Table of Contents
Related Manuals for Toro 74996
Summary of Contents for Toro 74996
- Page 1 Form No. 3400-689 Rev C Z Master ® Commercial 3000 Series Riding Mower with 60in TURBO FORCE ® Side Discharge Mower Model No. 74996—Serial No. 316000001 and Up *3400-689* C Register at www.Toro.com. Original Instructions (EN)
- Page 2 Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready. Figure 1 identifies the location of the model and serial numbers on the product.
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Page 3: Table Of Contents
Safety ............... 4 Checking the Rollover Protection System Safe Operating Practices........4 (ROPS) Knobs ..........49 Toro Mower Safety..........5 Adjusting the Tracking ........50 Slope Indicator ........... 7 Checking the Tire Pressure....... 50 Safety and Instructional Decals ......8 Checking the Wheel Lug Nuts...... -
Page 4: Safety
Safety properly. Do not operate the machine unless they are functioning properly. Improper use or maintenance of the machine can Operation result in injury. To reduce the potential for injury, comply with these safety instructions and always pay • Lightning can cause severe injury or death. If attention to the safety-alert symbol, which means lightning is seen or thunder is heard in the area, do Caution, Warning, or Danger—personal safety... -
Page 5: Toro Mower Safety
Toro Mower Safety The following list contains safety information specific to Toro products and other safety information that you must know. This product is capable of amputating hands and feet, and of throwing objects. Always follow all safety... - Page 6 • To best protect your investment and maintain machine. optimal performance of your Toro equipment, count on Toro genuine parts. When it comes to reliability, • Lower the ROPS temporarily only when absolutely Toro delivers replacement parts designed to the necessary.
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Page 7: 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°. 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°. Fold along the appropriate line to match the recommended slope. -
Page 8: 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. decal58-6520 58-6520 decal106-2655 1. Grease 106-2655 1. Warning—do not touch or approach moving belts; remove the ignition key and read the instructions before servicing or performing maintenance. - Page 9 decal110-2068 110-2068 1. Read the Operator's Manual. decal112-9028 112-9028 1. Warning—stay away from moving parts; keep all guards in place. decal107-3069 107-3069 1. Warning—there is no rollover protection when the roll bar is down. decal114-4466 2. To avoid injury or death from a rollover accident, keep the 114-4466 roll bar in the raised and locked position and wear the seat belt.
- Page 10 decal115-9625 115-9625 decal117-3848 1. Parking 2. Parking brake—engaged 117-3848 brake—disengaged 1. Thrown object hazard—keep bystanders a safe distance from the machine 2. Thrown object hazard, mower-do not operate the machine without the deflector, discharge cover, or grass collection system in place. 3.
- Page 11 decal126-4398 126-4398 1. Read the Operator’s 3. Unlock Manual 2. Lock decal121-7551 121-7551 1. Power take-off (PTO) 4. Continuous variable setting 2. Choke 5. Slow 3. Fast decal127-0326 127-0326 1. Read the Operator's 3. Remove the key from Manual. the ignition and read the Operator's Manual before decal126-2055 performing maintenance...
- Page 12 decal132-5063 132-5063 1. Cam lock 2. Cam unlock decalbatterysymbols 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 7. Wear eye protection; explosive gases can smoking cause blindness and other...
- Page 13 decal132-5067 132–5067 decal125-9383 125–9383 1. Check hydraulic fluid every 50 operating hours. 3. Check the tire pressure every 50 operating hours. 2. Read the Operator’s Manual for information on lubricating 4. Read the Operator’s Manual before servicing or performing the machine. maintenance.
- Page 14 decal132-0871 132-0871 Note: This machine complies with the industry standard stability test in the static lateral and longitudinal tests with the maximum recommended slope indicated on the decal. Review the instructions for operating the machine on slopes in the Operator’s Manual as well as the conditions in which you would operate the machine to determine whether you can operate the machine in those conditions on that day and at that site.
