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Figure 74

Clutch pulley

Square hole in the idler
arm for the ratchet

Mower belt

Idler grease fitting

Spring loaded idler pulley

Belt guide

Ratchet

10.

Install the belt guide on the idler arm shown in

Figure

11.

Using the ratchet in the square hole, install the idler
spring (

Figure 74

Make sure that the spring ends are seated in the anchor
grooves.

12.

Install the belt covers (

Figure 75

Figure 75

Position the belt cover

Ensure the tab is under
the metal catch

Slide belt cover under the
side catches

Replacing the Hydraulic
Pump-Drive Belt

Disengage the PTO and set the parking brake.

Stop the engine, remove the key, and wait for all moving
parts to stop before leaving the operating position.

Remove mower belt. Refer to

Replacing the Mower

Belt (page 49)

Raise the machine and support it with jack stands
(

Figure 76

Summary of Contents for 74955

Page 1: ... Commercial 3000 Series Riding Mower with 52in or 72in TURBO FORCE Side Discharge Mower Model No 74955 Serial No 315000001 and Up Model No 74959 Serial No 315000001 and Up Register at www Toro com Original Instructions EN 3394 324 A ...

Page 2: ...enclosed Engine Owner s Manual is supplied for information regarding the US Environmental Protection Agency EPA and the California Emission Control Regulation of emission systems maintenance and warranty Replacements may be ordered through the engine manufacturer Introduction This rotary blade riding lawn mower is intended to be used by residential homeowners or professional hired operators It is ...

Page 3: ...aintenance 34 Servicing the Air Cleaner 34 Servicing the Engine Oil 35 Servicing the Spark Plug 38 Check the Spark Arrester if equipped 39 Fuel System Maintenance 40 Replacing the Fuel Filter 40 Servicing the Fuel Tank 40 Electrical System Maintenance 41 Servicing the Battery 41 Servicing the Fuses 42 Drive System Maintenance 43 Checking the Seat Belt 43 Checking the Rollover Protection System ROP...

Page 4: ...perly Do not operate unless they are functioning properly Operation Lightning can cause severe injury or death If lightning is seen or thunder is heard in the area do not operate the machine seek shelter Never run an engine in an enclosed area Only operate in good light keeping away from holes and hidden hazards Be sure all drives are in neutral and parking brake is engaged before starting engine ...

Page 5: ... times until fueling is complete Do not use a nozzle lock open device If fuel is spilled on clothing change clothing immediately Never overfill fuel tank Replace fuel cap and tighten securely Maintenance and Storage Disengage drives set parking brake stop engine and remove key or disconnect spark plug wire Wait for all movement to stop before adjusting cleaning or repairing Clean grass and debris ...

Page 6: ... 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 6 ...

Page 7: ... 6520 1 Grease 93 7818 1 Warning read the Operator s Manual for instructions on torquing the blade bolt nut to 115 149 N m 85 110 ft lb 99 8936 1 Machine speed 4 Neutral 2 Fast 5 Reverse 3 Slow 106 2655 1 Warning do not touch or approach moving belts remove the ignition key and read the instructions before servicing or performing maintenance 106 5517 1 Warning do not touch the hot surface 7 ...

Page 8: ...ower the roll bar only when absolutely necessary do not wear the seat belt when the roll bar is down 3 Read the Operator s Manual drive slowly and carefully 110 2067 110 2068 1 Read the Operator s Manual 112 9028 1 Warning stay away from moving parts keep all guards in place 114 4466 1 Main 25A 3 Charge 25A 2 PTO 10A 4 Auxiliary 15A 115 7445 1 Grease pulleys and spindles 2 Maintenance interval 50 ...

Page 9: ...il 117 0346 1 Fuel leak hazard read the Operator s Manual do not attempt to remove the roll bar do not weld drill or modify the roll bar in any way 117 3848 1 Thrown object hazard keep bystanders a safe distance from the machine 2 Thrown object hazard mower do not operate without the deflector discharge cover or grass collection system in place 3 Cutting dismemberment of hand or foot stay away fro...

Page 10: ...inuous variable setting 2 Choke 5 Slow 3 Fast 126 2055 1 Wheel lug nut torque 95 ft lb 129 N m 4x 2 Wheel hub nut torque 235 ft lb 319 N m 3 Read and understand the Operator s Manual before performing any maintenance check torque after first 100 hours then every 500 hours thereafter 126 4398 1 Read the Operator s Manual 3 Unlock 2 Lock 10 ...

