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Toro 74901 Operator's Manual
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Toro 74901 Operator's Manual

With 48in or 52in turbo force side discharge mower
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Form No. 3367-151 Rev D
Z Master
®
G3 Riding Mower
with 48in or 52in TURBO FORCE
®
Side
Discharge Mower
Model No. 74901—Serial No. 311000001 and Up
Model No. 74901CP—Serial No. 311000001 and Up
Model No. 74903—Serial No. 311000001 and Up
Model No. 74903CP—Serial No. 311000001 and Up
To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com.
Original Instructions (EN)

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  • Page 1 Model No. 74901CP—Serial No. 311000001 and Up Model No. 74903—Serial No. 311000001 and Up Model No. 74903CP—Serial No. 311000001 and Up To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com. Original Instructions (EN)

  • Page 2: Introduction

    If you require a spark arrestor, contact your 1. Model and serial number location Authorized Toro Dealer. Genuine Toro spark arresters are approved by the USDA Forestry Service. Model No. Note: It is a violation of California Public Resource Code Section 4442 to use or operate the engine on Serial No.

  • Page 3: Table Of Contents

    Contents Electrical System Maintenance........ 40 Servicing the Battery........... 40 Servicing the Fuses ..........42 Introduction..............2 Drive System Maintenance ........43 Safety ................4 Checking the Seat Belt ........43 Safe Operating Practices ........4 Checking the Rollover Protection System Slope Indicator.............

  • Page 4: Safety

    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 – Use only an approved container can result in injury. To reduce the potential for injury, –...

  • Page 5: Slope Operation

    • Be certain that the seat belt can be released quickly • Use only Toro approved attachments. Warranty may in the event of an emergency. be voided if used with unapproved attachments.

  • Page 6: Slope Indicator

    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.

  • Page 7: Safety And Instructional Decals

    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 105-7798 1. Grease 66-1340...
  • Page 8 109-7929 110-2067 107-2102 110-2068 1. Read the Operator's Manual. 114-4466 1. Main, 25A 3. Charge, 25A 2. PTO, 10A 4. Auxiliary, 15A 109-7232...
  • Page 9 116-0157 115-2765 1. Fuel 6. Hour meter 2. Empty 7. PTO 116-0165 3. Half 8. Parking brake 4. Full 9. Neutral 5. Battery 10. Operator presence switch 116-0205 115-7445 1. Grease pulleys and spindles 2. Maintenance interval—50 hours 116-0090...
  • Page 10 116-4858 Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 6. Keep bystandersa safe 117-0876 distance from the battery. 1. PTO (Power Take-off) 4. Continuous variable 2. No fire, open flame, or 7. Wear eye protection; setting smoking.

  • Page 11: Product Overview

    Product Overview 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).

  • Page 12: Specifications

    Contact your Authorized Service Dealer or Distributor or go to www.Toro.com for a list of all approved attachments and accessories. Specifications Note: Specifications and design are subject to change without notice.

  • Page 13: Operation

    Operation DANGER In certain conditions during fueling, static Note: Determine the left and right sides of the electricity can be released causing a spark which machine from the normal operating position. can ignite the gasoline vapors. A fire or explosion from gasoline can burn you and others and can damage property.

  • Page 14: Checking The Engine Oil Level

    Breaking In a New Machine Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline. To minimize the New engines take time to develop full power. Mower chance of varnish deposits in the fuel system, use fuel decks and drive systems have higher friction when new, stabilizer at all times.

  • Page 15: Think Safety First

    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.

  • Page 16: Operating 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. Wear hearing protection when operating this machine. The use of protective equipment for eyes, ears, feet and head is recommended.

  • Page 17: Operating The Throttle

    Disengaging the Blade Control Switch (PTO) G009174 Figure 14 Operating the Throttle The throttle control can be moved between Fast and Slow positions (Figure 15). G008959 Always use the fast position when turning on the Figure 16 mower deck with the blade control switch (PTO). 1.

  • Page 18: Starting And Stopping The Engine

    Close the fuel shut-off valve for transport, maintenance, and storage. Ensure the fuel shut-off valve is open when starting the engine. G008948 Figure 18 1. On 2. Off Starting and Stopping the Figure 19 Engine 6. Turn the ignition key to the Start position Starting the Engine (Figure 17).

  • Page 19: The Safety Interlock System

    Stopping the Engine The Safety Interlock System CAUTION CAUTION Children or bystanders may be injured if they If safety interlock switches are disconnected or move or attempt to operate the tractor while it is damaged the machine could operate unexpectedly unattended.

  • Page 20: Driving Forward Or Backward

    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.

  • Page 21: Stopping The Machine

    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.

  • Page 22: Adjusting The Anti-Scalp Rollers

    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.

  • Page 23: Adjusting The Flow Baffle

    Adjusting the Flow Baffle The mower discharge flow can be adjusted for different types of mowing conditions. Position the nut and baffle to give the best quality of cut. 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake.

