Form No. 3361-228 Rev B Z Master G3 with a 48in or 52in TURBO FORCE® Side Discharge Mower Model No. 74901—Serial No. 290000001 and Up Model No. 74903—Serial No. 290000001 and Up To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com.
Warning CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. This spark ignition system complies with Canadian ICES-002 Because in some areas there are local, state, or federal regulations requiring that a spark arrester be used on the engine of this machine, a spark arrester is available as an option. If you require a spark arrestor, contact your Authorized Toro Dealer.
Checking the Engine Oil Level............................ 14 Breaking In a New Machine ................................ 14 Using the Rollover Protection System (ROPS) .......................................................... 14 Think Safety First ............................................... 15 Operating the Parking Brake ............................... 16 Operating the Mower Blade Control Switch (PTO) ............................................................ 16 Operating the Throttle ................
Safety • Use extra care when handling gasoline and other fuels. They are flammable and vapors are explosive. Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means CAUTION, WARNING, or DANGER-“personal safety instruction." Failure to comply with the instruction may result in personal injury or death.
• Check the area to be mowed and never fold the ROPS in areas where there are slopes, drop offs or water. • Do not operate the mower under the influence of alcohol or drugs. • Use extreme care when loading or unloading the machine into a trailer or truck. • Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision. • Lower the rollbar only when absolutely necessary. Do not wear the seat belt with the roll bar folded down. • Check carefully for overhead clearances (i.
Slope Chart 6
Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. 68-8340 1-403005 98-5954 103-2076 54-9220 58-6520 1.
109-7232 109-7304 107-2102 109-7929 107-2112 109-9477 8
110-2067 114-9834 1. Power Take-off (PTO) 4. Continuous variable setting 5. Slow 2. Choke 3. Fast 110-2068 1. Read the Operator’s Manual. 114-4466 1. Main, 25A 2. PTO, 10A 3. Charge, 25A 4. Auxiliary, 15A 115-7445 1. Grease pulleys 2.
116-0090 116-0166 116-0157 116-0165 116-0205 Manufacturer’s Mark 1. Indicates the blade is identified as a part from the original machine manufacturer.
Product Overview Use these times for scheduling regular maintenance (Figure 5). Fuel Gauge The fuel gauge is located with the hour meter and the bars light up when the ignition switch is on (Figure 5). The indicator light appears when the fuel level is low (approximately one gallon remaining in the fuel tank). Safety Interlock Indicators There are symbols on the hour meter and the indicate with a black triangle that the interlock component is in the correct position (Figure 5).
switch up to engage the blades and release. To disengage the blades, push the blade control switch (PTO) down or move a motion control lever into the neutral lock position. Length: Ignition Switch 48 inch Deck 52 inch Deck Roll Bar - Up 79.2 inches (201.2 cm) 79.2 inches (201.2 cm) Roll Bar - Down 80.9 inches (205.5 cm) 80.9 inches (205.5 cm) 60 inch Deck 72 inch Deck Roll Bar - Up 83.1 inches (211.1 cm) 86.1 inches (218.7 cm) Roll Bar - Down 84.8 inches (215.4 cm) 87.8 inches (223.
Operation In certain conditions during fueling, static electricity can be released causing a spark which can ignite the gasoline vapors. A fire or explosion from gasoline can burn you and others and can damage property. Note: Determine the left and right sides of the machine from the normal operating position. Adding Fuel Use unleaded regular gasoline suitable for automotive use (85 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available.
Checking the Engine Oil Level Important: Do not use fuel additives containing methanol or ethanol. Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking the Engine Oil Level. Add the correct amount of gas stabilizer/conditioner to the gas. Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline. To minimize the chance of varnish deposits in the fuel system, use fuel stabilizer at all times.
3. Lower the roll bar to the down position (Figure 7). Operating on wet grass or steep slopes can cause sliding and loss of control. Wheels dropping over edges can cause rollovers, which may result in serious injury, death or drowning. There is no rollover protection when the roll bar is down. Always keep the roll bar in the raised and locked position and use the seat belt. Read and follow the rollover protection instructions and warnings.
Setting the Parking Brake Parking brake may not hold machine parked on a slope and could cause personal injury or property damage. Do not park on slopes unless wheels are chocked or blocked 1 2 Figure 8 1. Safe Zone-use the Z Master here on slopes less than 15 degrees or flat areas. 2. Danger Zone- use a walk behind mower and/or a hand trimmer on slopes greater than 15 degrees, near drop-offs and water. 3.
