Form No. 3380-781 Rev A Z Master® Commercial 3000 Series Riding Mower with 72in TURBO FORCE® Side Discharge Mower Model No. 74959—Serial No. 314000001 and Up Register at www.Toro.com.
Introduction WARNING This rotary-blade, riding lawn mower is intended to be used by residential homeowners or professional, hired operators. It is designed primarily for cutting grass on well-maintained lawns on residential or commercial properties. It is not designed for cutting brush or for agricultural uses. CALIFORNIA Proposition 65 Warning This product contains a chemical or chemicals known to the State of California to cause cancer, birth defects, or reproductive harm.
Servicing the Spark Plug ..........................................35 Check the Spark Arrester (if equipped) ......................36 Fuel System Maintenance ...........................................37 Replacing the Fuel Filter..........................................37 Servicing the Fuel Tank ...........................................37 Electrical System Maintenance ....................................38 Servicing the Battery...............................................38 Servicing the Fuses ........
Operation Safety • Lightning can cause severe injury or death. If lightning Improper use or maintenance 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. • • • This product is capable of amputating hands and feet and throwing objects.
• Let engine cool before storing and do not store near • Be certain that the seat belt can be released quickly in flame. the event of an emergency. • Check the area to be mowed where there are slopes, drop • Shut off fuel while storing or transporting. Do not store offs or water. fuel near flames or drain indoors. • Check carefully for overhead clearances (i.e. branches, • Park the machine on level ground. Set the parking brake.
Slope Indicator G011841 Figure 3 This page may be copied for personal use. 1. The maximum slope you can safely operate the machine on is 15 degrees. Use the slope chart to determine the degree of slope of hills before operating. Do not operate this machine on a slope greater than 15 degrees. Fold along the appropriate line to match the recommended slope. 2. Align this edge with a vertical surface, a tree, building, fence pole, etc. 3. Example of how to compare slope with folded edge.
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.
110-2067 110-2068 1. Read the Operator's Manual. 107-2102 114-4466 1. Main, 25A 3. Charge, 25A 2. PTO, 10A 4. Auxiliary, 15A 109-7232 1. Fast 2. Slow 116-0205 3. Neutral 4.
116-1716 1. Fuel 2. Empty 6. Hour meter 7. PTO 3. Half 8. Parking brake 4. Full 5. Battery 9. Neutral 10. Operator presence switch 115-7445 1. Grease pulleys and spindles 2. Maintenance interval—50 hours 116-3303 116-0752 1. Latch 2.
Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 6. Keep bystanders a safe distance from the battery. 2. No fire, open flame, or smoking. 7. Wear eye protection; explosive gases can cause blindness and other injuries 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. 5. Read the Operator's Manual. 10. Contains lead; do not discard.
125–9382 1. Read the Operator’s Manual for more information on servicing the machine.
Hour Meter Product Overview The hour meter records the number of hours the engine has operated. It operates when the engine is running. Use these times for scheduling regular maintenance (Figure 6). Fuel Gauge The fuel gauge is located with the hour meter and the bars light up when the ignition switch is on (Figure 6). The indicator light appears when the fuel level is low (approximately one gallon remaining in the fuel tank).
Ignition Switch Specifications This switch is used to start the mower engine and has 3 positions: Start, Run, and Off. Note: Specifications and design are subject to change without notice. Motion Control Levers Width: 72 inch Deck The motion control levers are used to drive the machine forward, reverse, and turn either direction. Neutral Lock Position The neutral lock position is used with the safety interlock system to engage and to determine neutral position. Without Deck 150.1 cm (59.
Operation DANGER 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. • Always place gasoline containers on the ground away from your vehicle before filling.
Important: Lower the roll bar only when absolutely necessary. of varnish deposits in the fuel system, use fuel stabilizer at all times. Important: Ensure that the seat is secured to the machine. Filling the Fuel Tank 1. Shut the engine off and set the parking brake. 1. To lower the roll bar, apply forward pressure to the upper part of the roll bar. 2. Clean around the fuel tank cap and remove the cap.
Important: Always use the seat belt with the roll bar in the fully raised position. CAUTION Think Safety First This machine produces sound levels in excess of 85 dBA at the operators ear and can cause hearing loss through extended periods of exposure. Please read all safety instructions and symbols in the safety section. Knowing this information could help you or bystanders avoid injury. Wear hearing protection when operating this machine.
Releasing the Parking Brake 1 Operating the Throttle The throttle control can be moved between the Fast and Slow positions (Figure 14). 2 Always use the fast position when turning on the mower deck with the blade control switch (PTO). G016995 Figure 11 G008946 Operating the Mower Blade Control Switch (PTO) Figure 14 The blade control switch (PTO) starts and stops the mower blades and any powered attachments. Operating the Ignition Switch 1. Turn the ignition key to the Start position (Figure 15).