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Page 15: Product Overview
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 The indicator light appears when the fuel level is low—approximately 3.8 L (1 US gallon) remaining in the fuel tank. -
Page 16: Specifications
Contact your Authorized Service Dealer or Distributor or go to www.Toro.com for a list of all approved attachments and accessories. To best protect your investment and maintain optimal performance of your Toro equipment, count on Toro genuine parts. -
Page 17: Operation
Operation DANGER In certain conditions during fueling, static Note: Determine the left and right sides of the electricity can cause a spark which can ignite machine from the normal operating position. the gasoline vapors. A fire or explosion from gasoline can burn you and others and can Adding Fuel damage property. - Page 18 Filling the Fuel Tank Add the correct amount of fuel stabilizer/conditioner to the fuel, and follow the directions of the manufacturer. Note: Do not fill the fuel tank completely full. Fill the Note: Fuel stabilizer/conditioner is most effective fuel tank to the bottom of the filler neck. The empty when mixed with fresh gasoline.
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Page 19: Checking The Engine-Oil Level
Checking the Engine-Oil Level Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking the Engine-Oil Level (page 41). Breaking in a New Machine New engines take time to develop full power. Mower decks and drive systems have higher friction when new, placing additional load on the engine. -
Page 20: Entering The User Position
Entering the User Position Use the mower deck as a step to get into the user position (Figure g000963 Figure 10 1. Safe Zone—use the 3. Water machine here on slopes g029797 less than 15° or flat areas. Figure 9 2. -
Page 21: Operating The Parking Brake
Operating the Parking Operating the Mower Brake Blade-Control Switch (PTO) Always set the parking brake when you stop the The blade-control switch (PTO) starts and stops the machine or leave it unattended. mower blades and any powered attachments. Setting the Parking Brake Engaging the Blade-Control Switch (PTO) WARNING... -
Page 22: Operating The Choke
fails to start, allow a 15 second cool-down period between attempts. Failure to follow these instructions can burn out the starter motor. Note: You may need multiple attempts to start the engine when you start it the first time after the fuel system has been without fuel completely. -
Page 23: Starting And Shutting Off The Engine
Starting and Shutting Off Note: You may need to attempt to start the engine multiple times when you start it for the first time after the Engine the fuel system has been without fuel completely. Starting the Engine Raise the ROPS up and lock into place, sit on the seat, and fasten the seat belt. -
Page 24: Using The Safety-Interlock System
Understanding the Safety-Interlock System The safety-interlock system is designed to prevent the engine from starting unless: • The parking brake is engaged. • The blade-control switch (PTO) is disengaged. • The motion-control levers are in the N EUTRAL LOCK position. The safety-interlock system also is designed to shut off the engine when you move the traction controls from the locked position with the parking brake engaged or... -
Page 25: Driving Forward Or Backward
Testing the Safety-Interlock CAUTION System Machine can spin very rapidly. You may lose control of machine and injure yourself or Service Interval: Before each use or daily damage the machine. Test the safety-interlock system before you use the • Use caution when making turns. machine each time. -
Page 26: Shutting Off The Machine
Shutting Off the Machine To shut off the machine, move the traction-control levers to N , and then move them to the L EUTRAL OCKED position, disengage the power takeoff (blade-control switch (PTO), and turn the key in the ignition switch to the O position. - Page 27 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 moving the clevis pin into different hole locations. Move the transport lock to the lock position. 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...
