Form No. 3360-644 Rev B Z Master G3 with a 60in TURBO FORCE® Side Discharge Mower Model No. 74915—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 109-7929 107-2102 109-9477 107-2112 114-4466 1. Main, 25A 2. PTO, 10A 8 3. Charge, 25A 4.
116-0090 114-9834 1. Power Take-off (PTO) 4. Continuous variable setting 5. Slow 2. Choke 3. Fast 116-0157 116-0165 115-7445 1. Grease pulleys 2.
116-0211 116-0752 Manufacturer’s Mark 1. Locked 1. Indicates the blade is identified as a part from the original machine manufacturer. 109-7069 10 2.
Fuel Gauge Product Overview 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).
the blades, push the blade control switch (PTO) down or move a motion control lever into the neutral lock position. Specifications Ignition Switch Width: Note: Specifications and design are subject to change without notice. This switch is used to start the mower engine and has three positions: Start, Run and Off. 60 inch Deck Motion Control Levers The motion control levers are used to drive the machine forward, reverse, and turn either direction. Without Deck 53.0 inches (134.
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 Driving Backward 3. Forward 1. Move the levers to the center, unlocked position. 4. Backward 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. To stop, pull the motion control levers to the neutral position. 1.
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 27 1. Anti-scalp roller 2. Spacer 3. Bushing 4. Flange Nut 5. 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 28 1.
Position A Adjusting the Flow Baffle Cam Locks This is the full rear position. The suggested use for this position is a follows. This procedure is applicable only to machines with the flow baffle locks. Certain models will have nuts and bolts in-place of the flow baffle locks and can be adjusted the same. • Use for short, light grass mowing conditions. • Use in dry conditions. • For smaller grass clippings. The mower discharge flow can be adjusted for different types of mowing conditions.
Unlatching the Seat • Allows increased ground speed in heavy conditions. • This position is similar to the benefits of the Toro SFS mower. Figure 35 1. Seat latch 2. Seat Using the Drive Wheel Release Valves Figure 33 Positioning the Seat Hands may become entangled in the rotating drive components below the engine deck, which could result in serious injury. The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable.
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 38). 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.
9. Remove the grease zerk in the hole. Install the hex plug and dust cap (Figure 42). 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 40). 4. Grease the fittings on the side of the 3 spindle bearings until grease come out the bottom (Figure 40). Figure 42 10. Grease the caster wheel bearings (Figure 42).
Engine Maintenance 7. Insert one bearing, one new seal into the wheel. 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.
4. Clean the inside of the air cleaner cover with compressed air. 5. Gently slide the primary filter out of the air cleaner body (Figure 44). Oil Capacity: with a filter change, 59 ounces (1.75 L); with no filter change, 54 ounces (1.6 L) Viscosity: See the table below. Note: Avoid knocking the filter into the side of the body. 6. Remove the safety filter only if you intend to replace it. Important: Never attempt to clean the safety filter.
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 48). 1 2 G008804 3 5 1 2 3 4 4 6 5 6 G008796 Figure 48 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 49 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 installed at the factory to keep the fuel line away from components that can cause fuel line damage. Servicing the Fuel Tank Replacing the Fuel Filter Do not attempt to drain the fuel tank. Ensure that an Authorized Service Dealer drains the fuel tank and services any components of the fuel system. Service Interval: Every 500 hours/Yearly (whichever comes first) (more often in dirty or dusty conditions).
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 57). 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 59 Checking the Wheel Hub Slotted Nut Service Interval: After the first 100 hours Every 500 hours 1. Remove the cotter pin. 2. Torque the slotted nut to 200 ft-lb (271 N-m). 3. Check the distance from the bottom of the slot in the nut to the inside edge of the hole. Two threads (0.1 inch) or less should be showing. Figure 58 1. ROPS knob (locked position) 2. Pull ROPS knob out and rotate 90 degrees to change roll bar position 3. Roll bar in the upright position 4.
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. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the dust cap from caster and tighten lock nut (Figure 61). Figure 62 1. 2. 3. 4. 4.
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 66 1. Feeler gauge Figure 64 1. Brake mounting bolt B. Using needle nose pliers, or by hand, take hold of the tab and remove the shim (Do Not discard the shim until proper clutch function has been confirmed). Figure 67 1. Feeler gauge • If the gap is less than 0.
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 68). Figure 69 1. Engine guard 2. Engine air intake screen 3. Bolt G008804 4. Fan housing 5. Screw Check and Clean the Hydraulic Unit Shrouds Figure 68 Service Interval: Before each use or daily 1. Disengage the PTO and set the parking brake.