Using the Fuel Shut-Off Valve The fuel shut-off valve is located under the seat. Move the seat forward to access it. Close the fuel shut-off valve for transport, maintenance, and storage. Ensure the fuel shut-off valve is open when starting the engine. 1 2 G008948 Figure 16 1. On g017006 Figure 17 2. Off 6. Turn the ignition key to the Start position (Figure 15). When the engines starts, release the key.
Stopping the Engine The Safety Interlock System CAUTION CAUTION Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes. • Do not tamper with the interlock switches.
Using the Motion Control Levers 1. Sitting on the seat, engage the parking brake and move the blade control switch (PTO) to on. Try starting the engine; the engine should not crank. 2. Sitting on the seat, engage the parking brake and move the blade control switch (PTO) to off. Move either motion control lever (out of neutral locked position). Try starting the engine; the engine should not crank. Repeat for other control lever. 3.
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 the off position. Set the parking brake when you leave the machine; refer to Setting the Parking Brake (page 16). Remove the key from the ignition switch. CAUTION Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended.
Adjusting the Height-of-Cut Pin The height-of-cut is adjusted from 25 to 140 mm (1 to 5-1/2 inches) in 6 mm (1/4 inch) increments by relocating the clevis pin into different hole locations. 1. Move the transport lock to the lock position. 2. Push on the deck lift pedal with your foot and raise the mower deck to the transport position (also the 140 mm (5-1/2 inch) cutting height position) (Figure 25). 3. To adjust, rotate the pin 90 degrees and remove the pin from the height-of-cut bracket (Figure 25). 4.
Adjusting the Flow Baffle Cam Locks 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. The mower discharge flow can be adjusted for different types of mowing conditions. Position the cam locks and baffle to give the best quality of cut. 1. Disengage the blade control switch (PTO), move the motion control levers to the neutral locked position, and set the parking brake. Figure 26 1.
Positioning the Flow Baffle • Use in tall, dense grass mowing conditions. The following figures are only recommendations for use. Adjustments will vary by grass type, moisture content, and height of grass. • Use in wet conditions. • Lowers the engine power consumption. • Allows increased ground speed in heavy conditions. Note: If the engine power draws down and the mower ground speed is the same, open up the baffle. • This position is similar to the benefits of the Toro SFS mower.
Using the Drive Wheel Release Valves 4. Rotate the release valve levers horizontally to run the machine (Figure 34). Using the Side Discharge WARNING The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. Hands may become entangled in the rotating drive components below the engine deck, which could result in serious injury. DANGER Stop the engine, remove the key, and allow all moving parts to stop before accessing the drive wheel release valves.
Transporting Machines WARNING Loading a unit onto a trailer or truck increases the possibility of backward tip-over and could cause serious injury or death. 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.
Operating Tips setting. Then cut the grass again using the lower, normal setting. Maximizing Cutting Efficiency Stopping For best mowing and maximum air circulation, operate the engine at the fast throttle position. Air is required to thoroughly cut grass clippings, so do not set the height of cut so low as to totally surround the mower by uncut grass. Always try to have one side of the mower free from uncut grass, which allows air to be drawn into the mower.
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 lug nut torque. • Check the wheel hub slotted-nut torque. • Check the park brake adjustment. After the first 250 hours • Change the hydraulic filters and hydraulic oil when using any type of oil. Before each use or daily • • • • • • • • Check the safety system. Check the engine-oil level. Check the seat belt.
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 before you do any maintenance. Lubrication Greasing the Mower Lubricating the Machine Service Interval: Every 50 hours—Grease the mower deck spindles and idler arm. Yearly—Grease the pump belt idler arm. Grease more frequently when operating conditions are extremely dusty or sandy.
Lubricate the Caster Wheel Hubs Service Interval: Yearly 1. Stop the engine, wait for all moving parts to stop, and remove the key. Engage the parking brake. Figure 39 Figure 41 6. Remove the dust cap and adjust the caster pivots. 1. Seal guard Note: Keep the dust cap off until greasing is complete. Refer to Adjusting the Caster Pivot Bearing (page 41). 2. Spacer nut with wrench flats 2. Raise the front of the machine up and support it with jack stands. 7.
Engine Maintenance 13. Apply a thread locking adhesive to the second spacer nut and thread it onto the axle with the wrench flats facing outward. Servicing the Air Cleaner 14. Torque the nut to 8-9 N-m (75-80 in-lb), loosen, then re-torque to 2-3 N-m (20-25 in-lb). Service Interval: Every 150 hours Note: Make sure that the axle does not extend beyond either nut. 15. Every 300 hours/Yearly (whichever comes first)—Replace the primary air filter (more often in dusty or sandy conditions).
