Form No. 3326–964 Rev A Z350 Z-Master with 122cm Mower and Bagger Model No. 74804TE—Serial No.
This spark ignition system complies with Canadian ICES-002. Pushing the Machine by Hand . . . . . . . . . . . . . . . . Removing the Deck and Carrier Frame . . . . . . . . . Installing Deck and Carrier Frame . . . . . . . . . . . . . Install the Mulching Baffle . . . . . . . . . . . . . . . . . . Operating with Mulching Baffle . . . . . . . . . . . . . . Installing the Bagger and Discharge Baffles . . . . . Operating with Bagger . . . . . . . . . . . . . . . . . . . . . .
Introduction Safety Read this manual carefully to learn how to operate and maintain your product properly. The information in this manual can help you and others avoid injury and product damage. Although Toro designs and produces safe products, you are responsible for operating the product properly and safely. Safe Operation Practices for Ride-on (riding) Rotary Lawnmower Machines This machine meets or exceeds European Standards in effect at the time of production.
• lack of awareness of the effect of ground conditions, especially slopes; – do not stop or start suddenly when going up or downhill; • • incorrect hitching and load distribution. Preparation engage clutch slowly, always keep machine in gear, especially when travelling downhill; – machine speeds should be kept low on slopes and during tight turns; • While mowing, always wear substantial footwear and long trousers. Do not operate the equipment when barefoot or wearing open sandals.
• Stop the engine and disengage drive to attachment Sound Power Level – before refuelling; This unit has a sound power level of: 105 Lwa, based on measurements of identical machines per procedures outlined in Directive 84/538/EEC and amendments. – before removing the grass catcher; – before making height adjustment unless adjustment can be made from the operator’s position.
Slope Chart 7
Safety and Instruction 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. 100-3613 93-1265 1. Full body entanglement hazard—stay away from moving parts 1. Hot surface/burn hazard—stay a safe distance from the hot surface. 93-6696 1. Stored energy hazard—read the Operator’s Manual. 100-3952 1. Hydraulic oil level 2.
98-1974 1. Fast forward 2. Slow forward 3. Neutral 4. Slow reverse 5. Fast reverse 6. Continuous variable setting 7. Speed/direction controls 98-1975 1. Hot surface/burn hazard—stay a safe distance from the hot surface. 98-4358 1. Warning—read the Operator’s Manual. 2. Thrown object hazard—stay a safe distance from the machine. 3. Tipping hazard—do not drive the machine across a slope greater than 5 degrees, up a slope greater than 15 degrees, or down a slope greater than 10 degrees. 4.
98-4369 1. Cutting/dismemberment hazard of hand or foot, mower blade—stay a safe distance from the machine. 104-7808 1. 2. 3. 4. Choke Horn Slow Continuous variable setting 5. Fast 6. Power take-off (PTO) 7. 8. 9. 10. 11. Engine—stop Engine—run Engine—start Engage the parking brake Disengage the parking brake. 98-4387 1. Warning—wear hearing protection. 104-4163 1. Explosion hazard 2. No fire, open flames, or smoking. 3. Caustic liquid/chemical burn hazard 104-0381 1. Height of cut in millimeters 2.
104-5091 1. Contains lead; do not discard. 2. Recycle 3. Wear eye protection; explosive gases can cause blindness and other injuries 4. No sparks, flame, or smoking 5. Sulfuric acid can cause blindness or severe burns. 6. Flush eyes immediately with water and get medical help fast. 7. Maximum fill line 12 8. Minimum fill line 9.
Gasoline and Oil Warning Recommended Gasoline Gasoline is harmful or fatal if swallowed. Long-term exposure to vapors can cause serious injury and illness. Use UNLEADED Regular Gasoline suitable for automotive use (85 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available. • Avoid prolonged breathing of vapors. • Keep your face away from the nozzle and gas tank or conditioner opening. • Keep gas away from eyes and skin.
