Form No. 3389-840 Rev A 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.
or Exmark 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 .................................41 Adjusting the Caster Pivot Bearings...........................41 Cooling System Maintenance ......................................42 Cleaning the Engine Screen and Engine Oil Cooler...............................................................42 Servicing the Engine Oil Cooler ...............................42 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 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 engine, and remove key before making adjustments, servicing, or cleaning deck. 116-8943 2. Height of cut. 1.
116-8946 1. Rotate counterclockwise to release 2. Rotate clockwise to lock 3. Unlock to push 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 deck lock mechanism every 100 hours. 9. Grease deck pivots every 100 hours. 3. Grease front caster wheel bearings every 8 hours. 10. Check gearbox oil every 100 hours (use only Mobil 1 75W-90 gear oil). 4.
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 PTO is engaged, idler arm position must be in hatched area or adjustment is required. 117–2718 120-0625 1. Pinch point, hand—keep hands away. Molded in LH Console 1. PTO-disengage 3. Park 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. Stop engine and remove key before adjusting, servicing, or cleaning. 2. Sliding, tipping hazard-Do Not use the machine near drop-offs 6.
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. Contains lead; do not discard.
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).
Setting the Parking Brake Operating the Ignition Switch 1. Turn the ignition key to the Start position (Figure 12). When the engine starts, release the key. WARNING The parking brake may not hold machine parked on a slope and could cause personal injury or property damage. Important: Do not engage the starter for more than 10 seconds at a time. If the engine fails to start, allow a 60 second cool-down period between attempts. Failure to follow these instructions can burn out the starter motor.
Operating the PTO Engagement Lever The PTO engagement lever starts and stops the mower blades and blower. WARNING An uncovered discharge opening will allow objects to be thrown in an operator’s or bystander’s direction. Also, contact with the blower blades could occur. Thrown objects or blade contact can cause serious injury or death. g025096 Figure 15 Starting and Stopping the Engine Never operate the mower with the hopper or hopper door raised, removed, or altered.
Stopping the Engine 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. 4 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.
7. Close the fuel shut-off valve when the machine will not be in use for a few days, when transporting, or when the unit is parked inside a building. 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. The Safety Interlock System 1.
3. To move forward in a straight line move the speed control lever forward. 2. Release the mower deck locking pins on each side (Figure 19). Note: The machine will move faster the farther the speed control lever is moved away from neutral. 4. To turn left or right, pull one of the steering levers back toward neutral in the direction desired. 5. To stop, pull the speed control lever back to the neutral position. Driving Backward 1.
WARNING Operating the mower deck in the raised service position can be dangerous. Engaging the PTO with a deck in the raised position can result in a serious injury or property damage. Always lower and lock mower deck in the operation position before engaging the PTO. Lowering the Mower Deck to the Operating Position Figure 21 1. While firmly holding onto deck-lift handle, unhook mower deck latch from the machine and slowly lower mower deck to ground (Figure 20). 1. Hair pin and clevis pins 5.
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 park brake and dismount the machine to dump hopper. 9.
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.
Operating Tips 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 When Stopping For best mowing and maximum air circulation, operate the engine at the fast throttle position. Air is required to thoroughly cut grass clippings, so do not set the height-of-cut so low as to totally surround the mower by uncut grass.
Maintenance Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 50 hours • Change oil in all three gearbox housings. Add oil as needed until level with oil drain plug. After the first 100 hours • • • • Check the wheel lug nut torque. Check the wheel hub nut torque. Check the park brake adjustment. Change the hydraulic filter and reservoir hydraulic oil when using any type of oil. Before each use or daily • • • • • • • • Check the safety system.
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.
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. Important: To prevent seal and bearing damage, check the bearing adjustment often. Spin the caster tire. The tire should not spin freely (more than 1 or 2 revolutions) or have any side play. If the wheel spins freely, adjust the torque on the spacer nut until there is a slight amount of drag. Apply thread locking adhesive. Figure 28 1.
