Form No. 3329-833 Rev A Z355 Z-Master) with 48 in. Mower and Bagger Model No. 74805—Serial No. 240000001 and Up Operator’s Manual Register your product at www.Toro.
Warning Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Think Safety First . . . . . . . . . . . . . . . . . . . . . . . . Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating the Parking Brake . . . . . . . . . . . . . . . . Starting and Stopping the Engine . . . . . . . . . . . . Operating the Power Take Off (PTO) . . . . . . . . . The Safety Interlock System . . . . . . . . . . . . . . . . Driving Forward or Backward . . . . . . . . . . . . . .
Page Servicing the Castor Wheels and Tail Wheel Bearings . . . . . . . . . . . . . . . . . . . . . Checking the Tire Pressure . . . . . . . . . . . . . . . . . Servicing the Hydraulic System . . . . . . . . . . . . . Adjusting the Motion Controls . . . . . . . . . . . . . . Replacing the Power Take Off (PTO) Belt . . . . . Replacing the Traction Belt . . . . . . . . . . . . . . . . . Replacing the Blower Belt . . . . . . . . . . . . . . . . . . Turning Engine Lift Hook . . . . . . . . . . . . . . . . . .
Safe Operating Practices • Only operate in good light, keeping away from holes and hidden hazards. The following instructions are from ANSI standard B71.4—1999. • Be sure all drives are in neutral and parking brake is engaged before starting engine. Start the engine only from the operator’s position. Training • Never raise a deck with the blades running. • Read the Operator’s Manual and other training material.
• Clean grass and debris from cutting units, drives, mufflers, and engine to help prevent fires. Clean up oil or fuel spillage. • Remove obstacles such as rocks, tree limbs, etc., from the mowing area. Watch for holes, ruts or bumps, as uneven terrain could overturn the machine. Tall grass can hide obstacles. • Let engine cool before storing and do not store near flame. • Use a walk behind mower and/or a hand trimmer near drop–offs, ditches, steep banks or water.
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. 79-0360 1-523552 80-8760 43-8480 93-9198 98-4361 1.
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 4. Wear eye protection 5. Read the Operator’s Manual. 6. Keep bystanders a safe distance from the battery. 100-7769 104-7807 104-8172 104-0390 98-1313 1. Fast forward 2. Slow forward 3. Neutral 4. Slow reverse 5. Fast reverse 10 6.
98-1304 105-1603 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. 11 7. Maximum fill line 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.
Checking the Hydraulic Fluid Note: Never fill the battery with electrolyte while the battery is installed in the machine. Electrolyte could be spilled on other parts and cause corrosion. Check the hydraulic fluid level before the engine is first started. 3. Remove the vent caps from the battery (Fig. 3). Refer to Checking the Hydraulic Fluid on page 45. 4. Slowly pour electrolyte into each battery cell until the level is up to the upper line (Fig. 3) on the battery case.
2 Controls 1 Become familiar with all the controls before you start the engine and operate the machine (Fig. 6). 1 2 3 4 3 8 5 6 m–6478 Figure 4 1. Safe Zone—use the Z Master here on slopes less than 15 degrees or flat areas. 9 7 2. Use walk behind mower and/or hand trimmer near drop–offs and water. 3. Water or drop-off 10 11 m–5287 The use of protective equipment for eyes, ears, feet, and head is recommended. Figure 6 1. 2. 3. 4. 5. 6.
Operating the Parking Brake Note: If starter does not crank, move the motion control levers slightly forward or backward to locate neutral. Always set the parking brake when you stop the machine or leave it unattended. Important Do not engage starter for more than 10 seconds at a time. If engine fails to start allow 30 second cool-down period between attempts. Failure to follow these instructions can burn out starter motor. Setting the Parking Brake 7.
The Safety Interlock System Note: If the engine has been working hard or is hot, let it idle for a minute before turning the ignition key off. This helps cool the engine before it is stopped. In an emergency, the engine may be stopped by turning the ignition key to off immediately. Caution If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. 4.
