Service Manual

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Z Master® 8000 Series

Service Manual

LCE Products

Issued: September 2016

Form Number: 492-9355

Summary of content (157 pages)

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LCEPr oduct s ZMast er ®8000Ser i es Ser vi ceManual I ssued:Sept ember2016 For m Number :4929355
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ABOUT THIS MANUAL This service manual was written expressly for Toro and Lawn-Boy® service technicians. The Toro Company has made every effort to make the information in this manual complete and correct. Basic shop safety knowledge and mechanical/electrical skills are assumed. The Table of Contents lists the systems covered in this manual. The Toro Z Master 8000 Series is covered in this manual. The manual may also be specified for use on later model products.
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TABLE OF CONTENTS 1. General Information and Specifications...................................................................................................... 1-1 2. Specifications................................................................................................................................................ 2-1 3. Maintenance................................................................................................................................................... 3-1 4.
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GENERAL INFORMATION AND SAFETY Table of Contents Model and Serial Number..................................................................................................................................... 1-2 Safety Information................................................................................................................................................ 1-3 Think Safety First.....................................................................................................................
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GENERAL INFORMATION AND SAFETY 1 Model and Serial Number Location The chassis model number and serial number are located under the hopper, on the main frame, near the rear castor pivot.
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GENERAL INFORMATION AND SAFETY This symbol means WARNING or PERSONAL SAFETY INSTRUCTION – read the instruction because it has to do with your safety. Failure to comply with the instruction may result in personal injury or even death. This manual is intended as a service and repair manual only. The safety instructions provided herein are for troubleshooting, service, and repair of the Toro Z Master 8000 Series Riding Mower.
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SPECIFICATIONS Table of Contents Specifications....................................................................................................................................................... 2-2 Torque Specifications........................................................................................................................................... 2-3 Standard Torque Values..........................................................................................................................
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SPECIFICATIONS 8000 Series Direct Collect Models 74310 2 74312 74313 Engine Kohler 20.5 HP Command PRO Kohler 23 HP EFI Command PRO Kohler 25 HP Command PRO Model CH640-3164 ECH730-3064 CH740-3182 High/Low Idle Speed 74311 High: 3600 ± 50 RPM Low: 1500 ± 100 RPM Spark Plug Champion RC12YC Engine Oil Champion XC12YC 10W-30 Oil Capacity 2.0 qt. (1.9 L) CARB Yes EPA Yes Air Filter Heavy Duty Canister Fuel Capacity 7.5 gal. (28.
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SPECIFICATIONS SPECIFICATIONS Torque Specifications Fastener Identification Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in the service manual.
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SPECIFICATIONS SPECIFICATIONS Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Grade 1, 5, & SAE Grade 1 Bolts, Screws, SAE Grade 5 Bolts, Screws, SAE Grade 8 Bolts, Screws, 8 with Thin Studs, & Sems with Regular Studs, & Sems with Regular Studs, & Sems with Regular Height Nuts Height Nuts (SAE J995 Height Nuts (SAE J995 Height Nuts (SAE J995 Grade 2 or Stronger Nuts) Grade 2 or Stronger Nuts) Grade 2 or Stronger Nuts) Thread Size In-lb 2 # 6 - 32 UNC # 6 - 40 UNF # 8 - 32 UNC #
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SPECIFICATIONS SPECIFICATIONS Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners) Thread Size Class 8.8 Bolts, Screws, and Studs with Regular Height Nuts (Class 8 or Strong Nuts) Class 10.9 Bolts, Screws, and Studs with Regular Height Nuts ( Class 10 or Strong Nuts) M5 X 0.8 57 ± 5 in-lb 640 ± 60 N-cm 78 ± 7 in-lb 885 ± 80 N-cm M6 X 1.0 96 ± 9 in-lb 1018 ± 100 N-cm 133 ± 13 in-lb 1500 ± 150 N-cm M8 X 1.25 19 ± 2 ft-lb 26 ± 3 N-m 27 ± 2 ft-lb 36 ± 3 N-m M10 X 1.
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SPECIFICATIONS SPECIFICATIONS Other Torque Specifications Wheel Bolts and Lug Nuts SAE Grade 8 Steel Set Screws Recommended Torque Thread Size 2 Square Head Hex Socket 1/4 - 20 UNC 140 ± 20 in-lb 73 ± 12 in-lb 5/16 - 18 UNC 215 ± 35 in-lb 145 ± 20 in-lb 3/8 - 16 UNC 35 ± 10 ft-lb 18 ± 3 ft-lb 1/2 - 13 UNC 75 ± 15 ft-lb 50 ± 10 ft-lb Thread Size Recommended Torque** 7/16 - 20 UNF Grade 5 65 ± 10 ft-lb 88 ± 14 N-m 1/2 - 20 UNF Grade 5 80 ± 10 ft-lb 108 ± 14 N-m M12 X 1.25 Class 8.
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SPECIFICATIONS SPECIFICATIONS Equivalents and Conversions Decimal and Millimeter Equivalents Fractions 1/64 1/32 3/64 1/16 5/64 3/32 mm 0.015625 0.397 0.03125 0.794 0.046875 1.191 0.0625 1.588 0.078125 1.984 0.9375 2.381 0.1250 3.175 9/64 0.140625 3.572 0.15625 3.969 11/64 0.171875 4.366 0.1875 4.762 1/8 5/32 3/16 13/64 7/32 15/64 1/4 17/64 9/32 19/64 5/16 21/64 11/32 23/64 3/8 25/64 13/32 27/64 0.203125 5.159 0.21875 5.556 0.234375 5.953 0.2500 6.350 0.265625 6.747 0.
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SPECIFICATIONS SPECIFICATIONS U.S. to Metric Conversions 2 To Convert Into Linear Measurement Miles Yards Feet Feet Inches Inches Inches Kilometers Meters Meters Centimeters Meters Centimeters Millimeters Area Square Miles Square Feet Square Inches Acre Square Kilometers Square Meters Square Centimeters Hectare Volume Cubic Yards Cubic Feet Cubic Inches Cubic Meters Cubic Meters Cubic Centimeters 0.7646 0.02832 16.39 Weight Tons (Short) Pounds Ounces Metric Tons Kilograms Grams 0.9078 0.
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MAINTENANCE Table of Contents Recommended Maintenance Schedule.............................................................................................................. 3-2 Torque Values..................................................................................................................................................... 3-3 Chassis Lubrication............................................................................................................................................
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MAINTENANCE Recommended Maintenance Schedule 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 and torque the four wheel lug nuts on each drive wheel. -Check and torque the wheel hub nut on each side. -Check the park brake adjustment. -Change the hydraulic filter and reservoir hydraulic oil. Before each use or daily -Check the safety system.
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MAINTENANCE Recommended Maintenance Schedule (Cont.) Maintenance Service Interval Maintenance Procedure Every 2,000 hours -Change oil in all three gearbox housings. Monthly -Check the battery. Yearly -Grease the front caster pivots (more often in dirty or dusty conditions). -Grease the rear caster hub (more often in dirty or dusty conditions). -Grease the pump-belt idler arm (more often in dirty or dusty conditions). -Grease the PTO-belt idler arm (more often in dirty or dusty conditions).
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MAINTENANCE 3 Chassis Lubrication Rear Caster Wheel Lubrication Grease Points Service Interval: Yearly Grease more frequently when operating conditions are extremely dusty or dirty. Brake Handle Pivot Lubrication Grease Type Service Interval: 160 Hours No. 2 general-purpose lithium-based or molybdenum based grease. Lubricate the bronze bushings on the brake handle pivot with a spray type lubricant or light oil (Figure 4).
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MAINTENANCE Brake Rod Bushing Lubrication Steering linkage Rod End Lubrication Service Interval: 160 hours Service Interval: 160 hours 1. Unhook the seat latch and tilt the seat upward. 1. Tilt the seat forward. 2. Lubricate the bronze bushings on each end of the brake rod shaft with a spray type lubricant or a light oil (bushings are located to the inside of the flange bearings) (Figure 5). 2. Lubricate each end of the steering linkage rods with a spray lubricant or a light oil (Figure 6 and 7).
