 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 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 imme...

Page 30: ...hours Grease the castor wheels Clean the cooling systems 1 Check tire and castor tire pressures Every 40 hours Check the belts for wear cracks Grease the motion control lever pivot Check the mower gearbox oil Every 100 hours Change the engine oil Check the primary air cleaner 1 Check the hydraulic lines Change the mower gearbox oil initial Every 200 hours Change the oil filter Change the hydraulic...

Page 31: ...nt Always check gearbox output shafts for straightness after impacting solid objects with blades Severe damage could result if gearbox is operated with bent output shafts Before Inspecting or Servicing the Blades 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 and disconnect the spark plug wire s from the spa...

Page 32: ...utting edges properly when installing Sails of blades must point towards the top of the deck Front 1 M 4852 Figure 45 1 Cutting edge Note Use anti seize lubricant on spindle and keyway before installing blade retainer 1 Install the key in the retainer and install blade retainer to spindle Fig 46 2 Install the blade spacer washer and retainer bolt to spindle Fig 46 3 Torque the retainer bolt to 85 ...

Page 33: ...to Side Leveling on pages 33 33 and 34 Matching the Height of Cut The height of cut needs to be checked and correct before the front to rear pitch and side to side leveling is performed 1 Check the tire pressure on both deck and traction unit 2 Set the height of cut to the 2 1 2 inch position following the height of cut decal 3 With the machine on level surface position one blade front to rear Fig...

Page 34: ...ons Fig 53 from a level surface to the cutting edge of blade tips Fig 54 Front A B M 4852 Figure 53 MEASURE FROM TIP OF CUTTING EDGE TO A LEVEL SURFACE M 4852 Figure 54 3 The difference between measurements A and B should be no more than 1 4 inch Change the Side to Side Level Changing the side to side leveling is done by removing or adding washers to height of cut posts Do this to the correspondin...

Page 35: ...oving the Filter 1 Disengage the power take off PTO set the parking brake and turn the ignition key to off Remove the key 2 Remove the wing nut from the bolt in the air filter guard Rotate guard to gain access to filter Fig 57 1 3 2 m 4845 4 Figure 57 1 Filter guard 2 Wing nut 3 Bolt 4 Filter 3 Release the latches on the air cleaner and pull the air cleaner cover off of the air cleaner body Fig 58...

Page 36: ...he Filter on page 35 clean or replace the filter as needed 2 Reset the gauge by depressing the button in the bottom of the canister until the plunger returns to the lowest point Fig 59 2 1 M 4824 Figure 59 1 Filter minder 2 Button push to reset 3 Test run the engine and recheck the gauge If the plunger remains in the lowest range normal operation can resume If the plunger returns to the Change Fil...

Page 37: ...ximately 80 of the specified oil on page 36 into the fill opening Fig 60 Now check the oil level refer to Checking Oil Level page 36 Slowly add additional oil to bring to full mark on dipstick Changing the Engine Oil Filter Replace the oil filter after first 8 hours of use Replace the oil filter every 200 hours or every other oil change Note Change oil filter more frequently when operating conditi...

Page 38: ...l washer 2 1 m 5278 Figure 63 1 Spark plug wire 2 Spark plug Checking the Spark Plugs 1 Look at the center of the spark plug s Fig 64 If you see light brown or gray on the insulator the engine is operating properly A black coating on the insulator usually means the air cleaner is dirty Important Never clean the spark plug s Always replace the spark plug s when it has a black coating worn electrode...

Page 39: ...n you and others and can damage property Drain gasoline from the fuel tank when the engine is cold Do this outdoors in an open area Wipe up any gasoline that spills Never smoke when draining gasoline and stay away from an open flame or where a spark may ignite the gasoline fumes 1 Park the machine on a level surface to assure fuel tank drains completely Then disengage the power take off PTO set th...

Page 40: ...e and will reduce the possibility of overheating and mechanical damage 1 Remove the panels from the engine shroud 2 Clean the engine cooling fins 3 Install the panels onto the engine shroud 1 2 3 m 5766 Figure 68 1 Panel 2 Engine shroud 3 Screws Greasing and Lubricating The unit must be lubricated regularly Refer to the Recommended Maintenance Schedule on page 30 Grease Type No 2 general purpose l...

Page 41: ...Fig 73 1 m 4871 Figure 73 1 Push arm grease fitting 5 Grease the fittings on the carrier frame castor hubs and castor wheels Fig 74 1 2 m 4846 Figure 74 1 Carrier Frame Castor Hub Grease Fitting 2 Castor Wheel Grease Fitting Servicing the Gearbox Fluid Change fluid After initial 100 operating hours Note Fluid will not have to be changed again after initial 100 hour fluid change Fluid Type Automati...

Page 42: ...page 19 3 Remove plug on the side of the gearbox The fluid level must be up to side hole in gearbox Fig 75 4 If needed fill fluid into top hole until it runs out the side hole in gearbox It is full when it runs out the side hole Fig 75 Important Do not mix fluids Do not overfill gearboxes 5 Reinstall the top and side plugs into gearbox using pipe sealant Fig 75 6 Fill gearbox with fluid 7 Repeat f...

Page 43: ...check the bushings move the idler arms side to side and examine for wear If the idler arms are loose the bushings are worn and must be replaced 1 Disengage the power take off PTO and turn the ignition key to off Remove the key 2 Remove tension on idler arms and remove belt from the idler See one of the following figures 78 79 or 80 that shows the idler you are checking 3 Inspect the idler pivot pi...