Page 11: ...xplosion 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 8 Battery acid can cause blindness or severe burns 4 Wear eye protection 9 Flush eyes immediately with water and get medical help fast 5 Read the Operator s Manual 10 Contains lead do no...

Page 12: ...not operate when people and pets are in the area Keep deflector in place 3 Warning Disengage PTO move drive levers out to neutral lock position engage parking brake and stop engine before leaving the operator s position 6 Crushing dismemberment hazard of bystanders do not carry passengers look forward and down when operating the machine look behind and down when reversing 125 9383 1 Check hydrauli...

Page 13: ...slopes near open water do not use this machine on slopes greater than 15 degrees 2 Ramp hazard when loading onto a trailer do not use dual ramps only use a singular ramp wide enough for the machine and that has an incline less than 15 degrees back up the ramp in reverse and drive forward off the ramp 13 ...

Page 14: ...w approximately one gallon remaining in the fuel tank Safety Interlock Indicators There are symbols on the hour meter and the indicate with a black triangle that the interlock component is in the correct position Figure 6 Battery Indicator Light If the ignition key is turned to the On position for a few seconds the battery voltage will be displayed in the area where the hours are normally displaye...

Page 15: ...th the machine to enhance and expand its capabilities 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 Width 52 inch Deck 72 inch Deck Without Deck 119 cm 47 inches 150 cm 59 inches Deflector Up 135 cm 53 inches 187 cm 74 inches Deflec...

Page 16: ...not operate without entire exhaust system in place and in proper working condition 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 Do not fill gasoli...

Page 17: ...seat belt Ensure that the seat is secured to the machine WARNING There is no rollover protection when the roll bar is in the down position Lower the roll bar only when absolutely necessary Do not wear the seat belt when the roll bar is in the down position Drive slowly and carefully Raise the roll bar as soon as clearance permits Check carefully for overhead clearances i e branches doorways electr...

Page 18: ...rees Reduce speed and use extreme caution on slopes Avoid sudden turns or rapid speed changes Figure 8 1 Safe Zone use the Z Master here on slopes less than 15 degrees or flat areas 3 Water 2 Danger Zone use a walk behind mower and or a hand trimmer on slopes greater than 15 degrees near drop offs and water CAUTION This machine produces sound levels in excess of 85 dBA at the operators ear and can...

Page 19: ...w positions Figure 14 Always use the fast position when turning on the mower deck with the blade control switch PTO G008946 Figure 14 Operating the Ignition Switch 1 Turn the ignition key to the Start position Figure 15 When the engines starts release the key Important Do not engage starter for more than 5 seconds at a time If the engine fails to start allow a 15 second cool down period between at...

Page 20: ... the Parking Brake page 18 4 Move the blade control switch PTO to the off position Figure 17 5 Move the throttle lever midway between the slow and fast positions A B C D D g027336 Figure 17 6 Turn the ignition key to the Start position Figure 15 When the engines starts release the key Important Do not engage starter for more than 5 seconds at a time If the engine fails to start allow a 15 second c...

Page 21: ...eplace any damaged switches before operating the machine 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 neutral locked position The safety interlock system also is designed to stop the engine when the traction con...

Page 22: ... motion control 5 Sitting on the seat disengage the parking brake move the blade control switch PTO to off and move the motion control levers to neutral lock position Try starting the engine the engine should not crank Driving Forward or Backward The throttle control regulates the engine speed as measured in rpm revolutions per minute Place the throttle control in the fast position for best perfor...

Page 23: ... you leave the machine refer to Setting the Parking Brake page 18 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 Always remove the ignition key and set the parking brake when leaving the machine unattended even if just for a few minutes Adjusting the Height of Cut Using the Transport Lock T...

Page 24: ...in 90 degrees and remove the pin from the height of cut bracket Figure 25 4 Select a hole in the height of cut bracket corresponding to the height of cut desired and insert the pin Figure 25 5 Push on the deck lift pull back on the transport lock and slowly lower the mower deck Figure 25 1 Deck lift pedal 3 Transport lock 2 Cut of height pin Adjusting the Anti scalp Rollers Whenever you change the...