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MAINTENANCE Mower Deck Gearbox Lubrication Service Interval: Service every 100 hours or yearly First Service (50 hours): Change the mower deck gearbox oil in all three gearboxes. Normal Service (100 hours): Change the mower deck gearbox oil in all three gearboxes. 5. Apply pipe sealant to the three magnetic drain plugs (B) and fully install into the gearbox. 6. Place the gearbox on a level surface. 7.
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MAINTENANCE Tire Pressure Wheel Lug Nut Torque Front Caster Tire Each front tire is a semi-pneumatic tire and does not require air pressure maintenance. Service Interval: First Service (100 hours)- Check and torque the eight wheel lug nuts 95 ft-lbs. (128 Nm). Drive Tires 15 psi (103 kPa) Normal Service (500 hours)- Check and torque the eight wheel lug nuts 95 ft-lbs. (128 Nm) (Figure 10). Rear Caster Tire The rear tire is a semi-pneumatic tire and does not require air pressure maintenance.
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MAINTENANCE Front and Rear Caster Bearing Adjustment Rear Casters (Figure 13) A B Service Interval: Service every 500 hours or yearly 1. Remove the dust cap (A). C 2. Tighten the locknut (B) until the spring washers are flat, back-off a 1/8-1/4 turn to properly set the preload on the caster bearings. 3 NOTE: Make sure the spring washers are installed correctly as shown below. E F 3. Install the dust cap. Front Casters (Figure 12) A C B F E D Figure 13 A. Dust Cap B. Lock Nut C.
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MAINTENANCE Brake Maintenance Parking Brake Adjustment Service Interval: After the first 100 hours, and every 500 hours after. 7. Measure the compressed spring length on both vertical spring assemblies. The spring should measure between 2.35-2.85 in. (6-7 cm) . If necessary, adjust the nut at the top of the vertical spring assembly to achieve this distance (Figure 15). Check to make sure that the brake is adjusted properly.
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MAINTENANCE 8. The linkage length is adjusted with the two nuts at the bottom of the vertical spring assembly. The linkage should measure 8.92-9.16 in. (22.7-23.3 cm) (Figure 16). 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, stop the engine, and wait for all moving parts to stop. 3.
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MAINTENANCE Adjusting the Speed Control Lever Tension Adjusting the PTO Brake Spring 1. Stop the machine and move the speed-control lever to the neutral position. 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. 2. Disengage the PTO, engage the parking brake, stop the engine, and wait for all moving parts to stop. 3.
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MAINTENANCE Hydraulic System Maintenance Servicing the Hydraulic System Hydraulic Oil Type Toro® HYPR-OIL™ 500 hydraulic oil IMPORTANT: Only use the recommended hydraulic oil. Other fluids may cause system damage. Checking the Hydraulic Oil 3 A Service Interval: Every 40 hours - Check the hydraulic oil level. B 1. Position the machine on a level surface. 2. Move the speed control lever to the neutral position to stop the machine. 3.
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MAINTENANCE Replacing the Hydraulic Filter Service Interval: After the first 100 hours - Change the hydraulic filter and reservoir hydraulic oil. Every 250 hours - Change the hydraulic filter and reservoir hydraulic oil when using Mobil® 1 oil (more often in dirty or dusty conditions). Every 500 hours - Change the hydraulic filter and reservoir hydraulic oil when using Toro® HYPR-OIL™ 500 hydraulic oil (more often in dirty or dusty conditions). 7.
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MAINTENANCE Mower Deck Maintenance Servicing the Cutting Blades Leveling the Mower Deck Maintain sharp blades throughout the cutting season, 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. NOTE: Ensure that the mower deck is leveled before matching the height-of-cut (HOC). 1. Position the machine on a flat, level surface. 2.
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MAINTENANCE Inspecting the Blades Checking for Bent Blades Service Interval: Before each use or daily 1. Move the speed control lever to the neutral position to stop the machine. 1. Lift the mower deck and secure in the service position. 2. Inspect the cutting edges. If the edges are not sharp or have nicks, remove and sharpen the blades. Refer to Sharpening the Blades. 3. Inspect the blades, especially the curved area.
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MAINTENANCE Removing the Blades 3 NOTE: Make note of the red colored blade position, from the operator’s seat, 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 Toro replacement blades. Replacement blades made by other manufacturers may result in nonconformance with safety standards. 1.
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MAINTENANCE Installing the Blades NOTE: Determine the left and right sides of the machine from the normal operating position. NOTE: Ensure the red colored blade is installed on the right hand side. 1. Install the blade driver to the new blades with the shear bolts and lock nuts. 2. Torque the shear bolts to 7.5 ft-lb. (10 Nm). NOTE: The blade driver flats must be aligned with the flats on the shaft when installing the blade on the mower deck. 3.
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MAINTENANCE Cleaning the Engine Cooling Fins and Shrouds Engine Maintenance Service Interval: Every 100 hours or yearly 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. 3. Remove the air intake screen and fan housing. 3 4. Clean the debris and grass from the engine parts with compressed air. 5. Install air intake screen and fan housing.
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MAINTENANCE 6. Slide the primary filter out of the air cleaner body (Figure 27). NOTE: Avoid knocking the filter into the side of the body. A B C Servicing the Primary Filter • If the primary filter is dirty, bent, or damaged, replace it. • Do not clean the primary filter. Servicing the Safety Filter Replace the safety filter, never clean it. NOTE: Never attempt to clean the safety filter. If the safety filter is dirty, then the primary filter is damaged. Replace both filters.
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MAINTENANCE Servicing the Engine Oil Oil Type: Detergent oil (API service class SJ or higher). Oil Capacity (Non-EFI engines): With a filter change - 1.9 qts. (1.8 L) Without filter change - 1.7 qts. (1.6 L) Oil Capacity (EFI engines): With a filter change - 2.0 qts. (1.9 L) Without filter change - 1.7 qts. (1.6 L) 3 Viscosity: See the table below (Figure 28). Fuel System Maintenance WARNING Fuel system components are under high pressure.
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MAINTENANCE AB Neutral Adjustment WARNING C Engine must be running and drive wheels must be turning so motion control adjustment can be performed. Contact with moving parts or hot surfaces may cause personal injury. Keep fingers, hands, and clothing clear of rotating components and hot surfaces. Figure 29 A. Fuel Filter B. Hose Clamp C. Fuel Line 5. Squeeze the ends of the hose clamps together and slide them away from the filter. 6. Remove the filter from the fuel lines. 7.
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MAINTENANCE 9. To obtain the neutral position, adjust the left and right pump control rod linkages that connect the steering control to the pump control arms until the wheels stop or creep slightly in reverse (Figure 30). 3 Tracking Adjustment The tracking knob is located under the seat. 10. Adjust the left pump linkage by rotating the tracking adjustment knob (A). Rotating this knob allows fine tuning adjustments so that the machine tracks straight with the drive levers in the full forward position.
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CHASSIS AND CONTROLS Table of Contents Controls Exploded View...................................................................................................................................... 4-2 Main Frame Exploded View................................................................................................................................ 4-3 Frame Fenders Exploded View...........................................................................................................................
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CHASSIS AND CONTROLS Controls Speed control friction plate hardware set-up A B C D C 4 A B Spring disc washer Orientation Figure 32 A. Pivot Nut B. Spring Disc Washer C. Friction Disc D. Speed Control Hardware Set-up 0.63 in.
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CHASSIS AND CONTROLS Main Frame Exploded View A B C Washer Orientation D 4 E Figure 33 A. Lock Nut - Tighten until washers go flat then back off 1/8 of a turn B. Belleville Washer C. Flat Washer Toro®- Z Master® 8000 Series Service Manual September 2016 D. Belt Guide E.
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CHASSIS AND CONTROLS Frame Fenders A B C Toro CARB D 4 E Figure 34 A. Control Panel B. Choke Cable C. Throttle Cable 4-4 Table of Contents D. RH Fender E.
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CHASSIS AND CONTROLS Fuel System G B A F H C D 4 E Figure 35 A. Carbon Canister B. Fuel Filter C. Fuel Shut-Off Valve (if equipped) D. Check Valve Toro®- Z Master® 8000 Series Service Manual September 2016 E. Bulkhead Tank Fitting F. White Stripe to Canister G. Red Stripe to Engine H.