Brake Maintenance Adjusting the Parking Brake Service Interval: After the first 100 hours Every 500 hours Mechanical or hydraulic jacks may fail to support machine and cause a serious injury. • Use jack stand when supporting machine. • Do not use hydraulic jacks. Check to make sure the brake is adjusted properly. 1. Drive the machine onto a level surface. 2. Disengage the blade control switch (PTO), move the motion control levers to the neutral locked position and set the parking brake. 3.
Belt Maintenance standard nut. Do Not allow the cable to turn when the nuts are tightened. 15. Close the drive wheel release valve. Refer to Using the Drive Wheel Valves in Operation. Inspecting the Belts 16. Repeat on the opposite side of the machine. Service Interval: Every 50 hours 17. Install the rear tires and torque the lug nuts to 90-95 ft-lb (122-129 N-m).
Figure 74 1. Position the belt cover 3. Ensure the tab is under the metal catch 2. Slide belt cover under the side catches Replacing the Hydraulic Pump Drive Belt Figure 73 1. Clutch pulley 2. Mower belt 3. Spring loaded idler pulley 4. Ratchet 5. Square hole in the idler arm for the ratchet 6. Idler grease zerk 7. Belt guide 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. 10.
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 1. Idler pulley 2. Clutch pulley 3. Pump drive belt 4.
4. Temporarily install a jumper wire across the terminals in the connector of the main wiring harness. 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. 6. Run the unit at least 5 minutes with the drive levers at full forward speed to bring hydraulic oil up to operating temperature.
Adjusting the Motion Control Damper The top damper mounting bolt can be adjusted to obtain a more desired motion control lever resistance. See Figure 79 for mounting options. Figure 80 1. Flanged nut Figure 79 RH Motion Control Shown 1. Torque the lock nut to 200 in-lb (16.7 ft-lb). Bolt must protrude past end of locknut after torque. 2. Least resistance (softest feel) 3. Damper 4. Medium resistance (medium feel) 5.
Hydraulic System Maintenance Servicing the Hydraulic System Hydraulic Oil Type: Toro® HYPR-OIL™ 500 hydraulic oil or Mobil® 1 15W-50. 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 1 Service Interval: Every 250 hours Every 500 hours 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. 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.
Mower Deck Maintenance 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. Figure 84 3. Transport lock 1. Deck lift pedal 2. Height of cut pin 3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 6.
13. If the deck is too low, tighten the single point adjustment bolt by rotating it clockwise. If the deck is too high, loosen the single point adjustment bolt by rotating it counterclockwise (Figure 88). Note: Loosen or tighten the single point adjustment bolt enough to move the height-of-cut plate mounting bolts at least 1/3 the length of the available travel in their slots. This will regain some up and down adjustment on each of the four deck links. Figure 86 1. Adjustment nut 2. Jam Nut 3.
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.
Sharpening the Blades A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders. When sharpening blade, pieces of blade could be thrown and cause serious injury. • Always replace bent or damaged blade with a new blade. Wear proper eye protection when sharpening blade. • Never file or create sharp notches in the edges or surfaces of blade. 1. Use a file to sharpen the cutting edge at both ends of the blade (Figure 92). Maintain the original angle.
Installing the Blades Removing the Mower Deck 1. Install the blade onto the spindle shaft (Figure 94). Before servicing or removing the mower deck, the spring loaded deck arms must be locked out. Important: The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting. 2. Install the spring disk and blade bolt. The spring disk cone must be installed toward the bolt head (Figure 94). Torque the blade bolt to 85-110 ft-lb (115-150 N-m).
Figure 96 1. 2. 3. 4. Figure 95 1. Clutch pulley 2. Mower belt 3. Spring loaded idler pulley 4. Ratchet 5. Square hole in the idler arm for the ratchet 6. Idler grease zerk 7. Belt guide Right stabilizer Deck strut (right side shown) Remove the rear deck lift attachment shoulder bolt and nut. Remove the front deck lift attachment shoulder bolt and nut. 8. Raise the deck struts and secure them in the up position. Slide the deck out to the right side of the machine. 7.
Cleaning Note: Make sure the L end of the spring is installed behind the deck edge before installing the bolt as shown in Figure 97. Cleaning Under the Mower 3. Install the bolt and nut. Place the J hook end of the spring around the grass deflector (Figure 97). Service Interval: Before each use or daily Important: The grass deflector must be able to lower down into position. Lift the deflector up to test that it lowers into the full down position. 1.
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.
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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.