Page 25: ...ge the blade control switch PTO move the motion control levers to the neutral locked position and set the parking brake 2 Stop the engine remove the key and wait for all moving parts to stop before leaving the operating position 3 To adjust the cam locks swing the lever up to loosen the cam lock Figure 29 4 Adjust the baffle and cam locks in the slots to the desired discharge flow 5 Swing the leve...

Page 26: ... away from the mower Figure 30 Position B Use this position when bagging Always align it with the blower opening Figure 31 Position C This is the full open position The suggested use for this position is as follows Use in tall dense grass mowing conditions Use in wet conditions Lowers the engine power consumption Allows increased ground speed in heavy conditions This position is similar to the ben...

Page 27: ...s to the side and down toward the turf DANGER Without a grass deflector discharge cover or complete grass catcher assembly mounted in place you and others are exposed to blade contact and thrown debris Contact with rotating mower blade s and thrown debris will cause injury or death Never remove the grass deflector from the mower because the grass deflector routes material down toward the turf If t...

Page 28: ...se the machine to tip or lose control If loading on or near a slope position the trailer or truck so that it is on the down side of the slope and the ramp extends up the slope This will minimize the ramp angle WARNING Loading a machine onto a trailer or truck increases the possibility of tip over and could cause serious injury or death Use extreme caution when operating a machine on a ramp Ensure ...

Page 29: ...d position 4 Ramp is at least four times 4X as long as the height of the trailer or truck bed to the ground 2 Side view of full width ramp in loading position 5 H height of the trailer or truck bed to the ground 3 Not greater than 15 degrees 6 Trailer 29 ...

Page 30: ...y If you cannot mow for an extended period first mow at a high cutting height then mow again 2 days later at a lower height setting Choosing the Best Speed To improve cut quality use a slower ground speed in certain conditions Avoiding Cutting Too Low If the cutting width of the mower is wider than the mower you previously used raise the cutting height to ensure that uneven turf is not cut too sho...

Page 31: ... Inspect the primary filter and the air inlet screen Every 200 hours Change the engine oil filter Check clean and regap the spark plug Every 250 hours Change the hydraulic filters and hydraulic oil when using Mobil 1 oil more often in dirty or dusty conditions Every 300 hours Replace the primary air filter more often in dusty or sandy conditions Check the inner air filter Every 500 hours Replace t...

Page 32: ...f the bearings 5 Wipe up any excess grease Adding Light Oil or Spray Lubrication Service Interval Every 100 hours Lubricate the deck lift pivots G017050 Figure 38 Greasing the Mower Service Interval Every 50 hours Grease the mower deck spindles and idler arm Yearly Grease the pump belt idler arm Yearly Grease the front caster pivots more often in dirty or dusty conditions Yearly Repack the front c...

Page 33: ... Note that thread locking adhesive has been applied to lock the spacer nuts to the axle Remove the axle with the other spacer nut still assembled to it from the wheel assembly 6 Pry out the seals and inspect the bearings for wear or damage and replace if necessary 7 Pack the bearings with a general purpose grease 8 Insert 1 bearing and 1 new seal into the wheel Note The seals must be replaced 9 If...

Page 34: ...sandy conditions Every 300 hours Check the inner air filter Every 600 hours Replace the inner air filter Note Check the filters more frequently if the operating conditions are extremely dusty or sandy Removing the Filters 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...

Page 35: ...ers Important To prevent engine damage always operate the engine with both air filters and the cover installed 1 If installing new filters check each filter for shipping damage Note Do not use a damaged filter 2 If the inner filter is being replaced carefully slide it into the filter body Figure 44 3 Carefully slide the primary filter over the inner filter Figure 44 Note Ensure that the primary fi...

Page 36: ... 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 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 ...

Page 37: ... brake 4 Stop the engine remove the key and wait for all moving parts to stop before leaving the operating position Figure 47 G008804 Figure 47 5 Slowly pour approximately 80 of the specified oil into the filler tube and slowly add the additional oil to bring it to the Full mark Figure 48 B A C D E F g027660 Figure 48 6 Start the engine and drive to a flat area 7 Check the oil level again Changing...

Page 38: ...ck and adjust the air gap Install a new spark plug s if necessary Type Champion XC12YC or equivalent Air Gap 0 76 mm 0 030 inch 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 3 Remove the left hydraulic uni...