Servicing the Safety Filter Important: Never attempt to clean the inner filter. If the safety filter is dirty, then the primary filter is damaged. Replace both filters. Replace the safety filter, never clean it. Important: Do not attempt to clean the safety filter. If the safety filter is dirty, then the primary filter is damaged. Replace both filters. Installing the Filters 5 Important: To prevent engine damage, always operate the engine with both air filters and the cover installed. 4 3 1.
Checking the Engine-oil Level Service Interval: Before each use or daily Note: Check the oil when the engine is cold. WARNING G008804 Contact with hot surfaces may cause personal injury. 1 2 3 4 6 7 8 9 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. 5 1.
Changing the Engine Oil 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 47). Service Interval: After the first 8 hours Every 100 hours (more often in dirty or dusty conditions). 1 2 3 4 5 6 Note: Dispose of the used oil at a recycling center. 1. Start the engine and let it run for 5 minutes. Note: This warms the oil so it drains better. 2.
Removing the Spark Plug 1. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 2. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. G008804 1 2 3 4 5 3. Remove the left hydraulic unit shroud in the order listed with Figure 49. This gives you access to the front spark plug.
Check the Spark Arrester (if equipped) Service Interval: Every 50 hours WARNING G008803 Hot exhaust system components may ignite gasoline vapors even after the engine is stopped. Hot particles exhausted during engine operation may ignite flammable materials. Fire may result in personal injury or property damage. Do not refuel or run engine unless spark arrester is installed. Figure 50 1. Stop the engine, wait for all moving parts to stop, and remove the key. Engage the parking brake. 2.
Servicing the Fuel Tank Fuel System Maintenance 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. Replacing the Fuel Filter Service Interval: Every 500 hours/Yearly (whichever comes first) (more often in dirty or dusty conditions). The fuel filter is located near the engine on the front or rear side of the engine. 1.
Electrical System Maintenance WARNING 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 • Always Disconnect the negative (black) battery cable before disconnecting the positive (red) cable. Service Interval: Monthly WARNING • Always Reconnect the positive (red) battery cable before reconnecting the negative (black) cable. CALIFORNIA Proposition 65 Warning 1.
Installing the Battery 1. Position battery in the tray with the terminal posts opposite from the hydraulic tank (Figure 54). 2. First, install the positive (red) battery cable to positive (+) battery terminal. 3. Then install the negative (black) battery cable and ground wire to the negative (-) battery terminal. 4. Secure the cables with 2 bolts, 2 washers, and 2 locknuts (Figure 54). 5. Slide the red terminal boot onto the positive (red) battery post. 6.
Drive System Maintenance Checking the Seat Belt Service Interval: Before each use or daily Visually inspect seat belt for wear, cuts, and proper operation of retractor and buckle. Replace before operating if damaged. Checking the Rollover Protection System (ROPS) Knobs Service Interval: Before each use or daily WARNING To avoid injury or death from rollover: keep the roll bar in the fully raised locked position and use the seat belt. Ensure the seat is secured to the machine.
Checking the Wheel Lug Nuts Check and torque the wheel lug nuts to 122-129 N-m (90-95 ft-lb). Checking the Wheel Hub Slotted Nut Service Interval: After the first 100 hours Every 500 hours Check and ensure that the torque of the slotted nut is 286 to 352 N-m (211 to 260 ft-lb). Note: Do not use anti-seize on wheel hub. Figure 58 Left control lever shown 1. Control lever 3. Stop plate 2.
Removing the Clutch Shim 4. Tighten the locknut until the spring washers are flat and then back off a 1/4 turn to properly set the pre-load on the bearings (Figure 61). 1. Stop the engine, wait for all moving parts to stop, and remove the key. Important: Make sure the spring washers are installed correctly as shown in Figure 61. 2. Engage the parking brake and allow the machine to cool completely before starting these instructions. 5. Install the dust cap (Figure 61). 3.
F. Perform the following safety check: i. Sit on the seat and start the engine. ii. Make sure the blades Do not engage with the PTO switch “off ” and the clutch disengaged. If the clutch does not disengage, install the shim, and reference the Troubleshooting (page 60) section. iii. Engage and disengage the PTO switch 10 consecutive times to ensure the clutch is functioning properly. If the clutch does not engage properly, reference theTroubleshooting (page 60) section. Figure 65 1. Shim C.
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). G008804 Figure 69 1. Engine guard 4. Fan housing 2. Engine air intake screen 5. Screw 3. Bolt Figure 68 Before each use remove any build-up of grass, dirt, or other debris from the engine screen.
Brake Maintenance Check and Clean the Hydraulic Units Adjusting the Parking Brake Service Interval: Before each use or daily 1. Disengage the PTO and set the parking brake. Service Interval: After the first 100 hours 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Every 500 hours thereafter Check to make sure brake is adjusted properly.
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 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 5. Square hole in the idler arm for the ratchet 6. Idler grease fitting 3. Spring loaded idler pulley 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. 4. Ratchet 3.