Engine Maintenance 1. Stop 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. WARNING 3. Lubricate each end of both steering linkage rods with a spray lubricant or a light oil. Contact with hot surfaces may cause personal injury. Change the Gearbox Oil Keep hands, feet, face, clothing, and other body parts away the muffler and other hot surfaces.
Servicing the Engine Oil 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. Oil Type: Detergent oil (API service class SJ or higher) Oil Capacity (Non-EFI engines): with a filter change, 1.8 L (1.9 US qt); with no filter change, 1.6 L (1.7 US qt) 7.
Changing the Engine Oil 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. Service Interval: Every 100 hours (more often in dirty or dusty conditions). Important: Do not operate the engine with the oil level below the low (or add) mark on the dipstick, or over the full mark. Note: Dispose of the used oil at a recycling center. 1.
4. 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 33). 2 5. Start the engine and drive to a flat area. Check the oil level again (Figure 33). 6. If needed, add oil to the full mark on the dipstick. Changing the Engine-Oil Filter Service Interval: Every 200 hours Note: Change the engine oil filter more frequently when operating conditions are extremely dusty or sandy. 1.
Servicing the Spark Plugs 1 Service Interval: Every 200 hours—Check and gap the spark plug (EFI engines only). 2 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. Use a spark-plug wrench for removing and installing the spark plugs and a gapping tool/feeler gauge to check and adjust the air gap. Install new spark plugs if necessary.
Checking the Spark Arrester (if equipped) Fuel System Maintenance Service Interval: Every 50 hours WARNING WARNING Fuel system components are under high pressure. The use of improper components can result in system failure, gasoline leakage, and possible explosion. Hot exhaust system components may ignite gasoline vapors even after the engine is stopped. Hot particles exhausted during engine operation may ignite flammable materials. Fire may result in personal injury or property damage.
Electrical System Maintenance 1 2 Servicing the Battery 3 Service Interval: Monthly WARNING CALIFORNIA Proposition 65 Warning Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. G008963 Figure 39 1. Fuel filter 2. Hose clamp 3. Fuel line DANGER 5. Squeeze the ends of the hose clamps together and slide them away from the filter (Figure 39).
Charging the Battery 1. Move the speed control lever to the neutral position to stop the machine. WARNING 2. Disengage the PTO, engage the parking brake, stop the engine, and wait for all moving parts to stop. Charging the battery produces gases that can explode. 3. First disconnect the negative battery cable (black) from the negative (-)(black) battery terminal (Figure 40). Never smoke near the battery and keep sparks and flames away from battery. 4.
Servicing the Fuses reduce voltage drop between systems. Make sure that the cables are color coded or labeled for the correct polarity. 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 hand side behind the seat. 2. To replace the fuses, pull out on the fuse to remove it. 3. Install a new fuse.
Drive System Maintenance 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. 7. Start the vehicle and remove the cables in the reverse order of connection (the engine block (black) connection is the first to disconnect). Adjusting the Tracking The tracking knob is located under the seat.
Figure 45 Note: Do not add any type of tire liner or foam fill material to the tires. Figure 46 Front caster Checking the Wheel Lug Nuts Service Interval: After the first 100 hours 1. Spring washers 3. Dust cap 2. Locknut Every 500 hours Check and torque the wheel lug nuts to 122 to 129 N-m (90 to 95 ft-lb). Checking the Wheel Hub Nuts Service Interval: After the first 100 hours Every 500 hours Check and ensure that the torque of the slotted nut is 373 to 475 N-m (275 to 350 ft-lb).
Check and Clean the Hydraulic Pumps Cooling System Maintenance Service Interval: Before each use or daily Cleaning the Engine Screen and Engine Oil Cooler 1. Move the speed control lever to the neutral position to stop the machine. 2. Disengage the PTO, engage the parking brake, stop the engine, and wait for all moving parts to stop. Service Interval: Before each use or daily Remove any buildup of grass, dirt, or other debris from the oil cooler. 3. Raise the seat.
