Form No. 3389-840 Rev B Z Master® 8000 Series Riding Mower with 42in or 48in Direct-Collect Cutting Unit Model No. 74310—Serial No. 315000001 and Up Model No. 74311—Serial No. 315000001 and Up Model No. 74312—Serial No. 315000001 and Up Register at www.Toro.com.
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. Write the numbers in the space provided. WARNING CALIFORNIA Proposition 65 Warning This product contains a chemical or chemicals known to the State of California to cause cancer, birth defects, or reproductive harm.
Contents Checking the Wheel Hub Nuts .................................40 Adjusting the Caster Pivot Bearings...........................40 Cooling System Maintenance ......................................41 Cleaning the Engine Screen and Engine-Oil Cooler...............................................................41 Servicing the Engine-Oil Cooler ...............................41 Cleaning the Engine Cooling Fins and Shrouds.............................................................
Safety • Inspect the area where the equipment is to be used and This machine complies to the ANSI B71.4–2012 specification of the American National Standards Institute with the addition of the optional ROPS accessory. • Improperly using or maintaining the machine 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.
Safe Handling of Fuels • Use care when checking the blades. Wrap the blade(s) or wear gloves, and use caution when servicing them. Only replace blades. Never straighten or weld them. • To avoid personal injury or property damage, use extreme care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive. • Keep your hands and feet away from moving parts. If possible, do not make adjustments with the engine running.
Slope Indicator G011841 Figure 3 This page may be copied for personal use. 1. The maximum slope you can safely operate the machine on is 15 degrees. 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 recommended slope. 2. Align this edge with a vertical surface, a tree, building, fence pole, etc. 3. Example of how to compare slope with folded edge.
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. 93–6696 1. Stored energy hazard—read the Operator's Manual. 112-8760 1. Thrown object hazard—keep bystanders a safe distance from the machine. 2. Cutting/dismemberment of hand or foot—stay away from moving parts. 93-7818 1.
2 1 116-8936 3 4 5 6 1. Danger—do not operate with deck in tilt-up position. 7 NVXXXXXX 116-8813 1. Hopper up indicator 5. Parking brake 2. Battery 6. Neutral 3. Hour meter 7. Operator-presence switch 4. PTO 116-8941 116-8934 1. Warning—disengage blade clutch, shut off the engine, and remove the key before making adjustments, servicing, or cleaning the deck. 116-8943 2. Height of cut. 1.
116-8946 1. Rotate counterclockwise to release 2. Rotate clockwise to lock 3. Unlock to push the machine 4. Read the instructions before servicing or performing maintenance. 116-9044 1. Read the Operator’s Manual before performing any maintenance. 2. Check engine oil every 8 hours. 8. Grease the deck lock mechanism every 100 hours. 9. Grease the deck pivots every 100 hours. 3. Grease front caster wheel bearings every 8 hours. 10. Check the gearbox oil every 100 hours (use only Mobil 1 75W-90 gear oil).
116-9049 1. Rotating driveline hazard—keep all drivelines shields in place. Securely attach both ends of the driveline. 126-4207 1. Refer to the Operator’s Manual for adjustment procedure. When the PTO is engaged, the idler arm position must be in hatched area or an adjustment is required. 117–2718 120-0625 1. Pinch point, hand—keep hands away. Molded in LH Console 1. PTO—disengage 3. Parking brake—release 2. PTO—engage 4.
Molded into Front of Hopper 1. Warning—Read the Operator’s Manual. Do not operate this machine unless you are trained. Wear hearing protection. 5. Warning—Stay away from moving parts; keep all guards in place. Shut off the engine and remove the key before adjusting, servicing, or cleaning. 2.
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 fire, open flame, or smoking 7. Wear eye protection; explosive gases can cause blindness and other injuries. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection. 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. 5. Read the Operator's Manual. 10.
0–2881 1. Engine temperature 7. Retract the piston 2. Fast 8. Extend the piston 3. Slow 4. Neutral 5. Neutral 9. Fast 10. Slow 11. MIL toggle switch 6.
Motion-Control Levers Product Overview The motion-control levers are used to drive the machine forward, reverse, and turn either direction (Figure 4). Speed-Control Lever The speed-control lever sets maximum forward speed of the machine (Figure 4). Moving speed-control lever rearward to the NEUTRAL position places the drive system into neutral. Throttle Control The throttle is used to control engine speed. The throttle control is variable between FAST and SLOW .