Page 39: ...if equipped Service Interval Every 50 hours WARNING 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 1 Stop the engine wait for all moving parts to stop and remove...

Page 40: ...ng the operating position 5 Close the fuel shutoff valve under the seat Figure 54 Figure 54 1 Fuel filter 3 Fuel shutoff valve 2 Hose clamp 6 Squeeze the ends of the hose clamps together and slide them away from the filter Figure 54 7 Remove the filter from the fuel lines 8 Install a new filter and move the hose clamps close to the filter Figure 54 9 Open the fuel shutoff valve Note It is importan...

Page 41: ...ck battery cable before disconnecting the positive red cable Always Reconnect the positive red battery cable before reconnecting the negative black cable 1 Disengage the blade control switch PTO move the motion control levers to the neutral locked position and set the parking brake 2 Stop the engine remove the key and wait for all moving parts to stop before leaving the operating position 3 First ...

Page 42: ...ery posts Figure 56 3 Install the battery in the machine and connect the battery cables refer to Installing the Battery page 41 Note Do not run the machine with the battery disconnected electrical damage may occur Figure 56 1 Positive Battery Post 3 Red Charger Lead 2 Negative Battery Post 4 Black Charger Lead Servicing the Fuses The electrical system is protected by fuses It requires no maintenan...

Page 43: ...led rearward to get both knobs fully engaged Figure 58 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 Adjusting the Tracking 1 Disengage the blade control switch PTO 2 Drive to an open flat area move the motion control levers to the neutral locked position 3 Move the throttle mi...

Page 44: ...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 61 1 Slotted nut Adjusting the Caster Pivot Bearing Service Interval Every 500 hours Yearly whichever comes first 1 Disengage the blade control switch PTO move the motio...

Page 45: ... parking brake and allow the machine to cool completely before starting these instructions 3 Using an air compressor blow out any debris from under the brake pole and around the brake spacers Figure 64 4 Check the condition of the wire harness leads connectors and terminals Clean or repair as necessary 5 Verify that 12V is present at the clutch connector when the PTO switch is engaged 6 Measure th...

Page 46: ...eeler gauge Figure 68 1 Feeler gauge If the gap is less than 0 010 inch then reinstall the shim and reference the Troubleshooting page 63 section If the gap is sufficient proceed to the safety check in step F 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 dise...

Page 47: ...y of overheating and mechanical damage to the engine Figure 70 Cleaning the Engine Cooling Fins and Shrouds Service Interval Every 100 hours Yearly whichever comes first 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 Remove the air intake screen recoil starter and fan housing Figure 70 4 C...

Page 48: ... 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 engage the parking brake 3 Stop the engine wait for all moving parts to stop and remove the key 4 Raise the back of the machine up and support the machine with jack stands DANGER Mechanical or hydrau...

Page 49: ...intenance 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...

Page 50: ...ring ends are seated in the anchor grooves 12 Install the belt covers Figure 75 Figure 75 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 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 Rem...

Page 51: ...6 10 Install the mower belt Refer to Replacing the Mower Belt page 49 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...

Page 52: ...ector of the main wiring harness 5 Start the engine Note The brake must be engaged and the motion control levers must be out to start the 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 u...

Page 53: ...ce firmest feel 3 Damper 4 Medium resistance medium feel 5 Least resistance softest feel Adjusting the Motion Control Neutral Lock Pivot The flanged nut can be adjusted to obtain a more desired motion control lever resistance when moving it to the neutral lock position See Figure 81 for adjustment options 1 Loosen the jam nut 2 Tighten or loosen the flanged nut to the desired feel For more resista...

Page 54: ...rvoir 9 Remove the dipstick and look at the end Figure 82 Note If the oil level is at the add mark slowly pour only enough oil into the hydraulic reservoir to raise the level to the full or H line Important Do not overfill the hydraulic units with oil as damage may occur Do not run the machine with the oil below the add mark 10 Install the dipstick 11 Repeat procedure for the opposite dipstick G01...

Page 55: ...n 3 Raise the machine and support it with jack stands Figure 83 Figure 83 1 Jack stands 4 Remove both the mower belt and the pump drive belt refer to Replacing the Mower Belt page 49 and Replacing the Hydraulic Pump Drive Belt page 50 Note This prevents oil from getting on the belts 5 Place a drain pan under the filter remove the old filter and wipe the surface clean Figure 84 G008968 1 2 Figure 8...