Engaging the Blade Control Switch (PTO) 2. Pull up on the choke knob to engage the choke before using the ignition switch (Figure 15). Note: Engaging the blade control switch (PTO) with the throttle position at half or less will cause excessive wear to the drive belts. 3. Push down on the choke to disengage the choke after the engine has started (Figure 15). 1 G008945 Figure 12 Disengaging the Blade Control Switch (PTO) 2 G008959 Figure 15 1. On 2.
4. Move the blade control switch (PTO) to the Off position (Figure 18). 5. Move the throttle lever midway between the Slow and Fast positions. ST RT A N RU P ST O G008947 Figure 16 2. Turn the ignition key to stop to stop the engine. Using the Fuel Shut-Off Valve The fuel shut-off valve is located under the seat. Close the fuel shut-off valve for transport, maintenance, and storage. Ensure the fuel shut-off valve is open when starting the engine. Figure 18 6.
ST RT A N RU P ST O G008947 Figure 19 1. Off 2. Run 3. Start Stopping the Engine Children or bystanders may be injured if they move or attempt to operate the tractor while it is unattended. Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes. Figure 20 Let the engine idle at slow throttle (turtle) for 60 seconds before turning the ignition switch off.
Understanding the Safety Interlock System the motion control levers to neutral lock position. Now start the engine. While the engine is running, release the parking brake, engage the blade control switch (PTO) and rise slightly from the seat; the engine should stop. The safety interlock system is designed to prevent the engine from starting unless: • You are sitting on the seat. • The parking brake is engaged. • The blade control switch (PTO) is disengaged.
Using the Motion Control Levers G008952 Figure 23 Figure 22 1. Motion control lever-neutral lock position 2. Center, unlocked position 3. Forward Driving Backward 4. Backward 1. Move the levers to the center, unlocked position. 5. Front of machine 2. To go backward, slowly pull the motion control levers rearward (Figure 24). Driving Forward Note: The engine will kill if the traction control levers are moved with the parking brake engaged.
Stopping the Machine To stop the machine, move the traction control levers to neutral and move to locked position, disengage the power take off (blade control switch (PTO), and turn the ignition key to off. Set the parking brake when you leave the machine; refer to Setting the Parking Brake in Operation. Remember to remove the key from the ignition switch. Children or bystanders may be injured if they move or attempt to operate the tractor while it is unattended.
4. Select a hole in the height-of-cut bracket corresponding to the height-of-cut desired and, insert the pin (Figure 26). 5. Push on the deck lift, pull back on the transport lock, and slowly lower the mower deck. Figure 28 1. Anti-scalp roller 2. Bushing 3. Flange Nut 4. Bolt Figure 26 1. Deck lift pedal 2. Cut of height pin 3. Transport lock Adjusting the Anti-Scalp Rollers Whenever you change the height-of-cut, it is recommended to adjust the height of the anti-scalp rollers. Figure 29 1.
Using the Drive Wheel Release Valves Hands may become entangled in the rotating drive components below the engine deck, which could result in serious injury. Stop the engine, remove the key, and allow all moving parts to stop before accessing the drive wheel release valves. Figure 30 1. Nuts for positioning the flow baffle The engine and hydraulic drive units can become very hot. Touching a hot engine or hydraulic drive units can cause severe burns.
Transporting Machines Use a heavy-duty trailer or truck to transport the machine. Ensure that the trailer or truck has all necessary brakes, lighting, and marking as required by law. Please carefully read all the safety instructions. Knowing this information could help you, your family, pets or bystanders avoid injury. Driving on the street or roadway without turn signals, lights, reflective markings, or a slow moving vehicle emblem is dangerous and can lead to accidents causing personal injury.
Loading Machines Use extreme caution when loading units on trailers or trucks. One full width ramp that is wide enough to extend beyond the rear tires is recommended instead of individual ramps for each side of the unit (Figure 35). The lower rear section of the tractor frame extends back between the rear wheels and serves as a stop for tipping backward. Having a full width ramp provides a surface for the frame members to contact if the unit starts to tip backward.
Long Grass Operating Tips If the grass is ever allowed to grow slightly longer than normal, or if it contains a high degree of moisture, raise the cutting height higher than usual and cut the grass at this setting. Then cut the grass again using the lower, normal setting. Fast Throttle Setting For best mowing and maximum air circulation, operate the engine at the fast throttle position.
Maintenance Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 8 hours • Change the engine oil. After the first 100 hours • Check the wheel hub slotted nut torque. • Check the torque for wheel lug nuts. • Check the park brake adjustment. Before each use or daily • • • • • • • • Check the safety system. Check the engine oil level. Check the seat belt. Check the rollover protection system (ROPS) knobs. Clean the engine screen and the oil cooler.
