Form No. 3375-659 Rev C Z Master® Commercial 3000 Series Riding Mower with 60in TURBO FORCE® Side Discharge Mower Model No. 74956—Serial No. 313000001 and Up Register at www.Toro.com.
Introduction WARNING CALIFORNIA Proposition 65 Warning This product contains a chemical or chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. 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.
Servicing the Spark Plug ..........................................35 Check Spark Arrester (if equipped)............................36 Fuel System Maintenance ...........................................37 Servicing the Electronic Fuel Injection System ..............................................................37 Replacing the Low Pressure Fuel Filter ......................37 Servicing the High Pressure Fuel Filter ......................37 Servicing the Fuel Tank ..........................................
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.
• Allow engine to cool before refueling. • Never refuel the machine indoors. • Never store the machine or fuel container where there is • Use full width ramps for loading machine into trailer or truck. • Tie the machine down securely using straps, chains, cable, or ropes. Both front and rear straps should be directed down and outward from the machine. an open flame, spark, or pilot light such as on a water heater or on other appliances.
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 109-7232 1. Fast 2. Slow 3. Neutral 4. Reverse 8 1. Main, 25A 3. Charge, 25A 2. PTO, 10A 4.
116-0752 115-7445 1. Latch 1. Grease pulleys and spindles 2. Unlatch 2. Maintenance interval—50 hours 116-1654 116-0205 116-1716 1. Fuel 2. Empty 6. Hour meter 7. PTO 3. Half 8. Parking brake 4. Full 5. Battery 9. Neutral 10.
121–7586 1. Fast 2. Variable speed control 116-3303 3. Slow 4. Power take-off (PTO) Battery Symbols Some or all of these symbols are on your battery 116-4858 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.
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 Length: 60 inch Deck This switch is used to start the mower engine and has 3 positions: Start, Run and Off. Motion Control Levers Roll Bar - Up 211.1 cm (83.1 inches) Roll Bar - Down 215.4 cm (84.8 inches) Height: The motion control levers are used to drive the machine forward, reverse, and turn either direction. Roll Bar - Up Roll Bar - Down 179.1 cm (70.5 inches) 118.9 cm (46.
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.
Filling the Fuel Tank Breaking In a New Machine Note: Do not fill the fuel tank completely full. Fill the fuel tank to the bottom of the filler neck. The empty space in the tank allows the gasoline to expand. New engines take time to develop full power. Mower decks and drive systems have higher friction when new, placing additional load on the engine. Allow 40 to 50 hours of break-in time for new machines to develop full power and best performance. 1. Park the machine on level ground. 2.
Think Safety First Please read all safety instructions and symbols in the safety section. Knowing this information could help you or bystanders avoid injury. DANGER 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 fully raised and locked position and use the seat belt.
Releasing the Parking Brake CAUTION This machine produces sound levels in excess of 85 dBA at the operators ear and can cause hearing loss through extended periods of exposure. 1 2 Wear hearing protection when operating this machine. The use of protective equipment for eyes, ears, feet and head is recommended. 1 G016995 Figure 12 2 Operating the Mower Blade Control Switch (PTO) G009027 Figure 10 1.
Operating the Throttle Using the Fuel Shut-Off Valve The throttle control can be moved between Fast and Slow positions (Figure 15). The fuel shut-off valve is located under the seat. Move the seat forward to access it. Always use the fast position when turning on the mower deck with the blade control switch (PTO). Close the fuel shut-off valve for transport, maintenance, and storage. Ensure the fuel shut-off valve is open when starting the engine.
Stopping the Engine CAUTION Children or bystanders may be injured if they move or attempt to operate the machine 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. Let the engine idle at slow throttle (turtle) for 60 seconds before turning the ignition switch off. g017006 Figure 18 6. Turn the ignition key to the Start position (Figure 16). When the engines starts, release the key.
The Safety Interlock System 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. CAUTION 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.
Using the Motion Control Levers G008952 Figure 23 Driving Backward Figure 22 1. Motion control lever-neutral lock position 4. Backward 1. Move the levers to the center, unlocked position. 2. Center, unlocked position 5. Front of machine 2. To go backward, slowly pull the motion control levers rearward (Figure 24). 3. Forward 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. 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 1 to 5-1/2 inches (25 to 140 mm) in 1/4 inch (6 mm) 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 5-1/2 inch (140 mm) cutting height position) (Figure 26). 3. To adjust, rotate the pin 90 degrees and remove the pin from the height-of-cut bracket (Figure 26).
Adjusting the Flow Baffle Cam Locks Positioning the Flow Baffle The following figures are only recommendations for use. Adjustments will vary by grass type, moisture content, and height of grass. 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. Note: If the engine power draws down and the mower ground speed is the same, open up the baffle.
Using the Drive Wheel Release Valves Position C This is the full open position. The suggested use for this position is as follows. WARNING • Use in tall, dense grass mowing conditions. • Use in wet conditions. Hands may become entangled in the rotating drive components below the engine deck, which could result in serious injury. • Lowers the engine power consumption. • Allows increased ground speed in heavy conditions.