Setup Note: Determine the left and right sides of the machine from the normal operating position. Loose Parts Note: Use the chart below to verify all parts have been shipped. Description Qty. Use Mulching baffle 1 For mulching mode Key 2 Use in the ignition Safety booklet 1 Operator’s manual 1 Engine operator’s manual 1 Parts catalog 1 Registration card 1 Removing the bracket from Rear Tail Wheel Read before operating the machine. Fill out and return to Toro.
Checking the Hydraulic Fluid 4. Slowly pour electrolyte into each battery cell until the level is up to the upper line (Fig. 3) on the battery case. Check the hydraulic fluid level before the engine is first started. Important Do not overfill the battery because electrolyte (sulfuric acid) can cause severe corrosion and damage to the chassis. Refer to Checking the Hydraulic Fluid on page 43. 5. Wait five to ten minutes after filling the battery cells.
Releasing the Parking Brake 1 1. Push in on the button and lower parking brake lever to off (Fig. 7). 2 3 1 4 2 8 5 9 6 7 10 3 m–3287 Figure 7 m–5287 1. Parking brake—Set 2. Button Figure 5 1. 2. 3. 4. 5. Motion control lever Parking brake Ignition switch Throttle Power take off (PTO) 6. 7. 8. 9. 10. Hourmeter Choke Drink holder Fuel cap Hydro reservoir cap 3. Parking brake—Off Starting and Stopping the Engine Starting the Engine Hour Meter 1.
Important Make sure fuel shut off valve is closed before transporting or storing machine, as fuel leakage may occur. 1 2 Operating the Power Take Off (PTO) 2 1 The power take off (PTO) switch engages and disengages power to the attachment clutch (mower blades). m–5269 m–2719 Figure 8 Engaging the Power Take Off (PTO) Figure 9 1. PTO-Off 2. PTO-On 1. Choke–On 2. Choke–Off 1. With engine running, move motion control levers to neutral to stop the machine. 2.
Understanding the Safety Interlock System Driving Forward or Backward The throttle control regulates the engine speed as measured in rpm (revolutions per minute). Place the throttle control in the fast position for best attachment performance. Always operate in the full throttle position when operating attachments. The safety interlock system is designed to prevent the engine from starting unless: • The parking brake is set. • The power take off (PTO) is disengaged or off.
To turn move the motion control lever toward neutral, on the side you want to turn toward (Fig. 13). To slow or stop move the motion control levers to neutral. 1 Stopping the Machine 2 To stop the machine, move the motion control levers to neutral, disengage the power take off (PTO), and turn the ignition key to off. Also set the parking brake when you leave the machine; refer to Setting the Parking Brake, page 16. Remember to remove the key from the ignition switch. m–3280 Figure 15 1.
Caution The mower deck is heavy and could injure someone while raising or lowering the deck. • Use caution when raising or or lowering deck. 1 m–4863 Raising the Mower Figure 18 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to off. Remove spark plug wire(s) and remove the key. 1. Mower up 2. Lift on side of carrier frame near latch to release weight on latch pin. Lowering the Mower 1.
1 1 3 2 1 m–4861 m–5282 Figure 20 Figure 19 1. Rear Door latch 2. Front Hopper latch 3. Lift here 1. By-pass valve Removing the Deck and Carrier Frame 6. Lower the hopper. Firmly secure the hopper door so it latches and secure the front hopper latch (Fig. 19). Important Front hopper latch must be secured to prevent hopper from accidently tilting during transport. Ensure the hopper door latch is fully closed. 1.
1 10. Tilt carrier frame down. 3 4 2 5 7 8 11. Remove the two nuts and bolts that hold the bar for rubber guard. The bar is under the motion control levers. Fold the rubber guard onto the footrest (Fig. 24). 3 4 2 2 6 m–4851 Figure 22 1. 2. 3. 4. Bracket Plenum Cable Washer Nut 5. 6. 7. 8. Plenum Plenum cable guide Plenum Latches Blower Housing 1 5 m–4858 5. Tilt carrier frame into its upright position. Refer to Tilting the Mower on page 19. Figure 24 6.