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 before you do any maintenance. Lubrication Greasing and Lubrication Grease more frequently when operating conditions are extremely dusty or sandy. Grease Type: No. 2 general purpose lithium base or molybdenum base grease How to Grease 1.
8. Pump grease into the zerk until it oozes out around the top bearing. 1. Disengage the blade control switch (PTO), move the motion control levers to the neutral locked position, and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Grease the mower deck idler pulley pivot until grease come out the bottom (Figure 37). 4.
Engine Maintenance Note: The seals must be replaced. 8. If the axle assembly has had both spacer nuts removed (or broken loose), apply a thread locking adhesive to one spacer nut and thread onto the axle with the wrench flats facing outward. Do Not thread spacer nut all of the way onto the end of the axle. Leave approximately 1/8 inch (3 mm) from the outer surface of the spacer nut to the end of the axle inside the nut. Contact with hot surfaces may cause personal injury.
1. If installing new filters, check each filter for shipping damage. Do not use a damaged filter. 2. Install the precleaner (ensure it is oiled) onto the air filter element (Figure 41). 3. Install the air filter element onto the base (Figure 41). Ensure that it is fully seated. 4. Install the air filter element cover and secure it with the element cover nut (Figure 41). 5. Install the cover and secure it with the cover nut.
Checking the Engine Oil Level Service Interval: Before each use or daily Note: Check the oil when the engine is cold. Contact with hot surfaces may cause personal injury. Keep hands, feet, face, clothing and other body parts away from the muffler and other hot surfaces. Important: Do not overfill the crankcase with oil because damage to the engine may result. Do not run engine with oil below the low mark because the engine may be damaged. 1.
Changing the Engine Oil Service Interval: After the first 8 hours Every 100 hours (more often in dirty or dusty conditions) Note: Dispose of the used oil at a recycling center. G008804 1 1. Start the engine and let it run five minutes. This warms the oil so it drains better. 2 2. Park the machine so that the rear is slightly lower than the front to ensure the oil drains completely. 3. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake.
5. Slowly pour approximately 80% of the specified oil into the filler tube and slowly add the additional oil to bring it to the Full mark (Figure 45). 1 2 G008804 3 5 1 2 3 4 4 6 5 6 G008796 Figure 45 6. Start the engine and drive to a flat area. Check the oil level again. 3/4 Changing the Engine Oil Filter G008748 Service Interval: Every 200 hours Figure 46 Note: Change the engine oil filter more frequently when operating conditions are extremely dusty or sandy.
Servicing the Spark Plug Service Interval: Every 100 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. Type : Champion® RC12YC or equivalent Air Gap: 0.030 inch (0.76 mm) Removing the Spark Plug 1.
Checking the Spark Plug Check Spark Arrester (if equipped) Important: Never clean the spark plug(s). Always replace the spark plug(s) when it has: a black coating, worn electrodes, an oily film, or cracks. Service Interval: Every 50 hours If you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means the air cleaner is dirty. Hot exhaust system components may ignite gasoline vapors even after the engine is stopped.
Fuel System Maintenance Note: It is important to reinstall the fuel line hoses and secure with plastic ties the same as they were originally installed at the factory to keep the fuel line away from components that could cause fuel line damage. Replacing the Fuel Filter Servicing the Fuel Tank Service Interval: Every 500 hours/Yearly (whichever comes first) (more often in dirty or dusty conditions). Do not attempt to drain the fuel tank.
Electrical System Maintenance Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. Servicing the Battery Service Interval: Monthly • Always Disconnect the negative (black) battery cable before disconnecting the positive (red) cable. Warning • Always Reconnect the positive (red) battery cable before reconnecting the negative (black) cable.
Charging the Battery Charging the battery produces gasses that can explode. G008804 Never smoke near the battery and keep sparks and flames away from battery. 2 Important: Always keep the battery fully charged (1.265 specific gravity). This is especially important to prevent battery damage when the temperature is below 32°F (0°C). - + 1 1. Charge battery for 10 to 15 minutes at 25 to 30 amps or 30 minutes at 10 amps. + 4 - 3 - + 2.
Servicing the Fuses Drive System Maintenance The electrical system is protected by fuses. It requires no maintenance, however, if a fuse blows check the component/circuit for a malfunction or short. Checking the Seat Belt 1. The fuses are located on right hand console next to the seat (Figure 54). Service Interval: Before each use or daily 2. To replace the fuses, pull out on the fuse to remove it. Visually inspect seat belt for wear, cuts, and proper operation of retractor and buckle.