  • Page 24: Positioning The Seat

    G012120 Figure 32 Position B G012122 Figure 34 Use this position when bagging. Positioning the Seat The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable. To adjust, move the lever sideways to unlock seat (Figure 35).

  • Page 25: Using The Side Discharge

    WARNING DANGER The engine and hydraulic drive units can become Without a grass deflector, discharge cover, or very hot. Touching a hot engine or hydraulic drive complete grass catcher assembly mounted in units can cause severe burns. place, you and others are exposed to blade contact and thrown debris.

  • Page 26: Loading Machines

    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.

  • Page 27: Operating Tips

    Operating Tips WARNING Loading a unit onto a trailer or truck increases the Fast Throttle Setting possibility of backward tip-over and could cause serious injury or death. For best mowing and maximum air circulation, operate the engine at the fast throttle position. Air is required •...

  • Page 28: Blade Maintenance

    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.

  • Page 29: Maintenance

    • Check the torque for wheel lug nuts. Every 500 hours • Adjust the caster pivot bearing. • Check the park brake adjustment. • Change the hydraulic filters and hydraulic oil when using Toro® HYPR-OIL™ 500 hydraulic oil. • Check the battery. Monthly •...

  • Page 30: Lubrication

    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 and Lubrication Grease more frequently when operating conditions are extremely dusty or sandy.

  • Page 31: Lubricate Caster Wheel Hubs

    1. Disengage the blade control switch (PTO), move the 8. Pump grease into the zerk until it oozes out around motion control levers to the neutral locked position, the top bearing. and set the parking brake. 9. Remove the grease zerk in the hole. Install the hex 2.

  • Page 32: Engine Maintenance

    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 WARNING adhesive to one spacer nut and thread onto the axle Contact with hot surfaces may cause personal with the wrench flats facing outward.

  • Page 33: Servicing The Heavy Duty Air Cleaner

    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 44). 3. Install the air filter element onto the base (Figure 44). Ensure that it is fully seated.

  • Page 34: Servicing The Engine Oil

    1. If installing new filters, check each filter for shipping damage. Do not use a damaged filter. 2. If the safety filter is being replaced, carefully slide it into the filter body (Figure 45). 3. Carefully slide the primary filter over the safety filter (Figure 45).
  • Page 35 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. 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.

  • Page 36: Changing The Engine Oil

    Changing the Engine Oil 5. Slowly pour approximately 80% of the specified oil into the filler tube and slowly add the additional oil Service Interval: After the first 8 hours to bring it to the Full mark (Figure 49). Every 100 hours (more often in dirty or dusty conditions) Note: Dispose of the used oil at a recycling center.

  • Page 37: Servicing The Spark Plug

    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 G008804 the spark plug(s) and a gapping tool/feeler gauge to check and adjust the air gap.
  • Page 38 Checking the Spark Plug 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. 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.

  • Page 39: Check Spark Arrester (If Equipped)

    Check Spark Arrester (if Fuel System equipped) Maintenance Service Interval: Every 50 hours Replacing the Fuel Filter WARNING Service Interval: Every 500 hours/Yearly (whichever Hot exhaust system components may ignite comes first) (more often in dirty or gasoline vapors even after the engine is stopped. dusty conditions).

  • Page 40: Servicing The Fuel Tank

    Electrical System Note: It is important to reinstall the fuel line hoses and secure with plastic ties the same as they were originally Maintenance installed at the factory to keep the fuel line away from components that could cause fuel line damage. Servicing the Battery Servicing the Fuel Tank Service Interval: Monthly...

  • Page 41: Installing The Battery

    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. G008804 • Always Disconnect the negative (black) battery cable before disconnecting the positive (red) cable. •...

  • Page 42: Servicing The Fuses

    Servicing the Fuses Important: Always keep the battery fully charged (1.265 specific gravity). This is especially important The electrical system is protected by fuses. It requires to prevent battery damage when the temperature is no maintenance, however, if a fuse blows check the below 32°F (0°C).

  • Page 43: Drive System Maintenance

    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 Check that both the mounting hardware and the knobs are in good working condition.

  • Page 44: Checking The Tire Pressure

    7. If it tracks to the left, loosen the bolts and adjust the right stop plate rearward on the right T-slot until the machine tracks straight (Figure 60). 8. Tighten the stop plate (Figure 60). Figure 61 Checking the Wheel Hub Slotted Nut Service Interval: After the first 100 hours Every 500 hours...

  • Page 45: Adjusting The Caster Pivot Bearing

    Figure 63 1. 0.1 inch max 2. No more than two threads (0.1 inch max) should be showing here. 4. If more than two threads (0.1 inch) are showing remove nut and install washer between hub and Figure 64 nut. 1.
  • Page 46 2. Using an air compressor, blow out any debris from under the brake pole and around the brake spacers. Figure 68 1. Shim C. Using a pneumatic line, blow out any debris Figure 66 from under the brake pole and around the brake spacers.

  • Page 47: Cooling System Maintenance

    Cooling System • If the gap is less than 0.010 inch, then reinstall the shim and reference the Troubleshooting Maintenance section. • If the gap is sufficient, proceed to the safety check in step F. Cleaning the Engine Screen F. Perform the following safety check: and Engine Oil Cooler a.