Driving Backward 4. Set the parking brake, move power take off (PTO) to off and hold the motion control levers in neutral. Now start the engine. While the engine is running, move the motion control levers forward or reverse; the engine should stop. 1. Release the parking brake; refer to Setting the Parking Brake, page 16. 2. To go backward, slowly pull the motion control levers rearward (Fig. 14). 5.
Positioning the Seat Adjusting the Height-of-Cut The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable. The height-of-cut can be adjusted from 1 to 4-1/2 inch in 1/2 inch increments by relocating four hairpin cotter pins in different hole locations. 1. To adjust, remove the hairpin cotter and washer, and tip seat forward (Fig. 15). Note: Fine adjustment can be done by removing washers. 1.
Raising the Mower Lowering the Mower 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to off. Remove the key. 1. Pull out the latch pins and rotate into notch to hold in the unlocked position (Fig. 18). 2. Standing in front of the mower, pull the front deck handle forward and lower mower (Fig. 19). 2. Lift on side of carrier frame near latch to release weight on latch pin. 3.
Pushing the Machine by Hand 1 2 3 4 7 5 8 Important Always push the machine by hand. Never tow the machine because hydraulic damage may occur. Pushing the Machine 1. Disengage the power take off (PTO) and turn the ignition key to off. 2 2. Rotate pump by-pass valves counterclockwise 2 turns. This allows hydraulic fluid to by-pass the pump enabling the wheels to turn freely (Fig. 21). 6 m–4851 Figure 22 1. 2. 3. 4.
Note: Save all hardware for use when installing mower. Items 3 and 4 are part of traction unit. 9. Remove shoulder bolts (3/8 x 7/8 inch) and locknuts (3/8 inch) securing spring end plate assemblies to carrier frame (Fig. 24). 3 2 2 4 1 3 1 m–4870 m–3209 Figure 26 Figure 24 1. Spring assembly 2. Shoulder bolt, 3/8 x 7/8 inch 1. Pivot bracket 2. Push arm 3. Locknut, 3/8 inch 3. Pivot pin assembly–flat 4. Hairpin cotter Note: Drive shaft remains with traction unit. 14.
Note: Save all hardware for use when installing mower. 2. Position carrier frame in front of traction unit and place push arms into clevises (Fig. 30). 4 2 4 1 3 2 1 3 5 m–4870 m–3198 Figure 30 Figure 28 1. PTO drive shaft 2. Universal joint 3. Gearbox shaft 1. Clevis 2. Push arm 4. Bolt, 3/8 x 1-5/8 inch 5. Locknut, 3/8 inch 3. Pivot pin assembly–flat 4. Hairpin cotter 3. Install push arms with pivot pin assemblies, aligned with flat against frame, and secure with hairpin cotters (Fig. 30).
7. Install shoulder bolts (3/8 x 7/8 inch) and locknuts (3/8 inch) securing spring end plate assemblies to traction unit (Fig. 32). 3 3 2 1 2 1 m–4856 Figure 34 1. Carrier frame 2. Hairpin cotter m–3209 3. Height–of–cut post Figure 32 1. Spring assembly 2. Shoulder bolt, 3/8 x 7/8 inch 3. Locknut, 3/8 inch Note: All four hairpin cotters should be in the same hole location for a level cut. 13. Tilt carrier frame into its upright position. Refer to Tilting the Mower on page 19. 8.
16. Install the rubber guard with bar, nuts and bolts under the motion control levers. (Fig. 36). 4. Install baffle using hardware that was removed. (Fig. 37). Important All bagging and discharge baffles must be removed when mulching (Fig. 39). 3 4 Operating with Mulching Baffle 2 When operating the mower with the mulching baffle installed, you must disengage the blower drive belt. 1. Stop the engine, remove the key. 1 2. Remove hairpin cotter and clevis pin from idler arm (Fig. 38). 5 3.