Figure 56 Left control lever shown 1. Control lever 2. Bolt Checking the Tire Pressure Figure 55 1. ROPS knob (locked position) 2. Pull ROPS knob out and rotate 90 degrees to change roll bar position 3. Stop plate 3. Roll bar in the upright position 4. Roll bar in the folded position Service Interval: Every 50 hours/Monthly (whichever comes first) Maintain the air pressure in the rear tires at 13 psi (90 kPa). Uneven tire pressure can cause uneven cut.
Note: Do not use anti-seize on the wheel hub. Adjusting the Caster Pivot Bearing Service Interval: Every 500 hours/Yearly (whichever comes first) 1. Disengage the blade control switch (PTO), move the motion control levers to the neutral locked position and set the parking brake. Figure 57 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Checking the Wheel Hub Slotted Nut 3. Remove the dust cap from caster and tighten lock nut (Figure 59).
Note: Do Not remove the brake pole from the field shell/armature. The brake pole has worn to match the armature and needs to continue to match after the shim is removed to ensure proper brake torque. Figure 60 1. 2. 3. 4. Armature Field shell Rotor Brake mounting bolt 5. Brake spacer 6. Re-gap shim 7. Brake pole Figure 62 1. Brake mounting bolt Removing the Clutch Shim B.
Cooling System Maintenance Cleaning the Engine Screen and Engine Oil Cooler Service Interval: Before each use or daily Remove any build-up of grass, dirt or other debris from the oil cooler (Figure 66). Figure 64 1. Feeler gauge G008804 Figure 65 Figure 66 1. Feeler gauge Before each use remove any build-up of grass, dirt or other debris from the engine screen.
Figure 67 1. Engine guard 2. Engine air intake screen 3. Bolt 4. Fan housing 5. Screw Figure 68 1. Hydraulic unit shrouds Check and Clean the Hydraulic Unit Shrouds Service Interval: Before each use or daily 1. Disengage the PTO and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Raise the seat. 4. Clean the debris and grass from the hydraulic unit shrouds (Figure 68). 5. Lower the seat.
Brake Maintenance standard nut. Do Not allow the cable to turn when the nuts are tightened. Adjusting the Parking Brake 15. Close the drive wheel release valve. Refer to Using the Drive Wheel Valves in Operation. Service Interval: After the first 100 hours Every 500 hours 16. Repeat on the opposite side of the machine. 17. Install the rear tires and torque the lug nuts to 90-95 ft-lb (122-129 N-m). 18. Remove jack stands.
Belt Maintenance Inspecting the Belts Service Interval: Every 50 hours Check the belts for squealing when the belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks and cracks are signs of a worn mower belt. Replace the mower belt if any of these conditions are evident. Replacing the Mower Belt Squealing when the belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks and cracks are signs of a worn mower belt.
Figure 72 1. Position the belt cover 3. Ensure the tab is under the metal catch Figure 73 2. Slide belt cover under the side catches 1. Idler pulley 2. Clutch pulley 3. Pump drive belt 4. Right hand hydraulic pump pulley Replacing the Hydraulic Pump Drive Belt 5. Left hand hydraulic pump pulley 6. Square hole in idler arm 7. Idler spring 5. Use a ratchet in the square hole in the idler arm to remove the idler spring (Figure 73). 1. Disengage the PTO and set the parking brake. 2.
Controls System Maintenance Adjusting the Control Handle Position There are two height positions for the control levers; high and low. Remove the bolts to adjust the height for the operator. 1. Disengage the PTO, move the motion control levers to the neutral locked position, and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Figure 75 3. Loosen the bolts and flange nuts installed in the levers (Figure 74). 4.
Adjusting the Motion Control Damper 5. Start engine. Brake must be engaged and motion control levers out to start engine. Operator does not have to be in the seat because of the jumper wire being used. Run engine at full throttle and release brake. The top damper mounting bolt can be adjusted to obtain a more desired motion control lever resistance. See Figure 77 for mounting options. 6.
Hydraulic System Maintenance Servicing the Hydraulic System Hydraulic Oil Type: Toro® HYPR-OIL™ 500 hydraulic oil or Mobil® 1 15W-50. Figure 78 1. Flanged nut 2. Jam nut Important: Use oil specified or equivalent. Other fluids could cause system damage. Each Hydraulic System Oil Capacity: 52 ounces (1.5 l) per side with filter change Checking the Hydraulic Oil Service Interval: Every 50 hours—Check the hydraulic oil level. 1. Position the machine on a level surface. 2.