  • Page 48: Check And Clean The Hydraulic Unit Shrouds

    Figure 72 Figure 73 1. Engine guard 4. Fan housing 1. Hydraulic unit shrouds 2. Engine air intake screen 5. Screw 3. Bolt Check and Clean the Hydraulic Unit Shrouds Service Interval: Before each use or daily 1. Disengage the PTO and set the parking brake. 2.

  • Page 49: Brake Maintenance

    Brake 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 Adjusting the Parking Brake the Drive Wheel Valves in Operation. Service Interval: After the first 100 hours 16.

  • Page 50: Belt Maintenance

    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.

  • Page 51: Replacing The Hydraulic Pump Drive Belt

    Figure 77 1. Position the belt cover 3. Ensure the tab is under Figure 78 the metal catch 1. Idler pulley 5. Left hand hydraulic pump 2. Slide belt cover under the pulley side catches 2. Clutch pulley 6. Square hole in idler arm 3.

  • Page 52: Controls System Maintenance

    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.

  • Page 53: Adjusting The Motion Control Damper

    Adjusting the Motion Control not have to be in the seat because of the jumper wire being used. Run engine at full throttle and Damper release brake. The top damper mounting bolt can be adjusted to obtain 6. Run the unit at least 5 minutes with the drive levers a more desired motion control lever resistance.

  • Page 54: Hydraulic System Maintenance

    Hydraulic System Maintenance Servicing the Hydraulic System Hydraulic Oil Type: Toro ® HYPR-OIL ™ ® Figure 83 hydraulic oil or Mobil 1 15W-50. 1. Flanged nut 2. Jam nut Important: Use oil specified. Other fluids could cause system damage. Each Hydraulic System Oil Capacity: 52 ounces (1.5...
  • Page 55 1 oil. Every 500 hours—Change the hydraulic filters and hydraulic oil ® ™ when using Toro HYPR-OIL 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.

  • Page 56: Mower Deck Maintenance

    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.
  • Page 57 To increase the height, turn the adjuster screw clockwise; to decrease, turn counterclockwise. Figure 87 3. Transport lock 1. Deck lift pedal Figure 89 2. Height of cut pin 1. Whizlock nut 3. Jam nut 2. Adjuster screw 4. Yoke 6.

  • Page 58: Servicing The Cutting Blades

    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. For convenient sharpening and replacement, you may want to keep extra blades on hand.

  • Page 59: Removing The Blades

    Checking for Bent Blades performance and continued safety conformance of the machine, use genuine Toro replacement blades. 1. Disengage the blade control switch (PTO), move the Replacement blades made by other manufacturers may motion control levers to the neutral locked position result in non-conformance with safety standards.
  • Page 60 Installing the Blades 1. Install the blade onto the spindle shaft (Figure 97). Important: The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting. Figure 95 2. Install the spring disk and blade bolt. The spring disk cone must be installed toward the bolt head 1.

  • Page 61: Removing The Mower Deck

    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.

  • Page 62: Replacing The Grass Deflector

    g015594 Figure 100 Figure 99 1. Bolt 5. Spring installed 1. Right stabilizer 2. Spacer 6. Grass Deflector 2. Deck strut (right side shown) 3. Locknut 7. J hook end of spring 3. Remove the rear deck lift attachment shoulder bolt and nut. 4.

  • Page 63: Cleaning

    Cleaning Storage Cleaning and Storage Cleaning Under the Mower 1. Disengage the power take off (blade control switch Service Interval: Before each use or daily (PTO), set the parking brake, and turn the ignition key to Off. Remove the key. 1.
  • Page 64 B. Run the engine to distribute conditioned fuel through the fuel system (5 minutes). C. Stop the engine, allow it to cool, and drain the fuel tank; refer to Servicing the Fuel Tank in the Maintenance Section. D. Restart the engine and run it until it stops. E.

  • Page 65: Troubleshooting

    Troubleshooting Problem Possible Cause Corrective Action Starter does not crank 1. Blade control switch (PTO) is engaged. 1. Move blade control switch (PTO) to disengaged. 2. Parking brake is not on. 2. Set the parking brake. 3. Drive levers are not in neutral lock 3.
  • Page 66 Problem Possible Cause Corrective Action Machine does not drive. 1. By pass valves is not closed tight. 1. Tighten the by pass valves. 2. Pump belt is worn, loose or broken. 2. Change the belt. 3. Pump belt is off a pulley. 3.

  • Page 67: Schematics

    Schematics Wire Diagram (Rev. A)
  • Page 68 Countries Other than the United States or Canada Customers who have purchased Toro products outside the United States or Canada should contact their Toro Distributor (Dealer) to obtain guarantee policies for your country, province, or state. If for any reason you are dissatisfied with your Distributor's service or have difficulty obtaining guarantee information, contact the Toro importer.

This manual is also suitable for:

74901cp7490374903cpZ master g3Z master 74901Z master 74903

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