5. Install hairpin cotter and clevis pin in outer hole of idler arm for storage (Fig. 40). 3. Position the left and right front bagger baffles inside the mower and secure with screws into the retainer nuts (Fig. 39). 2 4. Position the left and right rear discharge baffles inside the mower. Secure with screws and washers through the bottom and carriage bolts inside of mower rear discharge. Secure carriage bolts with locknuts (Fig. 39). 2 1 7 4 3 3 1 m–3548 Figure 40 1. Idler arm 2.
4. Flip seat up and unlatch plenum from both sides of blower inlet (Fig. 41). Important When operating a machine with ROPS always use the seat belt and secure the seat base. 5. Pull plenum out from blower housing and place it on the ground (Fig. 41). Transporting the Machine 6. Pull or slide plenum out from between deck and traction tire (Fig. 41). 1 3 2 4 5 7 Use a heavy-duty trailer or truck to transport the machine.
Tips for Mowing Grass Avoid sudden acceleration when driving up a ramp and sudden deceleration when backing down a ramp. Fast Throttle Setting Warning For best mowing and maximum air circulation, operate the engine at fast. Loading a unit onto a trailer or truck increases the possibility of a loss of control and could cause serious injury or death. Cutting a Lawn for the First Time Cut grass slightly longer than normal to ensure that the cutting height of the mower does not scalp any uneven ground.
Keep the Underside of the Mower Clean Clean clippings and dirt from the underside of the mower after each use. If grass and dirt build up inside the mower, cutting quality will eventually become unsatisfactory. Blade Maintenance Maintain a sharp blade throughout the cutting season because a sharp blade cuts cleanly without tearing or shredding the grass blades. Tearing and shredding turns grass brown at the edges, which slows growth and increases the chance of disease.
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. Check the safety system. Clean the hopper. Clean the mower housing. Check the cutting blades. Every 8 hours • • • • • • Check the hydraulic fluid level.
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). Servicing the Cutting Blades Inspecting the Blades To ensure a superior quality of cut, keep the blades sharp.
exceeds 1/8 inch, the blade is bent and must be replaced. Refer to Removing the Blades, and Installing the Blades on page 32. Front Front 1 M–4852 Figure 45 1. Cutting edge Note: Use anti-seize lubricant on spindle and keyway before installing blade retainer. 1. Install the key in the retainer and install blade retainer to spindle (Fig. 46). 2. Install the blade, spacer, washer, and retainer bolt to spindle (Fig. 46). M–4852 Figure 44 3. Torque the retainer bolt to 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. 47). 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 inch position following the height-of-cut decal. 3. With the machine on level surface, position one blade front-to-rear (Fig. 49).
2. Position the blades side-to-side (Fig.53 ). Measure at A and B locations (Fig. 53) from a level surface to the cutting edge of blade tips (Fig.54). Front C C Front D B A D M–4852 Figure 51 M–4852 Figure 53 MEASURE FROM TIP OF CUTTING EDGE TO A LEVEL SURFACE M–4852 Figure 52 MEASURE FROM TIP OF CUTTING EDGE TO A LEVEL SURFACE M–4852 Figure 54 Changing the Front-to-Rear Pitch 3. The difference between measurements A and B should be no more than 1/4 inch.
2. Remove the wing nut from the bolt in the air filter guard. Rotate guard to gain access to filter (Fig. 57). 2. Position the blade in the A orientation as shown in Figure 55. Front A N1 N2 N2 1 B N1 M–4852 4 Figure 55 2 3 m–4845 Figure 57 1. Filter guard 2. Wing nut MEASURE FROM TIP OF CUTTING EDGE TO A LEVEL SURFACE 3. Bolt 4. Filter 3. Release the latches on the air cleaner and pull the air cleaner cover off of the air cleaner body (Fig. 58). M–4852 4.