Replacing the Hydraulic Filters and Hydraulic Oil Service Interval: Every 250 hours—Change the hydraulic filters and hydraulic oil when using Mobil 1 oil. Every 500 hours—Change the hydraulic filters and hydraulic oil when using Toro® HYPR-OIL™ 500 hydraulic oil. To replace the hydraulic oil, the filters need to be removed. Replace both at the same time. Refer to the oil specifications under Servicing the Hydraulic System for the correct oil. 1.
Mower Deck Maintenance 1 Leveling the Mower Deck Setting Up the Machine Note: Ensure the mower deck is leveled before matching the height-of-cut (HOC). 1. Position mower on a flat surface. 2. Disengage the blade control switch (PTO), move the motion control levers to the neutral locked position and set the parking brake. 3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 4. Check tire pressure of the drive tires.
6. Insert the height adjustment pin into the 3 inch (7.6 cm) cutting height location. 7. Release the transport lock and allow the deck to lower to the cutting height. 8. Raise the discharge chute. 9. On both sides of the deck, measure from the level surface to the front tip of the blade (Postion A). The measurement should read 3 inches (7.6 mm) (Figure 83). 11.
Servicing the Cutting Blades Maintain sharp blades throughout the cutting season because sharp blades cut cleanly without tearing or shredding the grass blades. Tearing and shredding turns grass brown at the edges, which slows growth and increases the chance of disease. Check the cutter blades daily for sharpness, and for any wear or damage. File down any nicks and sharpen the blades as necessary. If a blade is damaged or worn, replace it immediately with a genuine Toro replacement blade.
A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders. • Always replace bent or damaged blade with a new blade. • Never file or create sharp notches in the edges or surfaces of blade. Figure 87 1. Cutting Edge 2. Curved Area 3. Wear/slot Forming 4. Crack Removing the Blades Blades must be replaced if a solid object is hit, if the blade is out of balance or is bent.
Installing the Blades 1. Install the blade onto the spindle shaft (Figure 92). Important: The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting. Figure 90 2. Install the spring disk and blade bolt. The spring disk cone must be installed toward the bolt head (Figure 92). Torque the blade bolt to 85-110 ft-lb (115-150 N-m). 1. Sharpen at original angle 2. Check the balance of the blade by putting it on a blade balancer (Figure 91).
Removing the Mower Deck Before servicing or removing the mower deck, the spring loaded deck arms must be locked out. Deck lift arm assemblies have stored energy. Removing the deck with out releasing the stored energy can cause serious injury or death. Do Not attempt to disassemble the deck from the front frame without locking out the stored energy. 1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. 2. Remove the height adjustment pin and lower the deck to the ground.
Replacing the Grass Deflector Cleaning Cleaning Under the Mower An uncovered discharge opening could allow the lawn mower to throw objects in the operator’s or bystander’s direction and result in serious injury. Also, contact with the blade could occur. Service Interval: Before each use or daily • Never operate the lawn mower unless you install a cover plate, a mulch plate, or a grass chute and catcher. 2.
Storage B. Run the engine to distribute conditioned fuel through the fuel system (5 minutes). Cleaning and Storage C. Stop the engine, allow it to cool, and drain the fuel tank; refer to Servicing the Fuel Tank in the Maintenance Section. 1. Disengage the power take off (blade control switch (PTO), set the parking brake, and turn the ignition key to Off. Remove the key. 2. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine and hydraulic system.
Troubleshooting Problem Starter does not crank Engine will not start, starts hard, or fails to keep running Possible Cause 1. Blade control switch (PTO) is engaged. 1. Move blade control switch (PTO) to disengaged. 2. Parking brake is not on. 3. Drive levers are not in neutral lock position. 4. Operator is not seated. 5. Battery is dead. 6. Electrical connections are corroded or loose. 7. Fuse is blown. 8. Relay or switch is defective. 2. Set the parking brake. 3.
Problem Machine does not drive. Abnormal vibration. Uneven cutting height. Possible Cause 1. By pass valves is not closed tight. 1. Tighten the by pass valves. 2. 3. 4. 5. 2. 3. 4. 5. Pump belt is worn, loose or broken. Pump belt is off a pulley. Broken or missing idler spring. Hydraulic oil level is low or too hot. 1. Install new cutting blade(s). 2. Blade mounting bolt is loose. 3. Engine mounting bolts are loose. 4. Loose engine pulley, idler pulley, or blade pulley. 5. Engine pulley is damaged.
Schematics Wire Diagram (Rev.
Notes: 65
Notes: 66
Notes: 67
The Toro Total Coverage Guarantee A Limited Warranty (see warranty periods below) Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair the listed Toro Products if defective in materials or workmanship.