Controls System Maintenance Adjusting the Control Handle Position There are 2 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. 3. Loosen the bolts and flange nuts installed in the levers (Figure 76). Figure 75 1.
engine. The operator does not have to be in the seat because of the jumper wire being used. Run the engine at full throttle and release the brake. 6. Run the machine at least 5 minutes with the motion-control levers at full forward speed to bring the hydraulic oil up to operating temperature. Note: The motion-control lever needs to be in neutral while making any necessary adjustments. 7. Bring the motion-control levers into the neutral position. 8.
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 23 N-m (17 ft-lb). The bolt must protrude past the end of the locknut after torquing. 2. Most resistance (firmest 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. 3 H Important: Use oil specified. 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: After the first 250 hours—Change the hydraulic filters and hydraulic oil when using any type of oil. Every 250 hours—Change the hydraulic filters and hydraulic oil when using Mobil® 1 oil (more often in dirty or dusty conditions). Every 500 hours—Change the hydraulic filters and hydraulic oil when using Toro® HYPR-OIL™ 500 hydraulic oil (more often in dirty or dusty conditions).
Mower Deck Maintenance 3 1 Leveling the Mower Deck Setting Up the Machine Note: Ensure the mower deck is leveled before matching the height-of-cut (HOC). 2 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. G017027 4. Check tire pressure of the tires.
10. If needed, loosen the whizlock nut on the side of the yoke and the jam nut on top. Fine tune the screw adjuster by turning it to get 7.6 mm (3 inch) height (see Figure 86). 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). To increase the height, turn the adjuster screw clockwise; to decrease, turn counterclockwise.
convenient sharpening and replacement, you may want to keep extra blades on hand. DANGER A worn or damaged blade can break, and a piece of the blade could be thrown into the operator's or bystander's area, resulting in serious personal injury or death. • Inspect the blade periodically for wear or damage. • Replace a worn or damaged blade. Before Inspecting or Servicing the Blades Figure 90 Park the machine on a level surface, disengage the blade control switch (PTO), and set the parking brake.
Removing the Blades Blades must be replaced if a solid object is hit, if the blade is out of balance or is bent. To ensure optimum performance and continued safety conformance of the machine, use genuine Toro replacement blades. Replacement blades made by other manufacturers may result in non-conformance with safety standards. 1. Hold the blade end using a rag or thickly-padded glove. 2. Remove the blade bolt, curved washer, and blade from the spindle shaft (Figure 91). Figure 93 1. Blade 2. Balancer 3.
Removing the Mower Deck Lock out the spring loaded deck arms before servicing or removing the mower deck. WARNING 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 the engine, wait for all of the moving parts to stop, remove the key, and engage parking brake. 2.
Cleaning 9. Slide the deck out to the right side of the machine. Replacing the Grass Deflector Cleaning Under the Mower WARNING Service Interval: Before each use or daily 1. Disengage the blade control switch (PTO), move the motion control levers to the neutral locked position, and set the parking brake. 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. 2.
Storage Cleaning and Storage 1. Disengage the power take off (blade control switch (PTO), set the parking brake, and turn the ignition key to the off position. Remove the key. Stop the engine, allow it to cool, and drain the fuel tank; refer to Servicing the Fuel Tank (page 37) in the Maintenance Section. D. Restart the engine and run it until it stops. E. Dispose of fuel properly. Recycle as per local codes. Important: Do not store stabilizer/conditioned fuel over 90 days. 2.
Troubleshooting Problem The starter does not crank. The engine will not start, starts hard, or fails to keep running Possible Cause 1. The blade control switch (PTO) is engaged. 1. Move the blade control switch (PTO) to disengaged. 2. The parking brake is not on. 3. The drive levers are not in neutral lock position. 4. The operator is not seated. 5. The battery is dead. 6. The electrical connections are corroded or loose. 7. The fuse is blown. 8. The relay or switch is defective. 2.
Problem The machine does not drive. There is abnormal vibration. Mowing is resulting in uneven cutting height. Possible Cause 1. The by pass valves is not closed tight. 1. Tighten the by pass valves. 2. 3. 4. 5. 2. 3. 4. 5. The pump belt is worn, loose or broken. The pump belt is off a pulley. The idler sprint is broken or missing. The hydraulic oil level is low or too hot. 1. Install new cutting blade(s). 2. The blade mounting bolt is loose. 3. The engine mounting bolts are loose. 4.
Schematics G020788 Electrical Schematic (Rev.
Notes: 63
The Toro Total Coverage Warranty Landscape Contractor Equipment (LCE) A Limited Warranty (see warranty periods below) Conditions and Products Covered Instructions for Obtaining Warranty Service The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to the original purchaser to repair the Toro Products listed below if defective in materials or workmanship.