Cleaning the Primary Filter 3. Test run the engine and recheck the gauge. If the plunger remains in the lowest range, normal operation can resume. If the plunger returns to the “Change Filter” level, the primary element is restricted and must be replaced, even though it may not appear to be dirty. Blow compressed air from the inside to the outside of the primary filter. Important Do not exceed 685.5 kPa (100 psi) and keep the hose at least 5cm (2 inch) from the filter. 4.
Note: Dispose of the used oil at a recycling center. 3. Pull the oil dipstick and wipe the metal end clean (Fig. 60). 2 1 5. Slowly pour approximately 80% of the specified oil, on page 36, into the fill opening (Fig. 60). Now check the oil level; refer to Checking Oil Level, page 36. Slowly add additional oil to bring to full mark on dipstick. 3 Changing the Engine Oil Filter Replace the oil filter after first 8 hours of use. Replace the oil filter every 200 hours or every other oil change.
Servicing the Spark Plugs Checking the Spark Plugs Check the spark plug(s) after every 200 operating hours. Make sure the air gap between the center and side electrodes is correct before installing the spark plug. Use a spark plug wrench for removing and installing the spark plug(s) and a gapping tool/feeler gauge to check and adjust the air gap. Install a new spark plug(s) if necessary. 1. Look at the center of the spark plug(s) (Fig. 64).
Replacing the Fuel Filter Servicing the Fuel Tank Never install a dirty filter if it is removed from the fuel line. Draining The Fuel Tank 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to off. Remove the key. Danger 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. 2. Close fuel shut–off valve at fuel tank (Fig. 66).
Greasing and Lubricating 5. Install the fuel line onto the fuel shut-off valve. Slide the hose clamp close to the fuel shut-off valve to secure the fuel line (Fig. 66). The unit must be lubricated regularly. Refer to the Recommended Maintenance Schedule on page 30. Important Ensure that the fuel line is routed correctly to avoid damage to the fuel line. Grease Type: No. 2 general purpose lithium base or molybdenum base grease. Cleaning the Cooling Systems How to Grease 1.
1. Lubricate the castor wheel bearings and motion control lever pivot until grease begins to ooze out of the bearings (Fig. 70). 4. Grease the fittings on push arms (Fig. 73). 1 m–4871 m–3289 Figure 73 m–5283 1. Push arm grease fitting Figure 70 5. Grease the fittings on the carrier frame castor hubs and castor wheels (Fig. 74). 2. Grease the fittings on drive shaft and universal joints (Fig. 71). 1 2 m–3203 m–4846 Figure 71 1. PTO Driveshaft Figure 74 2. Universal Joint 1.
Changing the Gearbox Fluid 4. If needed, fill fluid into top hole until it runs out the side hole in gearbox. It is full when it runs out the side hole (Fig. 75). The gearbox fluid must be changed after first 100 operating hours. Change all three gearboxes. Important on page 41. Important gearboxes. Do not mix fluids. Use only specified fluid Do not mix fluids. Do not overfill 5. Reinstall the top and side plugs into gearbox using pipe sealant (Fig. 75). 1. Warm the fluid in gearbox.
Replacing Idler Arm Bushings 4. Insert a pin punch into the castor hub and carefully drive out the bushings (Fig. 77). Clean the inside of the mounting tube. There are idler arms for the blower belt, PTO belt and traction belt. All three idler arms have pressed in bushings. To check the bushings, move the idler arms side-to-side and examine for wear. If the idler arms are loose, the bushings are worn and must be replaced. 5. Grease the inside and outside of the new bushings.
4 2 6 1 3 4 2 3 5 1 m–4871 Figure 81 m–5298 1. Pin 2. Push arm Figure 79 1. PTO Idler and pulley 2. Bushing 3. Bolt 4. Nut 5. Spacer 6. Spring 3. Flat washer 1-1/2 inch 4. Retaining ring 4. Insert a pin punch into the push arm and carefully drive out the bushings (Fig. 82). Clean the inside of the push arm. 7 5. Use a hammer and flat plate to carefully drive new bushings into the end of push arm (Fig. 82). 6.