Page 44: ...Installation section 2 Inspect the pivot pin assembly for wear and replace if necessary 3 Remove the retaining ring and flat washer securing the push arm to the mower Fig 81 1 2 3 4 m 4871 Figure 81 1 Pin 2 Push arm 3 Flat washer 1 1 2 inch 4 Retaining ring 4 Insert a pin punch into the push arm and carefully drive out the bushings Fig 82 Clean the inside of the push arm 5 Use a hammer and flat pl...

Page 45: ... bushing and slide them into the wheel hub Place the second bushing into the wheel hub Fig 83 6 Install the castor wheel into the castor fork and secure with the wheel bolt and locknut Tighten the locknut until the spanner bushing bottoms against the inside of the castor forks Fig 83 7 Grease the fitting on the castor wheel Checking the Tire Pressure Maintain the air pressure in the front and rear...

Page 46: ... 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 condition and all hydraulic connections and fittings are tight before applying pressure to hydraulic system Warnin...

Page 47: ...d as required to maintain proper level 5 Repeat procedure on opposite wheel Check the Hydraulic Lines After every 100 operating hours check hydraulic lines and hoses for leaks loose fittings kinked lines loose mounting supports wear weather and chemical deterioration Make necessary repairs before operating Hydraulic fluid escaping under pressure can penetrate skin and cause injury If hydraulic flu...

Page 48: ...x pulley 4 PTO belt 5 Clutch stop 6 Bolt 7 Clutch 8 Clutch electrical connector 4 Install new PTO belt over clutch and route around gearbox pulley and above spring loaded idler Fig 91 5 Hold spring loaded idler against belts and pull spring down to install on idler stud Fig 90 6 Install clutch stop Fig 90 Tighten mounting bolts securely 7 Plug clutch wire into wire harness m 3225 4 2 3 1 Figure 91...

Page 49: ...be lifted The engine lift hook is positioned to allow clearance for the air cleaner hose 1 Locate on engine the lift hook in figure 94 2 Remove the lift hook from engine Rotate lift hook 180 degrees and reinstall 3 Use the engine lift hook 4 Rotate lift hook 180 degrees and reinstall to its original position Important Return lift hook to original position after engine has been reinstalled 1 2 M 48...

Page 50: ...ushing the skin Follow all instructions and comply with all safety messages on the electrolyte container Installing the Battery 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 When removing or installing the battery do not allow the battery terminals to touch any metal parts of ...

Page 51: ...st before you operate the machine This lets the water mix thoroughly with the electrolyte solution 1 Remove the battery from the machine 2 Clean the top of the battery with a paper towel Note Never fill the battery with distilled water while the battery installed in the machine Electrolyte could be spilled on other parts and cause corrosion 3 Remove the vent caps from the battery Fig 96 4 Slowly p...

Page 52: ...he Hopper Full Sensor The hopper full sensor inside the top right side of the hopper detects a beam of light from the transmitter to the receiver If the light beam is blocked the sensor buzzer sounds If the lenses are covered with clippings or debris it may give false hopper full signals and needs to be cleaned Note There are two different positions the hopper full sensors can be mounted The lower...

Page 53: ... OR Y GY CLOSED WHEN OPERATOR PRESENT SW1 SEAT OR 15A F3 OR PK S6 HOPPER SW Y S B J7 4 5 2 IGNITION S4 KEY SWITCH PN 88 9830 OFF NO CONNECTION ON B I A AND X Y START B I S R Y W 1 X I Y YELLOW T TAN R RED PK PINK ORANGE OR GY GREY BN BROWN BK BLACK BLUE BU GREEN GN VIOLET VIO WHITE W I B S X KEY SW A Y 3 A WIRE COLOR CODES 2 3 5 4 1 K2 START RELAY W GN Y W BU 25A F2 F1 30A R BU VIO W VIO 1 2 3 5 S...

Page 54: ...54 Hydraulic Diagram HYDRAULIC TANK REAR PUMP FILTER RIGHT MOTOR LEFT MOTOR A B FRONT PUMP A B I C B A C A I B ...

Page 55: ... the Fuel Tank page 39 C Restart engine and run until it stops Repeat on choke until engine will not restart D Dispose of fuel properly Recycle as per local codes Note Do not store stabilizer conditioned gasoline over 90 days 11 Remove the spark plug s and check its condition refer to Servicing the Spark Plug page 38 With the spark plug s removed from the engine pour two tablespoons of engine oil ...

Page 56: ... plugs are pitted fouled or gap is incorrect 5 Install new correctly gapped spark plugs 6 Dirt in fuel filter 6 Replace fuel filter 7 Dirt water or stale fuel is in fuel system 8 Fuel shut off valve is off 7 Contact Authorized Service Dealer 8 Turn shut off valve to on Engine loses power 1 Engine load is excessive 1 Reduce ground speed g p 2 Air cleaner is dirty 2 Clean air cleaner element 3 Oil l...

Page 57: ...horized Service Dealer 4 Loose deck gearbox bolts 4 Check and tighten bolts 5 Blades are bent 5 Replace blades 6 Gearbox output shaft spindle is bent 6 Contact Authorized Service Dealer Machine does not drive 1 Parking brake is on 2 Traction belt is worn loose or broken 1 Move parking brake to off 2 Contact Authorized Service Dealer 3 Traction belt is off pulley 3 Contact Authorized Service Dealer...

Page 58: ...58 ...

Page 59: ...59 ...

Page 60: ...Items and Conditions Not Covered There is no other express warranty except for special emission system coverage on some products This express warranty does not cover the following Cost of regular maintenance service or parts such as filters 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 re...

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Toro Z355 Z-Master, Operator'S Manual

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Summary of Contents for Z355 Z-Master

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