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Page 28: Adjusting The Anti-Scalp Rollers
g029956 Figure 30 1. Anti-scalp roller 3. Flange nut g029840 2. Bushing 4. Bolt Figure 28 1. Deck-lift pedal 3. Transport lock 2. Height-of-cut pin Adjusting the Anti-Scalp Rollers Whenever you change the height of cut, it is recommended to adjust the height of the anti-scalp rollers. -
Page 29: Positioning The Flow Baffle
Positioning the Flow Baffle Adjust the baffle and cam locks in the slots to the desired discharge flow. The following figures are only recommendations for Swing the lever back over to tighten the baffle use. Adjustments will vary by grass type, moisture and cam locks (Figure 32). -
Page 30: Positioning The Seat
Use to lower the engine-power consumption. • Use to allow increased ground speed in heavy conditions. • This position offers benefits similar to those of the Toro SFS mower. g005833 Figure 34 g005834 Figure 35 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. -
Page 31: Unlatching The Seat
rear-shock assemblies anywhere in the slot, not just in the detent positions. The following graphic shows the position for a soft or firm ride and the different detent positions (Figure 38). g008962 Figure 36 Unlatching the Seat g030065 Figure 38 1. -
Page 32: Using The Drive-Wheel Release Valves
Adjust the rear-shock assemblies (Figure 39). To adjust the front-shock assembly, open the floor pan and adjust it by using a spanner wrench (Toro Part No. 132-5069) or a slip-joint pliers (Figure 40). g030024 g030569 Figure 40 1. Middle position 3. -
Page 33: Using The Side Discharge
levers to the N position, apply the EUTRAL LOCK DANGER parking brake, and remove the key. Without a grass deflector, discharge cover, or Rotate the release valve levers vertically to push complete grass catcher assembly mounted in the machine (Figure 41). -
Page 34: Transporting The Machine
Transporting the Machine Loading the Machine Use a heavy-duty trailer or truck to transport the Use extreme caution when loading or unloading the machine. Ensure that the trailer or truck has all machine onto a trailer or a truck. Use a full-width ramp necessary brakes, lighting, and marking as required that is wider than the machine for this procedure. - Page 35 WARNING Loading a machine onto a trailer or truck increases the possibility of a tip-over and could cause serious injury or death. • Use extreme caution when operating a machine on a ramp. • Ensure that the ROPS is in the up position and use the seat belt when loading or unloading the machine.
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Page 36: Operating Tips
Alternate the mowing direction to keep the grass as necessary. If a blade is damaged or worn, replace standing straight. This also helps disperse clippings, it immediately with a genuine Toro replacement blade. which enhances decomposition and fertilization. Mowing at Correct Intervals Normally, mow every 4 days. -
Page 37: Maintenance
Every 500 hours • Adjust the caster-pivot bearing. • Check the parking-brake adjustment. • Change the hydraulic filters and hydraulic fluid when using Toro® HYPR-OIL™ 500 hydraulic fluid (more often in dirty or dusty conditions). • Check the battery. Monthly •... -
Page 38: 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 perform any maintenance. Lubrication Greasing the Mower Service Interval: Every 50 hours—Grease the Greasing and Lubrication mower-deck spindles and idler arm. -
Page 39: Lubricating The Caster-Wheel Hubs
g006115 Figure 49 1. Seal guard 2. Spacer nut with wrench flats Raise the front of the machine up, and support it g009030 with jack stands (or equivalent support) just high Figure 47 enough to allow the front wheels to turn freely. Remove the caster wheel from the caster forks. -
Page 40: Engine Maintenance
Engine Maintenance Torque the nut to 8 to 9 N∙m (75 to 80 in-lb), loosen it, then torque it to 2 to 3 N∙m (20 to 25 in-lb). WARNING Note: Make sure that the axle does not extend Contact with hot surfaces may cause personal beyond either nut. -
Page 41: Servicing The Engine Oil
Install the air-cleaner cover with the breather cap down, and rotate so the retaining clamps lock the cover in place (Figure 50). Servicing the Engine Oil Oil Type: Detergent oil (API service SG, SH, SJ, or higher) Crankcase Capacity: with a filter change, 2.3 L (2.4 US qt);... - Page 42 Changing the Engine Oil Service Interval: After the first 8 hours Every 100 hours Note: Dispose of the used oil at a recycling center. Start the engine and let it run for 5 minutes. g029644 Note: This warms the oil so that it drains better. Park the machine so that the rear is slightly lower than the front to ensure that the oil drains completely.
- Page 43 Changing the Engine-Oil Filter Slowly pour approximately 80% of the specified oil into the filler tube and slowly add the Service Interval: Every 200 hours additional oil to bring it to the F mark (Figure 54). Note: Change the engine-oil filter more frequently when operating conditions are extremely dusty or sandy.