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CHASSIS AND CONTROLS 42 in. Deck Support Frame B A D E 4 E F C Figure 36 A. Washer Orientation B. Nut - Tighten until washers flatten, back off 1/8-1/2 turn C. Nut - 30 ft-lbs. (40 Nm) 4-6 Table of Contents D. Locking Pin Stop E. Bearing F.
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CHASSIS AND CONTROLS 48 in. Deck Support Frame B A E 4 D B E E F C Figure 37 A. Washer Orientation B. Nut - Tighten until washers flatten, back off 1/8-1/2 turn C. Nut - 30 ft-lbs. (40 Nm) Toro®- Z Master® 8000 Series Service Manual September 2016 D. Locking Pin Shop E. Bearing F.
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CHASSIS AND CONTROLS Rear Caster Pivot Bearings 7. Install the six concave washers. Grease Type: No. 2 general purpose lithium-based molybdenum-based grease. 8. Install and tighten nut (Figure 38) (B) until the six concave washers are flat. Back off nut 1/8-1/4 turn for proper bearing preload. Disassembly (Figure 38) 1. Safely raise and support the unit so rear caster wheel is off the ground. 2. Remove the bearing cap (A). 3. Support the rear caster in current position. 4. Remove nut (B). 9.
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CHASSIS AND CONTROLS Rear Caster Wheel Bearings Assembly (Figure 39) Grease Type: No. 2 general-purpose lithium-based or molybdenum- based grease. NOTE: Thread locking adhesive has been applied to lock the spacer nuts to the axle. Remove the axle (with the other spacer nut still assembled to it) from the wheel assembly. Disassembly (Figure 39) 1. Pack the caster wheel bearings with No. 2 generalpurpose lithium-based or molybdenum- based grease. 1.
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CHASSIS AND CONTROLS NOTE: If the axle assembly has had both spacer nuts removed or loosened, apply a thread locking adhesive to one of the spacer nuts. Do not thread the spacer nut all of the way onto the end of the axle. Leave approximately 1/8 in. (3 mm) from the outer surface of the spacer nut to the end of the axle inside the nut. 7. Torque the nut to 75 in-lbs. (8.5 Nm), loosen, then re-torque to 22 in-lbs. (2.5 Nm). 3.
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CHASSIS AND CONTROLS Front Caster Pivot Bearings Assembly (Figure 41) Grease Type: No. 2 general-purpose lithium-based or molybdenum- based grease 1. Clean and inspect the pivot tube. A B C F 2. Press in new upper and lower bearing cups into the pivot tube until fully seated. 3. Pack both bearings with grease. 4. Install the lower bearing, hold in position, then install the lower grease seal until the seal face is flush with the pivot tube. 5. Install the upper bearing. E F D 6.
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CHASSIS AND CONTROLS 9. Remove the grease fitting plug and install a grease fitting (Figure 43). Front Caster Wheel Bearings Grease Type: No. 2 general-purpose lithium-based or molybdenum- based grease. A B C B A Figure 44 Figure 43 4 10. Grease the caster bearing cavity until grease purges through the upper bearing (Figure 43). Disassembly (Figure 44) 1. Safely raise the deck into the service position. 11. Install the bearing cap until fully seated. 2.
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CHASSIS AND CONTROLS Fuel Tank Service WARNING WARNING In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property. 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 yourself and others and can damage property. • Fill the fuel tank outdoors, in an open area, when the engine is cold.
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CHASSIS AND CONTROLS Fuel Tank 9. Remove the fuel hose clamp fastener. Removal 10. Disconnect the fuel supply hose and vent hoses from the fuel tank and carbon canister. 1. Allow the unit to cool. 2. Disconnect the battery terminals. 11. Remove the fuel tank routing clamp fastener. 3. Raise the hopper. 12. Under the fuel tank, remove the fuel hose from the fuel tank fitting (Figure 46). 4. Safely and completely drain or siphon fuel from the fuel tank.
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CHASSIS AND CONTROLS Installation 1. Position the fuel tank onto the fuel access door, align the mounting locations. 6. Under the fuel tank, safely install the fuel hose to fuel tank fitting (Figure 48). 2. Install the fuel tank shield. Torque the two mounting fasteners to 8 ft-lbs. (11 Nm). 3. Apply thread locker, install but do not tighten the fuel tank mounting bolt. 4. Apply thread lock to the lower bolt. Install the carbon canister and both mounting bolts. Tighten the upper bolt to 8 ft-lbs. (11 Nm).
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CHASSIS AND CONTROLS Throttle Control Assembly Installation Removal 1. Slide the throttle cable under the frame brace, through the clamp. 1. Remove the four screws securing the control panel to the RH console. 2. Remove the two lock nuts and carriage bolts securing the throttle control to the control panel. 2. Install the throttle control (Figure 50) (B) in the control panel using two carriage bolts and two lock nuts. NOTE: Mark the position of the cable in the plates. 3.
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CHASSIS AND CONTROLS Choke Cable Assembly (non-EFI units) Installation Removal 1. Slide the choke cable under the frame brace and through the clamp (Figure 52) (D). 1. Remove the four screws securing the control panel to the RH console. 2. Remove the two lock nuts and carriage bolts securing the choke assembly to the control panel. NOTE: Mark the position of the cable in the plates. 3. Remove the z-bend end of the cable from the choke plate (Figure 51) (C). 2.
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HYDRAULIC DRIVE SYSTEM Table of Contents Hydraulic Drive System Exploded View.............................................................................................................. 5-2 Pump and Wheel Motor Fitting Orientation........................................................................................................ 5-3 Pump and Tensioner/Idler Mounting...................................................................................................................
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HYDRAULIC DRIVE SYSTEM Hydraulic Drive System F F E I A G C B J F K G 5 D H Figure 53 A. RH Drive Pump B. RH Wheel Motor C. LH Drive Pump D. LH Wheel Motor E. Suction Hoses F. Case Drain Hoses 5-2 Table of Contents G. High Pressure Hoses H. Lug Nuts - 95 ft-lbs. (128 Nm) I. Pump to Frame Fasteners - 30 ft-lbs. (40 Nm) J. Hydraulic Oil Filter K. Wheel Motor to Frame Fasteners - 75 ft-lbs.
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HYDRAULIC DRIVE SYSTEM Pump and Wheel Motor Fitting Orientation A C D B 5 Figure 54 A. LH Wheel Motor Fitting B. LH Pump Fitting C. RH Wheel Motor Fitting D.
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HYDRAULIC DRIVE SYSTEM Pump and Tensioner/Idler Mount G F A B F C 5 E E D Figure 55 A. Pump to Frame Fasteners - 30 ft-lbs. (40 Nm) B. RH Drive Pump C. LH Drive Pump D. Drive Belt Tension Spring / Idler Spring 5-4 Table of Contents E. Pump Pulley Set Screws (two per pulley) F. Tensioner / Short Idler Arm Asm. G. Mounting Fasteners - 30 ft-lbs.
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HYDRAULIC DRIVE SYSTEM General Information IMPORTANT: Detailed Hydro-Gear® drive pump information is in the P Series pump service manual, which is located in the Toro Gateway Parts and Service Center and on the Hydro-Gear® website. Detailed Hydro-Gear® wheel motor information is in the HGM-H motor service manual, which is located in the Toro Gateway Parts and Service Center and on the Hydro-Gear® website. Fluid Type Toro® HYPR-OIL™ 500 Total System Capacity Pumps Wheel Motors 192 fl-oz. (6 qts.
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HYDRAULIC DRIVE SYSTEM Drive Pump Testing GPM Flow Droop Specifications Special Tools (Figure 57 and 58) Tool Part Number Flow Test Kit 116-1373 Flow Test Fitting Kit 120-3281 Hydro-Gear 12cc PK Type Pump Flow Test Engine RPM 3600 RPM Flow Test Pressure 300 PSI (21 bar) and 1100 PSI (76 bar) Maximum GPM Droop 2.0 GPM (7.6 l/ min) The acceptable MAXIMUM GPM flow droop is 2.0 gpm (7.6 l/min). If the flow droop is greater than 2.0 gpm (7.