Safety-Interlock Indicators Specifications There are symbols on the hour meter and the indicate with a black triangle that the interlock component is in the correct position (Figure 6). Note: Specifications and design are subject to change without notice. Width: Fuel-Shutoff Valve Close the fuel-shutoff valve (under the hopper) when transporting or storing the mower. PTO-Engagement Lever The PTO-engagement lever is used to engage the blades and the blower.
Operation DANGER In certain conditions during fueling, static electricity can cause 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.
Filling the Fuel Tank 1. Park the machine on level ground. 2. Shut the engine off and set the parking brake. 3. Clean around the fuel-tank cap and remove it. Add regular unleaded gasoline to the fuel tank until the level is 6 to 13 mm (1/4 to 1/2 inch) below the bottom of the filler neck. This space in the tank allows the gasoline to expand. Do not fill the fuel tank completely full; refer to (Figure 4).
Operating the Parking Brake Operating the Throttle Always set the parking brake when you stop the machine or leave it unattended. The throttle control can be moved between the FAST and SLOW positions (Figure 11). Setting the Parking Brake Always use the middle position when turning on the mower deck and blower with the PTO-engagement lever. WARNING The parking brake may not hold machine parked on a slope and could cause personal injury or property damage.
Using the Fuel-Shutoff Valve The fuel-shutoff valve is located under the hopper. Raise the hopper to access it. Close the fuel-shutoff valve for transport, maintenance, and storage. Ensure that the fuel-shutoff valve is open when starting the engine. 1 2 Figure 14 Disengaging the PTO-Engagement Lever G008948 Figure 13 1. On 2. Off 1. Set the throttle to the MIDDLE position. 2. Push PTO lever down to the STOP position stopping the blades and blower.
Stopping the Engine 5. On a cold engine, push the choke lever forward into the CLOSED/ON position (not on EFI engines). On a warm engine, leave the choke in the OPEN/OFF position. CAUTION Children or bystanders may be injured if they move or attempt to operate the machine 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.
Testing the Safety Interlock System 7. Close the fuel shut-off valve when you do not use the machine for a few days, when transporting, or when you park the machine inside a building. Service Interval: Before each use or daily 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. 1.
Raising the Mower Deck into Service Position 2. Release the parking brake; refer to Releasing the Parking Brake (page 18). 3. To move forward in a straight line move the speed-control lever forward. 1. Shut off the engine, wait for all moving parts to stop, remove the key, and engage the parking brake. Note: The machine moves faster the farther the speed-control lever is moved away from NEUTRAL. WARNING 4.
• Baffles open with standard blades—maximum collection • Baffles closed with standard blades—partial mulching • Baffles closed with mulch blades—intermediate mulching • Mulch plug installed with mulch blades—complete mulching (requires mulch kit) 1. Shut off the engine, wait for all moving parts to stop, remove the key, and engage the parking brake. 2. Remove the hairpins and clevis pins from both sides of the PTO guard (Figure 21). 3. Fold the guard forward. Figure 20 1.
1 2 g025067 Figure 24 1. Cotter pin 2. Mower-deck handle Emptying the Hopper Figure 23 A full hopper is indicated by a buzzer located behind the operator in the hopper. Empty the hopper when the buzzer sounds to prevent clogging of the blower or the mower deck. 1. Baffles shown in closed position 2. Baffles shown in open position 3. Bolt 4. Washer 5. Baffles 1. Disengage the PTO, move the speed control to NEUTRAL, set the parking brake, and dismount the machine to dump the hopper. 8.
Transporting the Machine Use a heavy-duty trailer or truck to transport the machine. Ensure that the trailer or truck has all necessary brakes, lighting, and marking as required by law. Please carefully read all the safety instructions. Knowing this information could help you, your family, pets, or bystanders avoid injury.
Loading the Machine Use extreme caution when loading the machine onto a trailer or truck. 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 machine (Figure 26). The lower rear section of the machine 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 machine starts to tip backward.
Long Grass Operating Tips 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. Fast Throttle 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 first 50 hours • Change oil in all 3 gearbox housings. Add oil as needed until it is level with the oil-drain plug. After the first 100 hours • • • • Check the wheel lug nut torque. Check the wheel hub nut torque. Check the parking brake adjustment. Change the hydraulic filter and reservoir hydraulic fluid when using any type of fluid.