4. Rotate the release valve levers horizontally to run the machine (Figure 35). WARNING Using the Side Discharge Loading a unit onto a trailer or truck increases the possibility of backward tip-over and could cause serious injury or death. The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. • Use extreme caution when operating a unit on a ramp. • Ensure the ROPS is in the up position while using the seat belt when loading the machine.
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. WARNING 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.
Operating Tips 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 When 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.
Maintenance Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure 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. Check the rollover protection system (ROPS) knobs.
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 Where to Grease the Mower Greasing and Lubrication 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 40 Figure 42 6. Remove the dust cap and adjust the caster pivots. Keep the dust cap off until greasing is done. Refer to Adjusting the Caster Pivot Bearing in Maintenance. 1. Seal guard 2. Spacer nut with wrench flats 7. Remove the hex plug. Thread a grease zerk into the hole. 2. Remove the caster wheel from the caster forks. 8.
14. Engine Maintenance Install the seal guards over the wheel hub and insert the wheel into the caster fork. Install the caster bolt and tighten the nut fully. Servicing the Air Cleaner Important: To prevent seal and bearing damage, check the bearing adjustment often. Spin the caster tire. The tire should not spin freely (more than 1 or 2 revolutions) or have any side play. If the wheel spins freely, adjust the torque on the spacer nut until there is a slight amount of drag.
Important: Never attempt to clean the inner filter. If the safety filter is dirty, then the primary filter is damaged. Replace both filters. Important: Do not press on the soft inside area of the filter. 4. Install the air cleaner cover and secure the latches (Figure 44). Servicing the Engine Oil Oil Type: Detergent oil (API service class SJ or higher) 5 Oil Capacity: with a filter change, 58 ounces (1.7 L); with no filter change, 48 ounces (1.4 L) 4 3 Viscosity: See the table below.
Changing the Engine Oil Service Interval: Every 100 hours (more often in dirty or dusty conditions) Note: Dispose of the used oil at a recycling center. 1. Park the machine so that the rear is slightly lower than the front to ensure the oil drains completely. G008804 1 2 2. Disengage the 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 (Figure 47).
Changing the Engine Oil Filter 4. 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 Service Interval: Every 200 hours Note: Change the engine oil filter more frequently when operating conditions are extremely dusty or sandy. 2 1. Drain the oil from the engine; refer to Changing the Engine Oil. 2. Change the engine oil filter (Figure 49). 3 4 G008804 5 6 G008796 Figure 48 1 2 3 4 5.
2. Remove the bolts holding the oil cooler to the engine housing . 3. Clean the inside of the oil cooler with a brush. 4. Install the oil cooler to the engine housing. G008804 1 2 Figure 51 2 g01301 1 1. Pull this tab out to the side in the direction of the arrow 2. Pull the shroud off of this frame tab in the direction of the arrow Figure 50 1. Engine oil cooler 2. Bolts Servicing the Spark Plug 3. Pull the shroud off of this frame tab in the direction of the arrow 4. Shroud 4.
Checking the Spark Plug 3. If any breaks in the screen or welds are observed, replace the arrester. Important: Replace the spark plug(s) when it has: a black coating, worn electrodes, an oily film, cracks or reuse is questionable. 4. If plugging of the screen is observed, remove the arrester and shake loose particles out of the arrester and clean screen with a wire brush (soak in solvent if necessary). Reinstall arrester on exhaust outlet.
Fuel System Maintenance 1 2 WARNING 3 Fuel system components are under high pressure. The use of improper components can result in system failure, gasoline leakage and possible explosion. Use only approved fuel lines and fuel filters. Servicing the Electronic Fuel Injection System G008963 Figure 55 This machine contains an electronic fuel injection system. It controls the fuel flow under different operating conditions. 1. Fuel filter 2.
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.
Installing the Battery 1. Position battery in the tray with the terminal posts opposite from the hydraulic tank (Figure 56). 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 56). 5. Slide the red terminal boot onto the positive (red) battery post. 6.
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 58). 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.
8. Tighten the stop plate (Figure 60). Figure 60 Left control lever shown 1. Control lever 3. Stop plate 2. Bolt Figure 59 1. ROPS knob (locked position) 3. Roll bar in the upright position 2. Pull ROPS knob out and rotate 90 degrees to change roll bar position 4. Roll bar in the folded position Checking the Tire Pressure Service Interval: Every 50 hours/Monthly (whichever comes first) Maintain the air pressure in the front and rear tires at 13 psi (90 kPa).
Checking the Wheel Lug Nuts 5. Torque the slotted nut to 200 ft-lb (271 N-m). Check and torque the wheel lug nuts to 90-95 ft-lb (122-129 N-m). 6. Then tighten nut until the next set of slots line up with the cross hole in shaft. Do not loosen nut to align the slot. If required, tighten to the next set of slots. Checking the Wheel Hub Slotted Nut 7. Install a new cotter pin. Note: Do Not use anti-seize on wheel hub.