Servicing the Castor Wheels and Tail Wheel Bearings Checking the Tire Pressure Maintain the air pressure in the front and rear tires as specified. Uneven tire pressure can cause uneven cut. Check the pressure at the valve stem after every 50 operating hours or monthly, whichever occurs first (Fig. 84 and 85). Check the tires when they are cold to get the most accurate pressure reading. The castor wheels and tail wheel rotate on a roller bearing supported by a spanner bushing.
1. Position machine on a level surface and set the parking brake. Replacing the Hydraulic Filter 2. Clean area around filler neck of hydraulic tank (Fig. 86). • After the first 8 operating hours Change the hydraulic filter: • After every 200 operating hours 1 2 1. Position machine on a level surface, stop the engine, and remove key from ignition switch. Important Do not substitute automotive oil filter or severe hydraulic system damage may result. 3 2.
5. Install replacement hydraulic filter onto the filter adapter. Do not tighten. Warning 6. Remove plastic bag from tank opening and allow filter to fill with hydro fluid. Hydraulic fluid escaping under pressure can penetrate skin and cause injury. 7. When fluid overflows filter turn the oil filter clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 1/2 turn (Fig. 88).
7. Plug clutch wire into wire harness. Important Hold motion control lever firmly against forward stop to determine when pump control reaches stop. 1 2 4. Rotate control rod 1 turn in reverse direction and tighten jam nuts (Fig. 89). Important Motion control lever must contact forward stop before pump contacts internal stop or pump damage may occur. 3 5. If motion control levers do not line up in neutral, identify control rod of handle closer to the seat. Rotate to lengthen this control rod a little.
Replacing the Blower Belt Squealing when the belt is rotating, blower slipping causing frequent clogging of chute and blower, frayed belt edges, burn marks and cracks are all signs of a worn blower belt. Replace the blower belt if any of these conditions are evident. 1 2 1. Stop the engine, remove the key and disconnect the spark plug wire(s) from the spark plug(s). M–4855 Figure 94 2. Push up on the spring loaded idler arm behind left hand traction tire to relax pressure on blower belt (Fig. 93).
Servicing the Battery Installing the Battery Warning Warning 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. Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.
6. Position support rods in mounting holes (Fig. 97). Secure battery with 2 support rods, a battery clamp and 2 wing nuts (1/4 inch). Tighten wing nuts so battery is held securely in position and will not slide. Do not overtighten. Adding Water to the Battery Important Route cables so they do not contact metal edges, frame members, or tail wheel. 1. Remove the battery from the machine. The best time to add distilled water to the battery is just before you operate the machine.
4. When the battery is fully charged, unplug the charger from the electrical outlet, then disconnect the charger leads from the battery posts (Fig. 98). 3. Clean the screen by brushing off with your hand, blowing with compressed air or spraying with a stream of water. 4. Replace the screens and secure with knobs (Fig. 99). Close and latch the hopper door.
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 4 3 1 4 3 BU 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 N
C A B I 54 C A PUMP REAR B I FRONT PUMP RIGHT MOTOR A B FILTER HYDRAULIC TANK MOTOR LEFT B A Hydraulic Diagram
Cleaning and Storage 11. Remove the spark plug(s) and check its condition; refer to Servicing the Spark Plug, page 38. With the spark plug(s) removed from the engine, pour two tablespoons of engine oil 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. p Engine g 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. 4. Loose deck gearbox bolts. 4. Check and tighten bolts. 5. Blades are bent. 5. Replace blades. 6. Gearbox output shaft (spindle) is bent. 6. Contact Authorized Service Dealer. 1.
The Toro Total Coverage Guarantee A One-Year Limited Warranty LCE Conditions and Products Covered Owner Responsibilities The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair any Toro Product used for commercial, institutional, or rental purposes if defective in materials or workmanship.