Maintenance Service Interval Yearly Yearly or before storage Maintenance Procedure • • • • • • Grease the front-caster pivots. Grease the rear-caster hub. Grease the pump-belt idler arm. Grease the PTO-belt idler arm. (more often in dirty or dusty conditions). Grease the rear-caster pivot. (more often in dirty or dusty conditions). Lubricate the caster wheel hubs. • Paint chipped surfaces. • Check all maintenance procedures listed above before storage.
Lubricate the Rear Caster Wheel Hub 14. Torque the nut to 8 to 9 N∙m (6.0 to 6.6 ft-lb), loosen, then re-torque to 2 to 3 N∙m (1.5 to 2.2 ft-lb). Service Interval: Yearly Note: Make sure that the axle does not extend beyond either nut. 1. Shut off the engine, wait for all moving parts to stop, remove the key, and engage the parking brake. 15. Install the seal guards over the wheel hub and insert the wheel into the caster fork. Install the caster bolt and tighten the nut fully.
Lubricate the Steering-Linkage-Rod Ends Note: Keep the mower deck level to the ground when filling the gearbox with oil. Do not fill thr gearbox with the mower deck raised in the service position. Service Interval: Every 160 hours 9. Apply a PTFE pipe sealant to the 3 large oil plugs and install them into the gearbox. 1. Shut off the engine, wait for all moving parts to stop, remove the key, and engage the parking brake. 2. Unhook the seat latch and tilt the seat up. 3.
Engine Maintenance 6. Remove the safety filter only if you intend to replace it. Important: Do not attempt to clean the safety filter. If the safety filter is dirty, then the primary filter is damaged. Replace both filters. WARNING Contact with hot surfaces may cause personal injury. 7. Inspect the primary filter for damage by looking into the filter while shining a bright light on the outside of the filter. Holes in the filter will appear as bright spots. If the filter is damaged, discard it.
Servicing the Engine Oil 8. Remove the dipstick and read the oil level. Oil Type: Detergent oil (API service class SJ or higher) 9. If the oil level is low, wipe off the area around the oil-fill cap, remove cap, and fill to the FULL mark on the dipstick (Figure 33). Do not overfill. Oil Capacity (Non-EFI engines): with a filter change, 1.8 L (1.9 US qt); with no filter change, 1.6 L (1.
Changing the Engine Oil 2. Change the engine-oil filter (Figure 35). Service Interval: Every 100 hours (more often in dirty or dusty conditions). Note: Allow 2 minutes for the new oil to be absorbed by the new filter material. Note: Dispose of the used oil at a recycling center. 1. Park the machine so that the rear is slightly lower than the front to ensure that the oil drains completely. 2. Move the speed-control lever to the NEUTRAL position to stop the machine. 3.
Servicing the Spark Plugs Installing the Spark Plugs Service Interval: Every 200 hours—Check and gap the spark plug (EFI engines only). Tighten the spark plugs to 24.4 to 29.8 N∙m (18 to 22 ft-lb). Every 500 hours—Check and gap the spark plug (Non-EFI engines only). Make sure that the air gap between the center and side electrodes is correct before installing the spark plugs.
Fuel System Maintenance 1 2 WARNING 3 Fuel system components are under high pressure. The use of improper components can result in system failure, gasoline leakage, and possible explosion. Use only approved fuel lines and fuel filters. Servicing the Electronic Fuel Injection System G008963 Figure 39 This machine contains an electronic fuel injection system. It controls the fuel flow under different operating conditions. 1. Fuel filter 2.
Electrical System Maintenance 1. Move the speed-control lever to the NEUTRAL position to stop the machine. 2. Disengage the PTO, engage the parking brake, shut off the engine, and wait for all moving parts to stop. Servicing the Battery 3. First disconnect the negative battery cable (black) from the negative (black) battery terminal (Figure 40). Service Interval: Monthly 4. Slide the red terminal boot off the positive (red) battery terminal and remove the positive (red) battery cable (Figure 40).