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HYDRAULIC DRIVE SYSTEM Drive System Bleeding Procedure Due to the affect air has on efficiency in hydrostatic drive applications, it is critical that air is purged from the system. These purge procedures should be implemented anytime a hydrostatic system has been opened for maintenance or any additional oil has been added to the system. Air creates inefficiency due to compression and expansion rates that are higher than that of oil.
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HYDRAULIC DRIVE SYSTEM Drive System Belt Service Drive Belt Removal Drive System Belt Routing 1. Disconnect the battery cables and remove the LH belt guard on the left side of the machine. Open the fuel access door. NOTE: For easier drive belt access, the air cleaner assembly can be removed. Be sure to plug the air intake so debris does not enter the engine. 2. Remove the PTO belt tensioner spring (Figure 62). 5 Figure 60 Figure 62 3. Remove the PTO belts from the crankshaft drive pulley. 4.
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HYDRAULIC DRIVE SYSTEM 5. Remove the drive belt off the LH drive pump pulley (Figure 64) (B). 6. Remove belt off the stationary idler pulley (C), then the RH drive pump pulley. Drive Belt Installation 1. Install the pump drive belt around the crankshaft pulley. 2. Route the belt around the tensioner pulley, RH pump pulley, stationary idler and LH pump pulley (Figure 65). C B Pump Drive Belt View From Rear of Unit LH Pump Idler RH Pump Idler / Tensioner Figure 64 7.
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HYDRAULIC DRIVE SYSTEM Drive Belt Tensioner/Idler Service Installation Removal 1. Install the tensioner assembly (C) onto the frame and torque the mounting fastener to 30 ft-lbs (40 Nm). 1. Replace if wear or damage is evident. NOTE: The drive system belt does not need to be completely removed to service the idler and tensioner. Simply remove the drive belt tensioner spring, slip the belt off the idler, tensioner and pump pulleys to service the tensioner/idler. 2.
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HYDRAULIC DRIVE SYSTEM Drive Belt Tensioner Service Installation Removal Grease Type: No. 2 general purpose lithium-based or molybdenum- based grease. 1. Remove the tensioner arm assembly. 1. Install the upper bearing retaining ring (B). 2. Remove and discard the two outer grease seals (Figure 67) (A). 2. Install the upper o-ring (D). 3. Remove the two retaining rings (B). 3. Press one bearing into the arm hub (E) until it bottoms on the retaining ring (B).
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HYDRAULIC DRIVE SYSTEM Pump Drive Belt Alignment Drive belt pulley alignment is necessary when: 4. Use a rigid straight edge to align the RH drive pump pulley face to the crankshaft pulley rear surface within 1/32–1/16 in. (0.8–1.5 mm). • The engine mounting bolts have been loosened or removed. 5. Slide the pump pulley on the pump shafts to get proper alignment. • The drive pump mounting or pulleys have been loosened or removed. 6.
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HYDRAULIC DRIVE SYSTEM Drive Pump Service 9. Remove the control linkage fastener. IMPORTANT: Detailed Hydro-Gear® drive pump information is in the P Series pump service manual, which is located in the Toro Gateway Parts and Service Center and on the Hydro-Gear website. 10. Remove the suction hose from both pumps. Removal 11. Remove the case drain hose. 12. Remove the pump to wheel motor hoses. 13. Remove the pump to frame mounting bolts and nuts (two fasteners per pump). 1. Allow unit to cool. 3.
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HYDRAULIC DRIVE SYSTEM Installation NOTE: Do not reuse any drive system o-rings. Inspect all fittings and hoses carefully and replace if wear or damage is evident. 1. Hold the pump in its frame mounting location. 2. Slide the pump pulley onto the pump shaft. 3. Install the pump to frame mounting fasteners (two fasteners per pump) and torque to 30 ft-lbs. (40 Nm). 4. Install the pump to wheel motor hoses. 5. Install the suction hose. 6. Install the case drain hose. 7.
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HYDRAULIC DRIVE SYSTEM Wheel Motor Service IMPORTANT: The Dual Hydro-Gear® HGM-H Series wheel motors must not be run without fluid. Internal wheel motor damage will occur if the wheel motors are run without fluid. IMPORTANT: Detailed Hydro-Gear® wheel motor information is in the HGM-H motor service manual, which is located in the Toro Gateway Parts and Service Center and on the Hydro-Gear® website. 4. Mark the location then remove the two pump to wheel motor hoses (Figure 74) (A) from the wheel motor.
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HYDRAULIC DRIVE SYSTEM Installation 1. Place wheel motor onto frame mounting location. 13. Fill hydraulic drive system reservoir with Toro® HYPR-OIL™ 500 and completely bleed the air out of the drive system. 2. Install but do not tighten the four mounting bolts/ nuts. Fluid Type 3. In a cross pattern, torque the four wheel motor fasteners mounted to the frame (C) to 75 ft-lbs. (101 Nm). Pumps 4. Install the case drain hose. Total System Capacity Wheel Motors Toro® HYPR-OIL™ 500 192 fl-oz. (6 qts.
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ENGINE Table of Contents Engine Mounting Exploded View......................................................................................................................... 6-2 Engine Removal.................................................................................................................................................. 6-3 Engine Installation...............................................................................................................................................
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ENGINE Engine Mounting E F B A 6 D C Figure 75 A. Crankshaft Bolt (Apply thread lock 45 ft-lbs. (61 Nm)) B. Spring Washers C. Engine Mount Bolts (30 ft-lbs. (40 Nm)) D. Concave Washers 6-2 Table of Contents E. Muffler and Heat Shield Bolts (30 ft-lbs. (40 Nm)) F. Concave Washers G. Muffler Exhaust Manifold Bolts (18 ft-lbs.
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ENGINE Removal 5. Remove the drive belt tensioner spring. NOTE: Additional engine service information, see the service information provided by the engine manufacturer. 6. Remove the PTO brake band pin and clip (Figure 77) (A). 1. Disconnect the battery terminals. 2. Remove the battery from the frame. 3. Remove two nuts and bolts that attach the LH side belt guard to the frame on the left side of the unit. A 4.
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ENGINE 10. On the right side of the unit, remove the two nuts that secure the fuel access door to the frame. Swing the door outward. EFI Unit (Figure 80) 11. Slip all three belts off of the engine crankshaft pulley. 12. Remove the harness bolt that secures the chassis harness to the engine (Figure 79). Figure 80 Carburetor Unit (Figure 81) Figure 79 13. Safely disconnect the fuel supply and vent hose from the engine. Properly dispose of any fuel in accordance with local laws. 6 14.
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ENGINE 15. Remove the hose bracket fastener and route hose away from the engine (Figure 82). Installation NOTE: The engine pulley, jackshaft pulley, and blower pulley must be aligned to prevent belt issues. 1. Verify the blower housing is fully installed and all fasteners are tight. 2. Lower the engine into the chassis and align the four engine to frame mounting holes. 3. Install, but do not tighten the four engine to frame mounting bolts, nuts and concave washers.
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ENGINE Blower Pulley to Crank Pulley Alignment (Figure 83) B 6. Torque the four jackshaft mounting bolts to the 30 ft-lbs. (40 Nm). 7. Torque the four engine mounting fasteners to the frame 30 ft-lbs. (40 Nm). 8. Properly route the PTO and drive belts (Figure 85). A Figure 83 A. Blower Pulley B. Crankshaft Pulley Blower Pulley to Jackshaft Pulley Alignment (Figure 84) Figure 85 6 9. Install the PTO brake band and clip. 10. Install the PTO and drive belt tensioner springs. Figure 84 A.
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ENGINE 11. Check and adjust all belt guides to specification. All belts must be checked with the PTO handle engaged (Figure 86). 16. Install and torque the two shield bolts and concave washers 30 ft-lbs. (40 Nm). NOTE: Make sure the washers are installed concave side towards the engine. C A D B 17. Install but do not tighten the four muffler manifold nuts. 18. Install and torque the two muffler mounting bolts and concave washers 30 ft-lbs. (40 Nm).
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ENGINE EFI Unit (Figure 88) 25. Swing the fuel access door inward. Install and torque the two nuts to 17 ft-lbs. (23 Nm). 26. Install the three wires at the starter, the engine block ground wire, the oil pressure sensor wire, and the screw that secures the chassis harness to the engine. 27. Install and connect the battery. 28. Verify engine oil is at the proper level. 29. Safely start engine and verify proper unit function. Figure 88 Carburetor Unit (Figure 89) 6 Figure 89 23.