Brake Maintenance Adjusting the Parking Brake Service Interval: After the first 100 hours Every 500 hours thereafter Check to make sure that the brake is adjusted properly. This procedure must be followed after the first 100 hours or when a brake component has been removed or replaced. 1. Stop the machine and move the speed control lever to the neutral position. 2. Disengage the PTO, engage the parking brake, stop the engine, and wait for all moving parts to stop. 3. Release the parking brake. 4.
Belt Maintenance Note: When the brakes are disengaged, there should be little to no free play in the brake linkage with no dragging in the brakes. 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, stop the engine, and wait for all moving parts to stop. 3. Tilt the hopper up and check the pump and PTO drive belts for wear, cracking, or contamination.
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. Figure 53 1. Pump Drive Belt 4. Pump 2. Pump 5. Idler 3. Idler 6. Engine 7. Install PTO Belts as stated in Replacing the PTO Belts (page 44). Figure 52 1. Tension Arm 2. Loosen jam nuts Adjusting the Belt Guides 3. When PTO is engaged, align top of idler arm with bottom of notch on tension arm, as shown. 4. Idler Arm 1.
Controls System Maintenance F. Install the seat frame assembly, if removed in step A. Adjusting the Speed-Control Lever Tension Adjusting the Reverse-Stop Rod 1. Stop the machine and move the speed-control lever to the neutral position. 1. Stop the machine and move the speed control lever to the neutral position. 2. Disengage the PTO, engage the parking brake, stop the engine, and wait for all moving parts to stop. 2.
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. Do not rely solely on mechanical or hydraulic jacks for support. Use adequate jack stands or equivalent support. Set neutral position as follows: 1. Stop the machine and move the speed-control lever to the neutral position. Figure 57 2.
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, stop the engine, and wait for all moving parts to stop. 3. Locate the brake spring and thread the two jam nuts out to the end of the brake spring rod (Figure 58). Figure 59 4.
Hydraulic System Maintenance Servicing the Hydraulic System Hydraulic Oil Type: Toro® HYPR-OIL™ 500 hydraulic oil or Mobil® 1 15W-50. Figure 61 Important: Use oil specified. Other fluids could cause system damage. 1. Full Checking the Hydraulic Oil 2. Add WARNING Service Interval: Every 40 hours—Check the hydraulic oil level. Hydraulic oil escaping under pressure can penetrate skin and cause injury.
Mower Deck Maintenance 2. Disengage the PTO, engage the parking brake, stop 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. 2.
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-hand 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 Exmark replacement blades. Replacement blades made by other manufacturers may result in non-conformance with safety standards. Figure 66 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 Exmark 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 the red colored blade is installed on the right-hand side. 1.
5. Unlatch the mower deck from the raised position and slowly lower the mower deck to ground; refer to Lowering the Mower Deck to the Operating Position (page 23). Note: The mower deck will become heavier once the springs are removed 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 69). Figure 71 1. Jackshaft 2. Drive shaft 9. Pull the mower deck forward to remove it from the machine.
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 operation 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 72). 1. Move the speed control lever to the neutral position to stop the machine. 2.
Storage C. Stop the engine, allow it to cool, and drain the fuel tank; refer to Servicing the Fuel Tank (page 37). Cleaning and Storage D. Restart the engine and run it until it stops. E. Dispose of fuel properly. Recycle as per local codes. 1. Disengage the power take off (blade control switch (PTO), set the parking brake, and turn the ignition key to Off. Remove the key. 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 Total Coverage Warranty Landscape Contractor Equipment (LCE) A Limited Warranty (see warranty periods below) Conditions and Products Covered The Exmark Company and its affiliate, Exmark Warranty Company, pursuant to an agreement between them, jointly promise to the original purchaser to repair the Exmark Products listed below if defective in materials or workmanship.