1. Slide the driveshaft on gearbox shaft. Install 2 bolts (3/8 x 1-5/8 inches) and locknuts (3/8 inch) in universal joint (Fig. 28). 1 Note: The gearbox shaft has a spline to correctly align gearbox and PTO drive shaft. Align the spline and slide the PTO drive shaft onto gearbox. 4 3 4 2 M–4532 3 Figure 26 1. PTO Driveshaft 2. Universal Joint 2 3. Gearbox shaft 4. Roll Pin 5 m–3198 1 14. Move deck and carrier frame away from traction unit.
5. Place a block, approximately 4 inches high, under the carrier frame. This will raise the frame vertically. 1 6. Secure spring end plate assembly to carrier frame with a shoulder bolt (3/8 x 7/8 inch) and a locknut (3/8 inch) (Fig. 30). 4 3 3 1 2 M–4532 2 m–4872 Figure 32 Figure 30 1. Spring Assembly 2. Shoulder Bolt, 3/8 x 7/8 inch 1. PTO Driveshaft 2. Universal Joint 3. Locknut, 3/8 inch 3. Gearbox shaft 4. Roll Pin 11. Remove the 4 inch block.
1 1. Tilt mower into the vertical position, refer to; Tilting the Mower, page 19. 3 2 4 5 7 8 2. Remove screws, washers, left and right bagger baffles locknuts, carriage bolts, and left and right discharge baffles from the mower (Fig. 38). Note: Reinstall all hardware into deck for use when reinstalling bagging baffles and safety. 3. Remove screws and washers that are installed into deck for securing mulching baffle (Fig. 36). 2 6 4. Install baffle using hardware that was removed. (Fig. 36).
4. Align hole in idler arm with slot in frame and insert clevis pin. Secure with hairpin cotter to hold in position. 2 1 2 4 7 3 3 4 1 5 6 m–3548 Figure 37 1. Idler arm 2. Frame slot m–5272 Figure 38 3. Clevis pin 4. Hairpin cotter 1. 2. 3. 4. 5. When operating in mulching mode, the plenum can be removed to prevent damage to it. Refer to Installing and Removing the Plenum on page 27. Bagger baffle Retainer Nut Cap Screw Discharge baffle 5. Carriage Bolt 6. Lock Nut 7.
4. Flip seat up and unlatch plenum from both sides of blower inlet (Fig. 40). 2 4 5. Pull plenum out from blower housing and place it on the ground (Fig. 40). 3 6. Pull or slide plenum out from between deck and traction tire (Fig. 40). 1 3 2 4 5 7 8 1 m–3548 Figure 39 1. Idler arm 2. Frame slot 3. Clevis pin 4. Hairpin cotter 2 Installing and Removing the Plenum 6 m–4851 Figure 40 1. 2. 3. 4. To avoid damage to the plenum, remove the plenum when not in bagging mode.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule Maintenance Service Interval After first use Maintenance Procedure • Check the hydraulic fluid level. • Change the oil. • Change the hydraulic filter. Each use • • • • • Check the oil level.1 Check the safety system. Clean the hopper. Clean the mower housing. Clean the cooling systems. Every 5 hours • • • • • • • Check the hydraulic fluid level.
1More often in dusty, dirty conditions Important Refer to your engine operator’s manual for additional maintenance procedures. Caution If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition and disconnect the wire(s) from the spark plug(s) before you do any maintenance. Set the wire(s) aside so that it does not accidentally contact the spark plug(s).
3 mm (1/8 inch), the blade is bent and must be replaced. Refer to Removing the Blades, and Installing the Blades on page 30. Front Front 1 M–4852 Figure 43 1. Cutting edge Note: Use anti-seize lubricant on spindle and keyway before installing blade retainer. 1. Install the key in the retainer and install blade retainer to spindle (Fig. 44). 2. Install the blade, spacer, washer, and retainer bolt to spindle (Fig. 44). M–4852 Figure 42 3. Torque the retainer bolt to 115–140 N m (85–110 ft.-lb.).