Using the Clutch Shim A. Loosen both brake mounting bolts one-half to one full turn as shown below. Some later model year units have been built with clutches that contain a brake shim. When the clutch brake has worn to the point where the clutch no longer engages consistently, the shim can be removed to extend the clutch life. Note: Do Not remove the brake pole from the field shell/armature.
Cooling System Maintenance Cleaning the Engine Screen and Engine Oil Cooler Figure 69 Service Interval: Before each use or daily 1. Feeler gauge Remove any build-up of grass, dirt or other debris from the oil cooler (Figure 71). G008804 Figure 70 1. Feeler gauge • If the gap is less than 0.010 inch, then reinstall Figure 71 the shim and reference the Troubleshooting section.
Check and Clean the Hydraulic Units 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. Move the seat forward. 4. Clean the debris and grass from the hydraulic units (Figure 73). 5. Position the seat. Figure 72 1. Engine guard 4. Fan housing 2. Engine air intake screen 5. Screw 3. Bolt g0151 17 Figure 73 1.
Brake Maintenance Adjusting the Parking Brake Service Interval: After the first 100 hours Every 500 hours thereafter Check to make sure brake is adjusted properly. This procedure must be followed after the first 100 hours or when a brake component has been removed or replaced. 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. Figure 74 Left Hand Brake Shown 3.
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 77 1. Position the belt cover 3. Ensure the tab is under the metal catch Figure 78 2. Slide belt cover under the side catches 1. Idler pulley 5. Left hand hydraulic pump pulley 2. Clutch pulley 6. Square hole in idler arm 3. Pump drive belt 7. Idler spring 4. Right hand hydraulic pump pulley Replacing the Hydraulic Pump Drive Belt 5. Use a ratchet in the square hole in the idler arm to remove the idler spring (Figure 78). 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. 3. Loosen the bolts and flange nuts installed in the levers (Figure 79). 4.
6. Run the unit at least 5 minutes with the drive levers at full forward speed to bring 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. Adjust pump control rod lengths by rotating the double nuts on the rod in the appropriate direction until the wheels slightly creep in reverse (Figure 81).
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 3 inch (7.6 mm) height (see Figure 89). 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 91). To increase the height, turn the adjuster screw clockwise; to decrease, turn counterclockwise.
Checking for Bent Blades Servicing the Cutting Blades 1. Disengage the blade control switch (PTO), move the motion control levers to the neutral locked position and set the parking brake. 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. 2.
Removing the Blades 2. Check the balance of the blade by putting it on a blade balancer (Figure 96). If the blade stays in a horizontal position, the blade is balanced and can be used. If the blade is not balanced, file some metal off the end of the sail area only (Figure 97). Repeat this procedure until the blade is balanced. Blades must be replaced if a solid object is hit, if the blade is out of balance or is bent.
Removing the Mower Deck Before servicing or removing the mower deck, the spring loaded deck arms must be locked out. 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 engine, wait for all moving parts to stop, and remove key. Engage parking brake. 2.
Cleaning 8. Raise the deck struts and secure them in the up position. Slide the deck out to the right side of the machine. Cleaning Under the Mower Replacing the Grass Deflector 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.
Storage Cleaning and Storage 1. Disengage the power take off (blade control switch (PTO), set the parking brake, and turn the ignition key to Off. 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 Malfunction Indicator Light (MIL) comes on. Possible Cause 1. Engine is too hot. 1. Turn engine off and let it cool. 2. Old gas in the gas tank. 3. The fuel shut-off valve is not open completely. 4. Air cleaner is dirty. 2. Use new gas. 3. Open the fuel shut-off valve. 5. Battery is not charged. 6. Incorrect fuel filters used or dirty fuel filters. 7. Connections to sensors electronic control unit (ECU) and fuel injectors are not secured properly. 8. Low voltage from battery.
Problem The engine loses power. Possible Cause Corrective Action 1. The engine load is excessive. 1. Reduce the ground speed. 2. The air cleaner is dirty. 3. The oil level in the crankcase is low. 4. The cooling fins and air passages above the engine are plugged. 5. The vent hole in the fuel cap is plugged. 6. There is dirt in the fuel filter. 7. There is dirt, water, or stale fuel is in the fuel system. 2. Clean the air cleaner element. 3. Add oil to the crankcase. 4.
Problem The clutch will not engage. Possible Cause Corrective Action 1. The fuse is blown. 1. Replace the fuse. Check coil resistance, battery charge, charging system, and wiring connections and replace if necessary. 2. There is low voltage supply at the clutch. 2. Check coil resistance, battery charge, charging system, and wiring connections and replace if necessary. 3. Replace the clutch. 4. Repair or replace the clutch lead wire or electrical system. Clean the connector contacts. 5.
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The Toro Total Coverage Warranty Landscape Contractor Equipment (LCE) A Limited Warranty (see warranty periods below) Conditions and Products Covered This warranty includes the cost of parts and labor, but you must pay transportation costs. 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.