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MOWER DECK AND DECK DRIVE Table of Contents 42 in. Deck Exploded View................................................................................................................................. 7-2 42 in. Deck Carrier Frame Exploded View.......................................................................................................... 7-3 PTO Drive Exploded View..................................................................................................................................
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MOWER DECK AND DECK DRIVE 42 in. Deck G E F H A 7 D C B Figure 90 A. RH Blade B. LH Blade C. Blade Bolt 100 ft-lbs. (135 Nm) D. Torque 7.5 ft-lbs. (10 Nm) 7-2 Table of Contents E. Gearbox to Deck Bolts 30 ft-lbs. (40 Nm) F. Drive Shaft Bolt 30 ft-lbs. (40 Nm) G. Torque 17 ft-lbs. (23 Nm) H. Torque 75 ft-lbs.
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MOWER DECK AND DECK DRIVE 42 in. Deck Carrier Frame A B D E F 7 C Figure 91 A. Washer Orientation B. Nut - Tighten until washers flatten, back off 1/8-1/2 turn C. Nut - 30 ft-lbs. (40 Nm) Toro®- Z Master® 8000 Series Service Manual September 2016 D. Locking Pin Stop E. Bearing F.
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MOWER DECK AND DECK DRIVE PTO Deck B A C G D F E Figure 92 7 A. Jackshaft Pulley Bolt (Apply Thread Lock) B. Concave Washers (concave side toward pulley) C. Jackshaft Asm. D. PTO Brake Spring 7-4 Table of Contents E. PTO Tensioner Spring F. PTO Handle G.
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MOWER DECK AND DECK DRIVE Mower Gearbox A H K B E F C A I D G F H G J 7 Figure 93 A. End Housing B. RH Connector Tube C. LH connector Tube D. Center Housing E. Pinion Asm. F. Output Shaft Asm. -Gearbox Fluid: Mobile® SCH (Synthetic) 75W-90 Gear Lube -Gearbox Capacity: Each Gearbox Section Holds 12 oz. (355 ml) Toro®- Z Master® 8000 Series Service Manual September 2016 G. Output Cap Asm. H. O-Rings I. Oil Seal J. Seal Protector K.
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MOWER DECK AND DECK DRIVE Raising the Mower Deck into Service Position 3. Using deck-lift handle, lift deck up and latch in an “up” position (Figure 95) (latch is located at the front center of the seat). 1. Stop engine, wait for all moving parts to stop and remove key. Engage the parking brake. E D WARNING Incorrectly raising or lowering a mower deck can be dangerous. A dropped mower deck can result in a serious injury or property damage.
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MOWER DECK AND DECK DRIVE Lowering the Mower Deck to the Operating Position 1. Unlatch the mower deck from the raised position, slowly lower the mower deck to the ground and lock the deck locking pins on each side. 2. Push the deck locking pins inward and rotate them forward to securely lock the mower deck in the lowered position. WARNING Operating mower without locking pins securely latched can result in the mower deck folding up unexpectedly.
PAGE 85
MOWER DECK AND DECK DRIVE Removal 1. Disconnect the battery terminals. 9. Remove the inner belt guide bolt (A) and loosen the outer belt guide bolt (B). Slide belt guard away from belts (Figure 97). 2. Remove the two nuts and bolts that attach the belt guard to the frame on the left side of the machine. A 3. Remove the PTO belt tensioner spring using spring removal tool P/N 92-5771. 4. Remove the PTO brake band pin and clip. B 5. Lift the PTO engagement handle into the engaged position. 6.
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MOWER DECK AND DECK DRIVE 11. Remove both belts from the deck drive jackshaft pulley. 12. Remove the belts from the tensioner/idler pulley on the left side of the unit. Installation 1. Install the two new belts onto the crankshaft pulley from beneath the unit (Figure 99). 13. Route belts above the lower belt guide. 14. Pull the belt slack to the left side of the unit. 15. Remove the belts from the engine pulley. 16. Remove the belts from the unit. Figure 99 2.
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MOWER DECK AND DECK DRIVE 3. Route the belts around the jackshaft drive pulley (Figure 101). 6. Adjust all belt guides to specification (Figure 103). C A D B F E Figure 103 Figure 101 4. Route the belts around the blower drive pulley. NOTE: Make sure the belts are routed through the “U” belt guide. 5. Verify the belt to pulley and belt to guide routing (Figure 102). A. Idler Belt Guide–1/8 in. (3 mm) gap from belt, torque idler pulley nut/bolt to 30 ft-lbs. (40 Nm). B. Upper Belt Guide – 7/16 in.
PAGE 88
MOWER DECK AND DECK DRIVE PTO Belt Alignment IMPORTANT: After properly aligning the PTO belt pulleys as shown below, the drive system belt alignment needs to be inspected. Blower Pulley to Crank Pulley Alignment (Figure 104) B NOTE: The engine pulley, jackshaft pulley, and blower pulley must be aligned to prevent belt issues. NOTE: The frame mounting points for the engine and jackshaft are slotted to allow proper pulley alignment. A 1.
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MOWER DECK AND DECK DRIVE Mower Deck Drive Shaft Service 9. Tilt seat forward to access the drive shaft quick coupler area. Removal 1. Remove the three bolts and washers that secure the gearbox cover (A) to the gearbox. 2. Remove the two pins and clips that secure the rubber PTO guard (B) to the frame. 10. Release the quick coupler by pulling the locking collar towards the front of the unit. 11. Pull the drive shaft forward and off the jackshaft splines. 12. Remove the drive shaft from the unit. 3.
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MOWER DECK AND DECK DRIVE Drive Shaft Alignment Installation The mower deck drive shaft slip joint is equipped with a master spline and can only be assembled one way. The photo below shows u-joint and grease fitting alignment (Figure 107). NOTE: Apply grease to jackshaft and gearbox spines before installing drive shaft. 1. Tilt seat forward to access the jackshaft. 2. Position the drive shaft quick coupler onto the jackshaft splines. 3.
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MOWER DECK AND DECK DRIVE 6. Install and torque the drive shaft pinch bolt and nut to 30 ft-lbs. (40 Nm) (Figure 109). Jackshaft Service Removal NOTE: Complete PTO belt removal is not required to replace the jackshaft assembly (Figure 110). B D A C G Figure 109 E F 7. Apply Loctite® 243 to the drive shaft set screw and torque to 20 ft-lbs. (27 Nm). 8. Install the gearbox cover assembly onto the unit. 9.
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MOWER DECK AND DECK DRIVE 6. Remove the PTO belt tensioner spring (Figure 111) (A) using spring removal tool P/N 92-5771. 7. Remove the PTO brake band pin and clip (B). Installation NOTE: The engine pulley, jackshaft pulley and blower pulley must be aligned to prevent belt issues. 1. Install the jackshaft assembly from underneath the unit frame. 2. Align the jackshaft and frame mounting holes and support the jackshaft assembly in position. B A Figure 111 8. Lift the PTO handle into the engaged position.
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MOWER DECK AND DECK DRIVE Blower Pulley to Crank Pulley Alignment (Figure 112) 6. Torque the four jackshaft to frame mounting bolts to 30 ft-lbs. (40 Nm). 7. Torque the four engine to frame mounting bolts to 30 ft-lbs. (40 Nm). B 8. Recheck the pulley alignment and adjust if necessary. 9. Properly route the PTO belts around all pulleys (Figure 114). A Figure 112 A. Blower Drive Pulley B. Engine Crankshaft Pulley Blower Pulley to Jackshaft Pulley Alignment (Figure 113) B Figure 114 A 7 10.
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MOWER DECK AND DECK DRIVE 12. Swing the fuel access door inward. Install and torque the two nuts to 17 ft-lbs. (23 Nm). 13. Lower the PTO handle into the disengaged position. Bearing Removal 1. Remove the jackshaft assembly from the unit frame. 2. Remove the pulley bolt (A) and three washers. 14. Swing the brake band downward and install the PTO brake band pin and clip. 3. Tap the pulley (B) off the shaft (C) with a rubber mallet. 15. Install the PTO belt tensioner spring. 4.