Sharpening the Blades 1. Check the tire pressure on both deck and traction unit. 1. Use a file to sharpen the cutting edge at both ends of the blade (Fig. 45). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges. 2. Set the height-of-cut to the 2-1/2 inches (63 mm) position following the height-of-cut decal. 3. With the machine on level surface, position one blade front-to-rear (Fig. 47).
Front C Front C B A D D M–4852 M–4852 Figure 49 Figure 51 MEASURE FROM TIP OF CUTTING EDGE TO A LEVEL SURFACE MEASURE FROM TIP OF CUTTING EDGE TO A LEVEL SURFACE M–4852 Figure 50 M–4852 Figure 52 Changing the Front-to-Rear Pitch Change the Side-to-Side Level Changing the side–to–side leveling is done by removing or adding washers to height of cut posts. Do this to the corresponding side that needs adjustment.
The plunger inside the gauge canister will change to red when the air cleaner element becomes dirty and restricted. When it changes red, air cleaner maintenance is required. 1. Start by visually checking the condition of the primary element. If the element is visually dirty, replace the primary element. Do not attempt to clean it. 1 2. Reset the gauge by depressing the button in the bottom of the canister until the plunger returns to the lowest point (Fig. 53). 3.
USE THESE SAE VISCOSITY OILS Cleaning the Primary Filter Blow compressed air from the inside to the outside of the primary filter. 10W–30 Important Do not exceed 685.5 kPa (100 psi) and keep the hose at least 5 cm (2 inches) from the filter. 5W–20, 5W–30 Installing the Filters 1. If installing new filters, check each filter for shipping damage. Do not use a damaged filter. –20 5F 0 2. If the safety filter is being replaced, carefully slide it into the filter body (Fig. 55).
Changing the Engine Oil Changing the Engine Oil Filter 1. Start the engine and let it run five minutes. This warms the oil so it drains better. Replace the oil filter after first 8 hours of use. Replace the oil filter every 200 hours or every other oil change. 2. Park the machine so that the drain side is slightly lower than the opposite side to assure the oil drains completely. Then disengage the power take off (PTO), set the parking brake, and turn the ignition key to off. Remove the key.
Removing the Spark Plugs 2 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to off. Remove the key. 3 1 2. Pull the wire(s) off the spark plug(s) (Fig. 59). Now clean around the spark plug(s) to prevent dirt from falling into the engine and potentially causing damage. 0.030 inch (0.76 mm) 3. Remove the spark plug(s) and metal washer. m–3215 Figure 60 2 1. Center electrode insulator 2. Side electrode 3. Air gap (not to scale) 1 Installing the Spark Plug(s) 1.
Important Ensure that the fuel line is routed correctly to avoid damage to the fuel line. 2 4 1 2 m–4853 3 Figure 61 1. Filter 2 2. Hose clamp m–3293 1 Figure 62 1. Fuel shut-off valve 2. Hose clamp Servicing the Fuel Tank 3. Fuel line 4. Fuel cap Draining The Fuel Tank Danger Cleaning the Cooling Systems 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.
3. Install the panels onto the engine shroud. 3 1 2 m–5766 m–3289 Figure 64 1. Panel 2. Engine shroud 3. Screws m–5283 Figure 65 2. Grease the fittings on drive shaft and universal joints (Fig. 66). Greasing and Lubricating The unit must be lubricated regularly. Refer to the Recommended Maintenance Schedule on page 28. Grease Type: No. 2 general purpose lithium base or molybdenum base grease. How to Grease m–3203 1. Disengage the power take off (PTO) and turn the ignition key to off.