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Page 44: Servicing The Spark Plugs
Servicing the Spark Plugs Service Interval: Every 100 hours—Check and gap the spark plugs. Make sure that the air gap between the center and side electrodes is correct before installing the spark plug. Use a spark plug wrench for removing and g029645 installing the spark plug(s) and a gapping tool/feeler gauge to check and adjust the air gap. -
Page 45: Checking The Spark Arrester
Checking the Spark Plugs Checking the Spark Arrester Important: Do not clean the spark plug(s). Always replace the spark plug(s) when it has: a black coating, worn electrodes, an oily film, or For a Model with a Spark Arrester cracks. Service Interval: Every 50 hours If you see light brown or gray on the insulator, the engine is operating properly. -
Page 46: Fuel System Maintenance
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). -
Page 47: Electrical System Maintenance
Electrical System WARNING Incorrect battery cable routing could damage Maintenance the machine and cables causing sparks. Sparks can cause the battery gases to explode, resulting in personal injury. Servicing the Battery • Always disconnect the negative (black) Service Interval: Monthly battery cable before disconnecting the positive (red) cable. - Page 48 Installing the Battery Position battery in the tray with the terminal posts opposite from the hydraulic tank (Figure 61). Install the positive (red) battery cable to positive (+) battery terminal. g029644 Then install the negative (black) battery cable and ground wire to the negative (-) battery terminal.
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Page 49: Servicing The Fuses
Drive System Maintenance Checking the Seat Belt Service Interval: Before each use or daily Inspect the seat belt for wear, cuts, and proper operation of the retractor and buckle. Replace the seat belt if it is damaged. Checking the Rollover g000960 Figure 62 Protection System (ROPS) -
Page 50: Adjusting The Tracking
Tighten the stop plate (Figure 65). g029647 Figure 65 Left control lever shown 1. Control lever 3. Stop plate 2. Bolt Checking the Tire Pressure Service Interval: Every 50 hours/Monthly (whichever comes first) g008943 Figure 64 Maintain the air pressure in the rear tires at 90 kPa (13 psi). -
Page 51: Checking The Wheel Lug Nuts
Checking the Wheel Lug Important: Make sure that the spring washers are installed correctly as shown in Nuts Figure Install the dust cap (Figure 68). Check and torque the wheel lug nuts to 122 to 129 N∙m (90 to 95 ft-lb). Checking the Wheel-Hub Slotted Nut Service Interval: After the first 100 hours... - Page 52 Removing the Clutch Shim Using needle-nose pliers, or by hand, hold the tab and remove the shim. Shut off the engine, wait for all moving parts to Note: stop, and remove the key. Engage the parking Do not discard the shim until proper brake.
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Page 53: Cooling System Maintenance
Cooling System Maintenance Cleaning the Engine Screen and Engine-Oil Cooler Service Interval: Before each use or daily g010873 Figure 74 Remove any buildup of grass, dirt, or other debris from the oil cooler (Figure 75). 1. Feeler gauge • If the gap is less than 0.25 mm (0.01 inch), then install the shim and refer to Troubleshooting (page 71). -
Page 54: Checking And Cleaning The Hydraulic-Unit Shrouds
g029645 g004218 g015117 Figure 76 Figure 77 1. Engine guard 4. Fan housing 1. Hydraulic-unit shrouds 2. Engine air-intake screen 5. Screw 3. Bolt Checking and Cleaning the Hydraulic-Unit Shrouds Service Interval: Before each use or daily Disengage the PTO and set the parking brake. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. -
Page 55: Brake Maintenance
Brake Maintenance Adjusting the Parking Brake Service Interval: After the first 100 hours (Or when a brake component has been removed or replaced). Every 500 hours Drive the machine onto a level surface. Disengage the blade-control switch (PTO), move the motion-control levers to the Neutral-locked g026961 position, and engage the parking brake. -
Page 56: Belt Maintenance
Belt Maintenance Inspecting the Belts Service Interval: Every 50 hours Replace the belt if it is worn. The signs of a worn belt include squealing while the belt is rotating; the blades slipping while cutting grass; and frayed edges, burn marks, and cracks on the belt. -
Page 57: Replacing The Hydraulic Pump-Drive Belt
Replacing the Hydraulic Pump-Drive Belt Disengage the PTO and set the parking brake. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Remove the mower belt; refer to Replacing the Mower Belt (page 56). -
Page 58: Controls System Maintenance