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MOWER DECK AND DECK DRIVE Bearing Installation Mower Deck 1. Press bearing (G) into housing until it bottoms in the bore. Blade Service NOTE: Make sure to press equally on the inner and outer races during installation. 2. Install the snap ring (F) into the groove behind the bearing (G). 3. Install bearing spacer (H). Fill 80% of the cavity between bearing spacer (H) and the jackshaft bearing housing with high temp, extended life, lithium based grease. 4. Support the inner and outer race of bearing (G).
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MOWER DECK AND DECK DRIVE 3. Remove the pins and washers at the top of the deck lift assist spring on each side of the unit (Figure 117). 6. Remove the two push arm pins (Figure 118) (A) on both sides of the machine. A B A C B Figure 117 A. Spring Anchor Pin Under Console B. Pin and Washer C. Upper Spring Mount 4. Remove the upper spring mount from the spring anchor. Repeat for other side of unit. Figure 118 A. Push Arm Pin B. Push Arm 7.
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MOWER DECK AND DECK DRIVE 8. Raise the seat and disconnect the drive shaft using the quick coupler at the jackshaft. 9. Pull the mower deck forward to remove it from the machine. Installation IMPORTANT: Do not transport the machine without an approved Toro front mount attachment. 1. Stop the engine, wait for all moving parts to stop and remove the key. Engage the parking brake. 2.
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MOWER DECK AND DECK DRIVE Locking Pin Stop Adjustment Mower Gearbox Service 1. Lower and lock the deck into mowing position. Removal 2. Loosen the lock nut (Figure 120) (A) and turn the stop screw (B) clockwise until the locking pin is tight and cannot be rotated by hand. 1. Raise the deck into service position. B A 2. Remove the two blade bolts and washers then remove blades from gearbox output shafts. NOTE: In the operator position, the RH blade is RED and the LH blade is BLACK. 3.
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MOWER DECK AND DECK DRIVE 10. Slide the driveshaft rearward, off the gearbox input shaft. 11. Inspect gearbox input shaft drive key, replace if necessary. 12. Safely lift and support front of deck so gearbox mounting nuts (Figure 122) (E) are accessible. Installation 1. Position the gearbox onto the deck and align the four mounting points. 2. Safely lift front of deck so gearbox mounting nuts are accessible. 13. Remove the four gearbox to deck mounting bolts (F) and nuts (E). 3.
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MOWER DECK AND DECK DRIVE 10. Install and tighten the two washers and nuts that secure the rubber PTO guard bracket to the deck. B A 11. Install the two pins and clips that secure the rubber PTO guard to the frame. 12. Raise the deck into service position. NOTE: In the operator position,the RH blade is RED and the LH blade is BLACK. C 13. Install the two blades, washers and blade bolts and torque the blade bolts to 100 ft- lbs. (135 Nm) (Figure 124). D Figure 125 F A. Gearbox Cover Asm. B.
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MOWER DECK AND DECK DRIVE Mower Gearbox Internal Service A H IMPORTANT: Do not disassemble the following gearbox components (Figure 127): K B E F (2) Connector Tube Assemblies (B and C) (2) Output Shaft Assembly (F) (1) Input Pinion Assembly (E) C A I • If a problem exists with any of the above components, the complete subassembly must be replaced. G D F • All gearbox o-rings and seals are available as replacement parts.
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MOWER DECK AND DECK DRIVE Gearbox 5. Remove the housing from the connector tube. Remove and discard the o-ring (Figure 130) (A). Disassembly 1. Remove the gearbox asm. from the mower deck as shown in this chapter. A 2. Remove the drain/fill plugs and magnetic drain plugs. Completely drain the three individual gearboxes and dispose of the gear lube properly. 3. Use a paint pen or scratch awl to mark location and orientation of the RH and LH housings (Figure 128) (A) and output caps (B).
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MOWER DECK AND DECK DRIVE 8. Press the output shaft assembly (A) out of the output cap (B). 9. Inspect the output shaft bearings and gear. If excessive wear or damage is evident, replace the output shaft assembly. 12. Extract the output cap oil seal, clean the cap, and install a new seal until it is fully seated in the cap bore (Figure 133). 10. Inspect the output cap bearing race. If excessive wear or damage is evident, replace the output cap assembly. 11. Inspect the seal guard (Figure 132) (C).
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MOWER DECK AND DECK DRIVE 15. Remove the eight bolts that attach the connector tubes to the center housing. Discard the o-rings (Figure 135). A 17. Remove the four bolts that secure the input pinion assembly to the center housing. Discard the o-ring (Figure 137). A Figure 135 16. Inspect all of the gears, bearings and the housings for excessive wear or damage. Replace the component assemblies if necessary (Figure 136). Figure 137 18. Inspect the center housing, gear, bearings and seals.
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MOWER DECK AND DECK DRIVE 21. When replacing seals, apply Mobile® HTS grease to the sealing lips of A and B. Install a new input pinion oil seal until seal face is flush with the housing. Install a new v-ring. Gearbox Assembly NOTE: Do not re-use the gearbox seals or o-rings. Torque Specifications: ALL Gearbox Case Bolts – 55 ft-lbs. (74 Nm) Gearbox to Deck Bolts/Nuts (4) – 30 ft-lbs. (40 Nm) 1. Thoroughly inspect and clean all gearbox components that are being reused. 2. Install the input pinion asm.
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MOWER DECK AND DECK DRIVE 8. Secure the gear case on a level surface, output shafts down. A H K B E 9. Install the three magnetic drain plugs. 10. Fill each of the three gearboxes with approximately 12 oz. (355 ml) of Mobil® SHC (synthetic) 75W-90 Gear Lube. The fluid must be filled until level with the fill plug threads (Figure 140). F C A I G D F H G Figure 141 Figure 140 11. Install the check/fill plugs. 12. Install the gearbox onto the deck. 13. Safely verify proper PTO function. J A.
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HOPPER AND BLOWER FAN Table of Contents Hopper Mounting Exploded View......................................................................................................................... 8-2 Hopper Exploded View......................................................................................................................................... 8-3 Hopper Door Exploded View................................................................................................................................
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HOPPER AND BLOWER FAN Hopper Mounting G E F D B C A Figure 142 8 A. Hopper Frame B. Shoulder Pivot Bolt 30 ft-lbs. (40 Nm) C. Deflector D. Damper 8-2 Table of Contents E. Hooper Full Switch F. Hopper Wiper Motor G. Hopper Door Asm.
PAGE 109
HOPPER AND BLOWER FAN Hopper G B C E D F A Figure 143 A. Hopper Screen B. Hopper Full Buzzer C. Hopper Harness D. Hopper Reinforcement E. Door Brace F. Guard Plate G.
PAGE 110
HOPPER AND BLOWER FAN Hopper Door E C D B A Figure 144 A. Damper B. Door Support C. Door Pivot D. Door Support Bolts 11 ft-lbs. (14.5 Nm) E.
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Blower Fan Mounting HOPPER AND BLOWER FAN E Spring Disc washer Orientation F G A C G B D F Figure 145 A. Pulley Bolt 55 ft-lbs. (use thread lock) B. Concave Washers (concave side toward pulley) C. Standard Washer D. Belt Guide Blower Fan Torque Sequence: E. Side Mount Bolt 30 ft-lbs. (40 Nm) F. Lower Mounting Bolt 75 ft-lbs. (104 Nm) G. Front Mounting Bolt 75 ft-lbs.
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HOPPER AND BLOWER FAN Blower Fan-Internal Spring disc washer orientation K E Spacer Orientation C B A D F G H I J Figure 146 8 A. Pulley Bolt (use thread lock) B. Concave Washers C. Standard Washer D. Retaining Ring E. Bearing F. Bearing Spacer 8-6 Table of Contents G. Blower Spacer H. Key I. Impeller J. Blower Cover Nuts 17 ft-lbs. (23 Nm) K. Discharge Chute Fasteners 17 ft-lbs.
PAGE 113
HOPPER AND BLOWER FAN Hopper Service Installation Removal 1. Safely place the hopper asm. onto the frame and align the rear pivot points. 1. Disconnect the battery terminals. 2. Lift the hopper up into the dump position and securely support it. 3. Disconnect the hopper wire harness connection. 4. Remove upper damper nut. Rotate damper downward (Figure 147). Figure 147 5. Lower the hopper downward into the mow position. 6. Remove the four pivot fasteners at the rear of the frame.