2 2 3 1 2 3 m–4846 1 Figure 68 1. Carrier Frame Castor Hub Grease Fitting 2. Castor Wheel Grease Fitting 4 3 1 4 m–4857 Figure 69 Servicing the Gearbox Fluid 1. Gearbox 2. Top plug Change fluid: 3. Side plug 4. Bottom plug • after initial 100 operating hours. • each year before storage. Checking the Gearbox Fluid Fluid Type: 85W–140 Mobilube or equivalent fluid. Important The gearbox fluid must be checked after every 100 operating hours. Check all three gearboxes. Do not mix fluids.
2. Remove the cap, thrust washer and 1/2 inch spacer from the top of the castor wheel fork (Fig. 70). 8. Grease the fitting on the carrier frame castor hub using No. 2 general purpose lithium base or molybdenum base grease. 3. Pull the castor wheel fork out of the mounting tube, leaving the 1 inch spacer and thrust washers on the fork. Remember the location of thrust washers on each fork to ensure correct installation, and to maintain a level deck. 2 1 1 2 2 3 m–3282 Figure 71 4 1.
4 7 6 10 1 9 1 6 5 3 8 7 8 3 2 2 4 m–5299 6. 7. 8. 9. 10. Pump Idler Pulley Idler arm Bushing Nut Bolt m–5297 Figure 74 Figure 72 1. 2. 3. 4. 5. 5 1. 2. 3. 4. Washer Spacer Shoulder bolt Spring Traction Belt Blower Idler Pulley Bushing Spacer Washer 5. 6. 7. 8. Nut Bolt Blower Belt Spring Replacing Push Arm Bushings 4 The push arms have pressed in bushings on the end mounted to the traction unit. To check the bushings, move the push arms side-to-side and examine for wear.
6. Install the castor wheel into the castor fork and secure with the wheel bolt and locknut. Tighten the locknut until the spanner bushing bottoms against the inside of the castor forks (Fig. 77). 4. Insert a pin punch into the push arm and carefully drive out the bushings (Fig. 76). Clean the inside of the push arm. 5. Use a hammer and flat plate to carefully drive new bushings into the end of push arm (Fig. 76). 7. Grease the fitting on the castor wheel. 6.
6. Recheck level while fluid is warm. Add fluid to raise level to top of the baffle, if required. Note: Fluid level should be to the top of the baffle when fluid is warm (Fig. 80). 1 7. Install cap on filler neck. 1 2 m–1872 Figure 78 1. Drive Wheel and Tail Wheel Valve Stem 3 m–5279 Figure 80 1. Cap 2. Baffle 1 3. Fluid level—full m–3281 Warning Figure 79 1. Castor Wheel Valve Stem Hydraulic fluid escaping under pressure can penetrate skin and cause injury.
2. Remove hydro cap and temporarily cover opening with a plastic bag and rubber band to prevent all hydro fluid from draining out. 1 3 3. Place drain pan under filter, remove the old filter and wipe the filter adapter gasket surface clean (Fig. 81). 2 m–1256 Figure 82 1. Hydraulic filter 2. Gasket 1 3.
1 Warning 5 4 5 3 Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • If hydraulic fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result if this is not done. • Keep body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid. • Use cardboard or paper to find hydraulic leaks.
Replacing the Traction Belt 2. Using a rag or thickly padded glove, hold spring loaded idler against belts and pull spring down to remove from idler stud (Fig. 85). Check traction drive belt for wear after every 50 hours of operation. 3. Lower idler to relax tension on PTO belt and remove belt from gear box pulley (Fig. 85). 1. Remove PTO belt; refer to Replacing Power Take Off (PTO) Belt on page 45. 4. Remove clutch stop mounting bolts and unplug clutch wire harness (Fig. 85). Remove belt over clutch.
Servicing the Fuse 2 1 Service Interval/Specification The electrical system is protected by fuses. It requires no maintenance, however, if a fuse blows check component/circuit for malfunction or short. 3 Fuse: Main F1–30 amp, blade-type Alternator F2–25 amp, blade-type Safety Interlock and Clutch F3–15 amp, blade-type 4 1. Remove dash panel screws to gain access to fuse holder (Fig. 90). m–5280 Figure 88 1. Blower belt 2. PTO Gearbox pulley 2.