Charging the Battery Servicing the Fuses The electrical system is protected by fuses. It requires no maintenance; however, if a fuse blows, check the component/circuit for a malfunction or short. 1. The fuses are located on right side of the machine, behind the seat. 2. To replace the fuses, pull out the fuse to remove it. 3. Install a new fuse. WARNING Charging the battery produces gases that can explode. Never smoke near the battery and keep sparks and flames away from battery.
properly sized jumper cables with short lengths to reduce voltage drop between systems. Make sure that the cables are color coded or labeled for the correct polarity. 5. Connect the black negative (–) cable to the other terminal (negative) of the booster battery. 6. Make the final connection on the engine block of the stalled vehicle (not to the negative battery post) away from the battery and stand back. CAUTION 7.
Drive System Maintenance Adjusting the Tracking The tracking knob is located under the seat. Rotating this knob allows fine tuning adjustments so that the machine tracks straight with the drive levers in the full forward position. Figure 45 1. Run the unit at 3/4 speed for at least 5 minutes to bring the hydraulic fluid up to the operating temperature. Stop the machine and wait for all moving parts to stop. Note: Do not add any type of tire liner or foam fill material to the tires. 2.
Cooling System Maintenance Cleaning the Engine Screen and Engine-Oil Cooler Service Interval: Before each use or daily Remove any buildup of grass, dirt, or other debris from the oil cooler. Before each use remove any buildup of grass, dirt, or other debris from the engine screen. This helps ensure adequate cooling and correct engine speed and reduces the possibility of overheating and damaging the engine. Figure 46 Front caster 1. Spring washers Servicing the Engine-Oil Cooler 3. Dust cap 2.
Brake Maintenance Check and Clean the Hydraulic Pumps Adjusting the Parking Brake Service Interval: Before each use or daily 1. Move the speed-control lever to the NEUTRAL position to stop the machine. Service Interval: After the first 100 hours Every 500 hours thereafter 2. Disengage the PTO, engage the parking brake, shut off the engine, and wait for all moving parts to stop. Follow this procedure also whenever you remove or replace a brake component. 3. Raise the seat. 1.
9. Engage and disengage the brakes to check for proper engagement and disengagement. Adjust them if necessary. Note: When the brakes are disengaged, there should be little to no free play in the brake linkage with no dragging in the brakes. Figure 49 1. Parking brake 4. Vertical spring assembly 2. Steering lever 5. Nut 3. Speed-control lever 6. 6 to 7 cm (2.35 to 2.85 inches) 8. The linkage length is adjusted with the 2 nuts at the bottom of the vertical spring assembly.
Belt Maintenance 12. Engage the PTO lever. 13. Loosen the jam nuts and adjust the linkage until the top of the idler arm is aligned with the bottom of the notch on the tension arm as shown in Figure 52. Inspecting the Belts Service Interval: Every 40 hours 1. Stop the machine and move the speed-control lever to the NEUTRAL position. 2. Disengage the PTO, engage the parking brake, shut off the engine, and wait for all moving parts to stop. 3.
Controls System Maintenance Adjusting the Reverse-Stop Rod 1. Stop the machine and move the speed-control lever to the NEUTRAL position. 2. Disengage the PTO, engage the parking brake, shut off the engine, and wait for all moving parts to stop. 3. Check the movement of the steering levers as follows: • If the levers move slightly forward up to 3 mm (1/8 inch) then no adjustment is necessary. • If the levers do not move, then proceed with the following steps: A.
Adjusting the Speed-Control Lever Tension CAUTION Raising the mower deck for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous. The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the unit to fall, which could cause injury. 1. Stop the machine and move the speed-control lever to the NEUTRAL position. 2. Disengage the PTO, engage the parking brake, shut off the engine, and wait for all moving parts to stop. 3.
pulleys are aligned within 0.8 to 1.6 mm (1/32 to 1/16 inch) (Figure 58). Note: Use a straight edge to align all 3 surfaces. Figure 57 1. Rotate tracking knob on left side Figure 58 2. Rotate double nuts on right side 1. Align the 3 pump-drive pulley surfaces shown with this pattern within 0.8 to 1.6 mm (1/32 to 1/16 inch). 12. Move the steering levers to the reverse position. While applying slight pressure to the levers, allow the steering levers to return to NEUTRAL.
5. Tighten the pulley set screws and check the alignment. Adjusting the PTO Brake Spring The PTO brake spring adjustment is only necessary if the blower has been removed or replaced or if the PTO drive idler arm has been disassembled. 1. Stop the machine and move the speed-control lever to the NEUTRAL position. 2. Disengage the PTO, engage the parking brake, shut off the engine, and wait for all moving parts to stop. Figure 60 3.