PAGE 114
HOPPER AND BLOWER FAN Hopper Full Switch Service Installation NOTE: Hopper full switch and motor testing is detailed in the Electrical Chapter. 1. Position the switch back onto the mounting bracket. Removal 1. Disconnect the battery terminals. 2. Tighten the two mounting fasteners (D). Install the nut and bolt (C) that secures the switch wiring clamp to the chute and torque to 10 ft-lbs. (14 Nm). IMPORTANT: Do not drop mounting hardware down the discharge tube and into the blower. 2.
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HOPPER AND BLOWER FAN Hopper Full Switch Motor Service Removal 7. Remove the fastener (Figure 151) (A) that secures the wire clamp to the switch and motor plate. 1. Disconnect the battery terminals. 2. Open the hopper door. 3. Cut and remove cable tie (Figure 150) (A). A A Figure 151 8. Remove the nut and spring washer (C) that secures the switch bracket to the shaft. Remove the switch and switch bracket from the motor assembly. Figure 150 4.
PAGE 116
HOPPER AND BLOWER FAN 9. Remove the dust cap (Figure 152) (A), the nut (B), the washer (C) and the rubber washer (D) from the shaft. 10. Remove the two fasteners (E) that secure switch plate to the motor assembly. A Installation 1. Install the switch plate onto the motor asm., torque the two fasteners (Figure 154) (A) to 10 ft-lbs. (14 Nm). 2. Install the rubber washer, washer, nut and the dust cap onto the shaft. Torque the shaft nut (B) to 15 ft-lbs (20 Nm). B C D E B A Figure 152 11.
PAGE 117
HOPPER AND BLOWER FAN 5. Install the asm. into the hopper diffuser mounting location. 6. Install the seven nuts and bolts that attach the switch and motor plate to the hopper brackets. Torque all fasteners to 10 ft-lbs. (14 Nm). IMPORTANT: Do not drop and mounting hardware down the discharge tube and into the blower. 7. Connect the switch and motor harness connections. Route and tuck the wiring under the mounting bracket, and use a new cable tie to secure it. NOTE: Make sure harness is routed so switch asm.
PAGE 118
HOPPER AND BLOWER FAN 10. Remove the PTO brake band pin and clip (Figure 157) (A). A Figure 157 11. Rotate the brake band fully upward. 12. On the right side of the unit, remove the two nuts that secure the fuel access door to the frame. Swing the door outward. Figure 158 17. Remove the bolt and nut (A) that secure the bottom of the blower housing to the frame. 18. Remove the bolt and washer (Figure 159) (B) that secure the right side of the blower to the frame. 13.
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HOPPER AND BLOWER FAN Installation 1. Safely lift and support the unit. 7. Align the rear pulley surfaces of the engine pulley, jackshaft pulley, and the blower pulley using a straight edge as shown below: 2. Lift the blower asm. up into the chassis and align the mounting points. • Use the rear surface of the blower pulley as a fixed base line. 3. Install but do not tighten the lower mounting bolt and nut (Figure 160) (A).
PAGE 120
HOPPER AND BLOWER FAN Blower Pulley to Jackshaft Pulley Alignment (Figure 162) B A C B A Figure 163 11. Lower the unit. Figure 162 A. Blower Pulley B. Jackshaft Pulley 8. If loosened, torque the four jackshaft to frame mounting bolts to 30 ft-lbs. (40 Nm). 9. If loosened, torque the four engine to frame mounting fasteners to 30 ft-lbs. (40 Nm). 10. Torque all three blower to frame fasteners in sequence to specification: 12.
PAGE 121
HOPPER AND BLOWER FAN 19. Install the fastener (A) retaining the plenum guide (B) to the frame (Figure 164). NOTE: Make sure the plenum guide slips under the housing retaining clip. Blower Fan Disassembly 1. Remove the blower fan asm. from the frame. 2. Remove the pulley bolt (Figure 165) (A), concave washers (B) and the standard washer (C). 3. Remove the pulley from the blower shaft using a 2-3 Jaw Pulley Puller. NOTE: Do not damage the belt sheave surfaces. 4.
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HOPPER AND BLOWER FAN Blower Fan Reassembly 1. Clean and inspect all blower fan components and replace if excessive wear or damage is evident. 2. Clean the bearing hub bore and install the bearings, bearing spacer and snap rings. NOTE: Make sure bearing spacer is centered in the bore. 3. Install the blower spacer (H). 4. Apply anti-seize to the impeller shaft and install the impeller into the housing. 5. Install the pulley onto the impeller shaft.
PAGE 123
ELECTRICAL Table of Contents Fuses.................................................................................................................................................................. 9-2 Seat Switch......................................................................................................................................................... 9-4 Ignition Switch...............................................................................................................................
PAGE 124
ELECTRICAL Fuses How it Works Location The fuses protect the electrical system from electrical surges. The three chassis fuses are located under the operator’s seat, on the right side of the unit (Figure 166). Testing Use a multi-meter, set to Ohm or Continuity setting, check the continuity between the fuse blades. If the fuse is OPEN, replace it and test the circuit. The fuses used in this application can also be visually inspected.
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ELECTRICAL Fuse Circuits Ignition Switch Optional Accesories Plug View From Back of Switch 15A Fuse F3 Battery Engine Charging System F1 25A Fuse F2 25A Fuse Figure 168 9 Toro®- Z Master® 8000 Series Service Manual September 2016 Table of Contents 9-3
PAGE 126
ELECTRICAL Seat Switch How it Works Purpose When the seat is vacated, the switch is open and there should be NO continuity between the two terminals. When the seat is occupied, the switch closes and there should be continuity between the two terminals. The seat switch is a part of the safety interlock system.
PAGE 127
ELECTRICAL Seat Switch Circuit View From Back of Switch Ignition Switch Battery Seat Switch 25A Fuse Seat Switch Closed With Operator in Seat Figure 170 9 Toro®- Z Master® 8000 Series Service Manual September 2016 Table of Contents 9-5
PAGE 128
ELECTRICAL Ignition Switch Ignition Switch Wiring Connections Purpose B- Battery voltage In S- Starting Circuit I- PTO Switch, Safety Interlock Switches, Fuel Solenoid A- Seat Switch, Safety Interlock Switches R- Regulator, Charging Circuit The ignition switch makes the proper connections for the starter, accessories, and safety circuits. Location The ignition switch is located on the control panel, on the right fender (Figure 171). Testing 1. Disconnect the switch from the wiring harness. 2.
PAGE 129
ELECTRICAL Ignition Switch Circuit Ignition Switch View From Back of Switch ECU (EFI Only) Accessory Plug (B+) Stator / Charging System Battery Hopper Switch Neutral Switch Parking Brake Switch Seat Switch PTO Switch ECM / Hour Meter Figure 173 9 Toro®- Z Master® 8000 Series Service Manual September 2016 Table of Contents 9-7
PAGE 130
ELECTRICAL Parking Brake Switch How it Works Purpose Ignition switch ON, and the parking brake switch closed (brake ON), the switch supplies battery voltage to pin 11 of the ECM/hourmeter. The parking brake switch is part of the safety interlock system. The parking brake switch circuit can: • Prevent the engine from cranking if parking brake is not engaged Testing 1. Tilt the seat forward into the service position.
PAGE 131
ELECTRICAL Parking Brake Circuit View From Back of Switch Ignition Switch Battery Parking Brake Switch 25A Fuse Parking Brake Switch Closed With Brake ON Figure 175 9 Toro®- Z Master® 8000 Series Service Manual September 2016 Table of Contents 9-9
PAGE 132
ELECTRICAL Neutral Switch Testing Purpose 1. Tilt the seat forward into the service position. The Neutral Switch is part of the safety interlock system. The Neutral Switch circuit can: 2. Disconnect the harness connection from the Neutral Switch. • Prevent the engine from cranking if speed control lever is not in the neutral position 3.