Installing the Battery 2. Look at the side of the battery. The electrolyte must be up to the upper line (Fig. 91). Do not allow the electrolyte to get below the lower line (Fig. 91). Warning 3. If the electrolyte is low, add the required amount of distilled water; refer to Adding Water to the Battery, page 49. Battery terminals or metal tools could short against metal machine components causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury.
Adding Water to the Battery 2 4 3 The best time to add distilled water to the battery is just before you operate the machine. This lets the water mix thoroughly with the electrolyte solution. 9 9 1. Remove the battery from the machine. 2. Clean the top of the battery with a paper towel. Note: Never fill the battery with distilled water while the battery installed in the machine. Electrolyte could be spilled on other parts and cause corrosion. 8 2 7 3. Remove the vent caps from the battery (Fig.
Cleaning the Hopper Full Sensor 4 2 1 The hopper full sensor, inside the top right side of the hopper, detects a beam of light from the transmitter to the receiver. If the light beam is blocked the sensor buzzer sounds. If the lenses are covered with clippings or debris it may give false hopper full signals and needs to be cleaned. 3 Note: There are two different positions the hopper full sensors can be mounted.
PK BK BAG SENSOR GN BK GY D1 PK GND BK PTO CLUTCH PK BUZZER PK BK 7 4 PK 1 Y SW5 (BRAKE) BU D2 Y SHOWN WITH PARK BRAKE DISENGAGED BU SHOWN IN OFF POSITION Y W BN (SEAT) SW1 Y BN BN W K1 (KILL RELAY) GN CLOSED WHEN TRACTION DRIVE IS IN NEUTRAL SW2 (NEUTRAL) CLOSED WHEN TRACTION DRIVE IS IN NEUTRAL Y GY W CLOSED WHEN OPERATOR PRESENT SW3 (NEUTRAL) BN 5 BU 5 2 F1 30A VIO B 4 A 3 R VIO REG S 5 W 5 Y 2 OR X I S S4 (IGNITION) KEY SWITCH PN 88–9830 OFF NO
Hydraulic Diagram HYDRAULIC TANK B I A C FILTER REAR PUMP 52 B I A C FRONT PUMP B A RIGHT MOTOR A LEFT MOTOR B
Cleaning and Storage 11. Remove the spark plug(s) and check its condition; refer to Servicing the Spark Plug, page 35. With the spark plug(s) removed from the engine, pour two tablespoons of engine oil into the spark plug hole. Now use the starter to crank the engine and distribute the oil inside the cylinder. Install the spark plug(s). Do not install the wire on the spark plug(s). 1. Disengage the power take off (PTO), set the parking brake and turn the ignition key to off. Remove the key. 2.
Troubleshooting PROBLEM Starter does not crank Engine g will not start, starts hard, or f il to fails t keep k running. i Engine g loses power. g Engine overheats. POSSIBLE CAUSES CORRECTIVE ACTION 1. Power take off (PTO) is ENGAGED. 1. Move power take off (PTO) to DISENGAGED. 2. Parking brake is not on. 2. Set parking brake. 3. Motion control levers are not in neutral neutral. 3. Move motion control levers into neutral neutral. 4. Battery is dead. 4. Charge the battery. 5.
PROBLEM Abnormal vibration. Machine does not drive. POSSIBLE CAUSES CORRECTIVE ACTION 1. Engine mounting bolts are loose. 1. Tighten engine mounting bolts. 2. Loose engine pulley, idler pulley, or blade pulley. 2. Tighten the appropriate pulley. 3. Engine pulley is damaged. 3. Contact Authorized Service Dealer. 1. Parking brake is on. 1. Move parking brake to off. 2. Traction belt is worn, loose or broken. 2. Contact Authorized Service Dealer. 3. Traction belt is off pulley. 3.