Page 56: ...king brake 3 Check the tire pressure in the drive tires Proper inflation pressure for tires is 90 kPa 13 psi Adjust if necessary 4 Position the transport lock in the latching position 5 Push the deck lift pedal all the way forward and the deck will latch at the 14 cm 5 1 2 inch transport position Figure 85 Figure 85 1 Deck lift pedal 3 Transport lock 2 Height of cut pin 6 Insert the height adjustm...

Page 57: ...g017036 Figure 89 1 Single point adjustment bolt 14 Tighten the two bolts at the bottom of the height of cut plate Figure 88 Torque to 37 45 N m 27 33 ft lb Note In most conditions the back blade tip should be adjusted 6 4 mm 1 4 inch higher than the front 15 On both sides of the deck measure from the level surface to the back tip of the blade Postion B The measurement should read 8 3 cm 3 1 4 inc...

Page 58: ... Disengage the blade control switch PTO move the motion control levers to the neutral locked position and set the parking brake 2 Stop the engine remove the key and wait for all moving parts to stop before leaving the operating position 3 Rotate the blades until the ends face forward and backward Figure 91 Measure from a level surface to the cutting edge position A of the blades Figure 91 Note thi...

Page 59: ...if the same amount of material is removed from both cutting edges Figure 93 1 Sharpen at the original angle 2 Check the balance of the blade by putting it on a blade balancer Figure 94 Note If the blade stays in a horizontal position the blade is balanced and can be used Figure 94 1 Blade 2 Balancer 3 If the blade is not balanced file some metal off the end of the sail area only Figure 97 4 Repeat...

Page 60: ... locks the deck lift arms in the lowest position when the deck is removed and the stored energy in the deck spring is released 4 Remove the belt covers 5 Lift up the floor pan and insert a ratchet into the square hole in the deck idler Figure 96 6 Rotate the deck idler clockwise and remove the mower belt Figure 96 Figure 96 1 Clutch pulley 5 Square hole in the idler arm for the ratchet 2 Mower bel...

Page 61: ...ring behind deck edge Note Make sure that one J end of spring is installed behind deck edge before installing the bolt as shown in Figure 98 4 Install the bolt and nut 5 Place one J hook end of spring around grass deflector Figure 98 Important The grass deflector must be able to rotate Lift the deflector up to the full open position and ensure that it rotates into the full down position Cleaning C...

Page 62: ...e with the blade control switch PTO engaged and the engine at high idle for 2 to 5 minutes after washing 11 Check the condition of the blades refer to Servicing the Cutting Blades page 57 12 Prepare the machine for storage when non use occurs over 30 days Prepare the machine for storage as follows A Add a petroleum based stabilizer conditioner to fuel in the tank Follow mixing instructions from th...

Page 63: ...ions are corroded loose or faulty 9 Check the electrical connections for good contact Clean the connector terminals thoroughly with electrical contact cleaner apply dielectric grease and reconnect 10 The relay or switch is defective 10 Contact an Authorized Service Dealer 11 The spark plug is faulty 11 Clean adjust or replace spark plug The engine will not start starts hard or fails to keep runnin...

Page 64: ...k is not level 3 Level the mower deck from side to side and front to rear 4 The underside of mower is dirty 4 Clean the underside of the mower 5 The tire pressure is not correct 5 Adjust the tire pressure Mowing is resulting in uneven cutting height 6 The blade spindle bent 6 Contact an Authorized Service Dealer 1 The mower deck belt is worn loose or broken 1 Install a new deck belt 2 The mower de...

Page 65: ...Schematics G020788 Electrical Schematic Rev A 65 ...

Page 66: ...Notes 66 ...

Page 67: ...Notes 67 ...

Page 68: ... provided contact us at RLC Customer Care Department Toro Warranty Company 8111 Lyndale Avenue South Bloomington MN 55420 1196 888 865 5676 U S Customers 888 865 5691 Canada customers Owner Responsibilities You must maintain your Toro Product by following the maintenance procedures described in the Operator s Manual Such routine maintenance whether performed by a dealer or by you is at your expens...

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