Hydraulic System Maintenance Servicing the Hydraulic System Hydraulic Fluid Type: Toro® HYPR-OIL™ 500 hydraulic fluid or Mobil® 1 15W-50. Figure 62 Important: Use fluid specified. Other fluids could cause system damage. 1. Full Checking the Hydraulic Fluid 2. Add WARNING Service Interval: Every 40 hours—Check the hydraulic-fluid level. Hydraulic fluid escaping under pressure can penetrate skin and cause injury.
Mower Deck Maintenance 2. Disengage the PTO, engage the parking brake, shut off the engine, and wait for all moving parts to stop. 3. Carefully clean the area around the filter. Important: Ensure that no dirt or contamination enter the hydraulic system. Leveling the Mower Deck 4. Unscrew and remove the filter and allow the oil to drain from the reservoir. Setting up the Machine Note: Ensure that the mower deck is leveled before matching the height of cut (HOC). 1. Position the machine on a flat surface.
Servicing the Cutting Blades 4. Lower the mower deck into operating position. Refer to Lowering the Mower Deck to the Operating Position (page 23). 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. Checking for Bent Blades 1. Move the speed-control lever to the NEUTRAL position to stop the machine.
Removing the Blades Note: Make note of the red colored blade position. From the normal user position, it is located on the right side. 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 non-conformance with safety standards. Figure 67 1. Sharpen at original angle 1.
Removing the Mower Deck Installing the Blades Note: Determine the left and right sides of the machine from the normal operating position. WARNING Operating this machine without an approved Toro front mount attachment increases the possibility of operator entanglement in drive wheels or forward tip over. Entanglement or tip-over could cause serious injury or death. Note: Ensure that the red blade is installed on the right side of the machine. 1.
Lowering the Mower Deck to the Operating Position (page 23). Note: The mower deck will become heavier after you remove the springs from the anchors. Lower the mower deck carefully. 6. Remove the lynch pins at front of push arms on both sides of the machine (Figure 70). Figure 72 1. Jackshaft 2. Driveshaft 9. Pull the mower deck forward to remove it from the machine. Installing the Mower Deck Important: Do not transport the machine without an approved Toro front mount attachment. Figure 70 1.
Adjusting the Locking-Pin Stop on the Mower Deck Cleaning Cleaning under the Mower 1. Slide the mower deck-locking pins in on both sides and rotate to lock the deck in the operating position. Service Interval: Before each use or daily 2. Loosen the jam nut and turn the stop screw clockwise until the locking pin is tight and cannot be rotated by hand (Figure 73). 1. Move the speed-control lever to the NEUTRAL position to stop the machine. 2.
Storage Cleaning and Storage 1. Disengage the power takeoff (blade control switch (PTO), set the parking brake, and turn the ignition key to Off. Remove the key. Shut off the engine, allow it to cool, and drain the fuel tank; refer to Servicing the Fuel Tank (page 36). D. Start 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. 2.
Troubleshooting Problem The malfunction Indicator Light (MIL) comes on. Possible Cause 1. The engine is too hot. 1. Turn the engine off and let it cool. 2. There is old gas in the gas tank. 3. The fuel shut-off valve is not open completely. 4. The air cleaner is dirty. 2. Use new gas. 3. Open the fuel shut-off valve. 5. The battery is not charged. 6. Incorrect fuel filters are being used or the fuel filters are dirty. 7.
Problem The engine loses power. The engine overheats. The mower pulls left or right (with levers fully forward). The machine does not drive. The machine vibrates abnormally. The machine produces an uneven cutting height. Possible Cause 1. The engine load is excessive. 1. Reduce the ground speed. 2. The air cleaner is dirty. 3. The oil level in the crankcase is low. 4. The cooling fins and the air passages above the engine are plugged. 5. The vent hole in the fuel cap is plugged. 6.
Schematics Wire Diagram (Not EFI machines) (Rev.
Wire Diagram (EFI machines) (Rev.
Hydraulic Diagram (Rev.
Notes: 62
Notes: 63
The Toro Warranty Landscape Contractor Equipment (LCE) A Limited Warranty (see warranty periods below) Instructions for Obtaining Warranty Service Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to the original purchaser to repair the Toro Products listed below if defective in materials or workmanship.