PAGE 133
ELECTRICAL Neutral Switch Circuit View From Back of Switch Ignition Switch Battery Neutral Switch 25A Fuse Neutral Switch Closed When Control Levers in Neutral Figure 177 9 Toro®- Z Master® 8000 Series Service Manual September 2016 Table of Contents 9-11
PAGE 134
ELECTRICAL PTO Switch How It Works Purpose PTO OFF The PTO switch is part of the safety interlock system. The PTO switch also supplies battery voltage to the hopper fill switch and hopper switch motor. The PTO switch circuit can: Ignition switch ON, and the PTO OFF (switch plunger IN), battery voltage is sent from to the PTO switch to pin 3 of the ECM/hourmeter (Figure 179).
PAGE 135
ELECTRICAL Testing 1. Disconnect the harness connection from PTO switch. 2. Use a multi-meter, set to the Ohm or Continuity setting, check the continuity between the two A terminals. Plunger OUT – The two (Figure 181) A terminals should NOT have continuity, OPEN. Plunger IN – The two A terminals should have continuity, CLOSED. 3. Use a multi-meter, set to the Ohm or Continuity setting, check the continuity between the two B terminals.
PAGE 136
ELECTRICAL PTO Switch Circuit Ignition Switch View From Back of Switch PTO Switch ON (Plunger OUT) Battery 25A Fuse Hopper Fill Switch (Empty) A A B B Wiper Motor Buzzer Figure 182 9 9-14 Table of Contents Toro®- Z Master® 8000 Series Service Manual September 2016
PAGE 137
ELECTRICAL Safety Switch Adjustment Switch plunger depth adjustment is required for proper function and wear of the: • Parking Brake Switch • Neutral Switch • PTO Switch • Hopper Tilt Switch 1. Loosen the two switch mounting screws. 2. Slide the switch to adjust the plunger compressed depth to 3/16-1/4 in. (4.8-6.4mm) (Figure 183). 3. Tighten the two switch mounting screws and recheck measurement. Switch Depressed Depth 3/16 to 1/4” (4.8 to 6.
PAGE 138
ELECTRICAL Oil Temperature Switch, LED Lamp, and Circuit NOTE: Please contact the engine manufacturer for switch testing procedures. Purpose The oil temperature switch is used to ground a buzzer and illuminate the LED lamp circuit to notify the operator that the oil temperature is out of specification. How It Works Ignition switch ON and the oil temperature out of specification, the oil temperature switch will close which will illuminate the LED lamp on the control panel and sound a warning buzzer.
PAGE 139
ELECTRICAL Oil Temperature Circuit View From Back of Switch Ignition Switch Battery Buzzer 25A Fuse Oil Temperature Switch LED Lamp Figure 187 9 Toro®- Z Master® 8000 Series Service Manual September 2016 Table of Contents 9-17
PAGE 140
ELECTRICAL Hopper Tilt Switch How It Works Purpose The key ON and the hopper in mowing/transport position, the switch is closed which sends battery voltage from the key switch to pin 5 of the ECM/ hourmeter – the LED on the ECM will NOT be illuminated. The hopper tilt switch is used to illuminate the LED on the ECM/hourmeter to signal the operator that the hopper is tilted upward.
PAGE 141
ELECTRICAL Hopper Tilt Switch Circuit View From Back of Switch Ignition Switch Hopper LED Illuminates When Hopper UP (Switch OPENS) Battery Hopper Tilt Switch 25A Fuse Tilt Switch CLOSED With Hopper DOWN Figure 190 9 Toro®- Z Master® 8000 Series Service Manual September 2016 Table of Contents 9-19
PAGE 142
ELECTRICAL Hopper Full Switch Testing Purpose 1. Disconnect the harness connection from the hopper tilt switch (Figure 192). The hopper fill switch is used to sound a buzzer when the hopper is at or near full capacity. Location 2. Use a multi-meter, set to the Ohm or Continuity setting, check the continuity between the two terminals: The hopper full switch is located inside the hopper asm., above the switch motor (Figure 191).
PAGE 143
ELECTRICAL Hopper Full Switch Circuit Ignition Switch View From Back of Switch PTO Switch ON (Plunger OUT) Battery 25A Fuse Hopper Fill Switch (Hopper Full) A A B B Switch Motor Buzzer Figure 193 9 Toro®- Z Master® 8000 Series Service Manual September 2016 Table of Contents 9-21
PAGE 144
ELECTRICAL Hopper Switch Motor Purpose The hopper switch motor is used to swing the hopper full switch from side-to-side to monitor hopper content level. NOTE: Battery voltage and ground can be manually applied to the motor terminals to bypass the unit wire harness and test motor operation (Figure 195). Location The hopper switch motor is located inside the hopper asm., below the hopper full switch (Figure 194).
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ELECTRICAL Hopper Motor Circuit Ignition Switch View From Back of Switch PTO Switch ON (Plunger OUT) Battery 25A Fuse Hopper Fill Switch (Hopper Full) A A B B Switch Motor Buzzer Figure 197 9 Toro®- Z Master® 8000 Series Service Manual September 2016 Table of Contents 9-23
PAGE 146
ELECTRICAL Start Relay and Circuit Operation Location The start relay located under the operator’s seat, on the right side of the unit (Figure 198). Figure 198 Starter Relay Circuit and Operation The ECM/hourmeter controls the start relay ground to allow the engine to crank if all the safety interlock inputs are correct. The start relay will only ground through the ECM/ hourmeter and activate the starter when: • The ignition switch is in the START position.
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ELECTRICAL Starter Solenoid Circuit View From Back of Switch Battery Ignition Switch START Neutral Switch in Neutral Parking Brake Switch Brake ON PTO Switch PTO OFF Start Relay Engaged Starter Motor 9 Figure 199 Toro®- Z Master® 8000 Series Service Manual September 2016 Table of Contents 9-25
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ELECTRICAL ECM/Hourmeter NOTE: The Toro eDealer Campus training center contains in-depth information and diagnostics training course for the Toro ECM/hourmeter. Harness Pin-Out Information (Figure 201) BU V Y T BN OR GY R Course Title: “Fuel/Hourmeter Control Module” Web Address: http://toro.learnerhall.com (Toro Dealer login required) Indicators: The ECM/hourmeter is equipped with six indicator lights (Figure 200). BK PK Figure 201 W GN Pin Location (Figure 202) Figure 200 A.
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ELECTRICAL Pin 1: Start Relay Input: Battery voltage from ignition switch present only when ignition switch in the START position. The ECM will ground this input to activate the starter solenoid if all safety interlock switch inputs are correct. Pin 2: Neutral Input: Battery voltage from ignition switch present only when the ignition switch is ON and the unit is in neutral (neutral switch closed).
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ELECTRICAL Wire Harness (non-EFI) View 1 of 3 9 Figure 203 9-28 Table of Contents Toro®- Z Master® 8000 Series Service Manual September 2016
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ELECTRICAL Wire Harness (non-EFI) View 2 of 3 Figure 204 Toro®- Z Master® 8000 Series Service Manual September 2016 9 Table of Contents 9-29
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ELECTRICAL Wire Harness (non-EFI) View 3 of 3 Figure 205 9 9-30 Table of Contents Toro®- Z Master® 8000 Series Service Manual September 2016
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ELECTRICAL Wire Harness (EFI) View 1 of 3 Figure 206 9 Toro®- Z Master® 8000 Series Service Manual September 2016 Table of Contents 9-31
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ELECTRICAL Engine Harness Side MIL Indicator LED Light Chassis Harness Side Wire Harness (EFI) View 2 of 3 9 Figure 207 9-32 Table of Contents Toro®- Z Master® 8000 Series Service Manual September 2016
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ELECTRICAL MIL Indicator LED Light Chassis Harness Side Engine Harness Side Wire Harness (EFI) View 3 of 3 9 Figure 208 Toro®- Z Master® 8000 Series Service Manual September 2016 Table of Contents 9-33
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ELECTRICAL Hopper Wire Harness-All Models Alarm / Buzzer Hopper to Chassis Connector Hopper Full Switch Hopper Wiper Motor Hopper Full Switch Alarm / Buzzer 9 Hopper Wiper Motor Hopper to Chassis Connector Figure 209 9-34 Table of Contents Toro®- Z Master® 8000 Series Service Manual September 2016
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LCEPr oduct s 2016TheT or oCompany . Al l r i ght sr es er v ed.