Controls System Remove the belt from the hydraulic-unit-drive pulleys and the engine pulley. Maintenance Install the new belt around the engine pulley and the 2 drive pulleys. Using a ratchet in the square hole in the idler Adjusting the arm, install the idler spring to the frame (Figure Control-Handle Position 82). -
Page 59: Adjusting The Motion-Control Linkage
Temporarily install a jumper wire across the terminals in the connector of the main wiring harness. Start the engine, run it at full throttle, and release the brake. Note: The brake must be engaged and motion-control levers out to start engine. You do not have to be in the seat because of the jumper wire being used. -
Page 60: Adjusting The Motion-Control Damper
Adjusting the Shutoff the unit, remove the jumper wire from the wire harness and plug the connector into the Motion-Control seat switch. Remove the jack stands. Neutral-Lock Pivot Raise the deck and install the height-of-cut pin. You can adjust the flanged nut to obtain the desired Check that the machine does not creep in motion-control lever resistance when moving it to the with the park brakes disengaged. -
Page 61: Hydraulic System Maintenance
Hydraulic System Maintenance Servicing the Hydraulic System Hydraulic Fluid Type: Toro ® HYPR-OIL ™ hydraulic fluid or Mobil ® 1 15W-50. Important: Use the fluid specified. Other fluids could damage the hydraulic system. Each Hydraulic System Fluid Capacity: 1.5 L (1.59... - Page 62 Mobil ® 1 fluid (more often in dirty or dusty conditions). Every 500 hours—Change the hydraulic filters and hydraulic fluid when using Toro ® HYPR-OIL ™ 500 hydraulic fluid (more often in dirty or dusty conditions).
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Page 63: Mower Deck Maintenance
Mower Deck Maintenance Leveling the Mower Deck Setting up the Machine Note: Ensure that the mower deck is level before matching the height of cut (HOC). Position the machine on a flat surface. Disengage the blade-control switch (PTO), move g029840 Figure 91 the motion-control levers to the N EUTRAL... -
Page 64: Servicing The Cutting Blades
Loosen or tighten the any wear or damage. File down any nicks and sharpen single-point-adjustment bolt enough to the blades as necessary. If a blade is damaged or move the height-of-cut plate-mounting bolts at worn, replace it immediately with a genuine Toro... - Page 65 Checking for Bent Blades balance or is bent. To ensure optimum performance and continued safety conformance of the machine, Disengage the PTO, move the motion-control use genuine Toro replacement blades. Replacement levers to the N position, and set the EUTRAL LOCK parking brake.
- Page 66 g000277 Figure 100 1. Blade 2. Balancer If the blade is not balanced, file some metal off the end of the sail area only (Figure 101). Repeat this procedure until the blade is balanced. Installing the Blades Install the blade onto the spindle shaft (Figure g004536 101).
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Page 67: Removing The Mower Deck
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. -
Page 68: Replacing The Grass Deflector
Replacing the Grass Raise the deck struts and secure them in the up position. Slide the deck out to the right side of Deflector the machine. WARNING Operating the machine with the engine running at a speed greater than the factory setting can cause the machine to throw a part of the blade or engine at you or bystanders, resulting in serious injury or death. -
Page 69: Cleaning
Cleaning Storage Cleaning and Storage Cleaning under the Mower Disengage the power takeoff (blade-control Service Interval: Before each use or daily switch (PTO)), set the parking brake, and turn the ignition key to the off position. Remove the Disengage the blade-control switch (PTO), move key. - Page 70 Run the engine to distribute conditioned fuel through the fuel system (5 minutes). Shut off the engine, allow it to cool, and drain the fuel tank; refer to Servicing the Fuel Tank (page 46). Restart the engine and run it until it stops. Dispose of fuel properly.
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Page 71: Troubleshooting
Troubleshooting Problem Possible Cause Corrective Action The starter does not crank. 1. The blade-control switch (PTO) is 1. Move the blade-control switch (PTO) engaged. to the disengaged position. 2. The parking brake is not on. 2. Set the parking brake. 3. - Page 72 Problem Possible Cause Corrective Action The machine does not drive. 1. The bypass valves are not closed tight. 1. Tighten the bypass valves. 2. The pump belt is worn, loose, or 2. Change the belt. broken. 3. The pump belt is off a pulley. 3.
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Page 73: Schematics
Schematics g009180 Wire Diagram (Rev. A) - Page 74 Notes:...
- Page 75 Notes:...
- Page 76 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. If all other remedies fail, you may contact us at Toro Warranty Company.