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Maintenance

Recommended Maintenance Schedule(s)

Maintenance Service

Interval

Maintenance Procedure

After the first 8 hours

• Change the engine oil.

After the first 100 hours

• Check the wheel lug nut torque.
• Check the wheel hub slotted-nut torque.
• Check the park brake adjustment.

After the first 250 hours

• Change the hydraulic filters and hydraulic oil when using any type of oil.

Before each use or daily

• Check the safety system.
• Check the engine-oil level.
• Check the seat belt.
• Check the rollover protection system (ROPS) knobs.
• Clean the engine screen and the oil cooler.
• Check and clean the hydraulic units.
• Check the mower blades.
• Clean the mower deck.

Every 50 hours

• Grease the mower deck spindles and idler arm.
• Check the spark arrester (if equipped).
• Check the tire pressure.
• Inspect the belts for cracks and wear.
• Check the hydraulic oil level.

Every 100 hours

• Lubricate the mower deck lift pivots.
• Change the engine oil (more often in dirty or dusty conditions).
• Check and clean engine cooling fins and shrouds.

Every 150 hours

• 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 the fuel filter. (more often in dirty or dusty conditions).
• Check the wheel lug nut torque.
• Check the wheel hub slotted-nut torque.
• 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 (more often in dirty or dusty conditions).

Every 600 hours

• Replace the inner air filter.

Monthly

• Check the battery.

Yearly

• Grease the pump belt idler arm.
• Grease the front caster pivots (more often in dirty or dusty conditions).
• Repack the front caster wheel bearings (more often in dirty or dusty conditions).
• Lubricate the caster wheel hubs.

Yearly or before storage

• Paint chipped surfaces.
• Check all maintenance procedures listed above before storage.

Important:

Refer to your engine operator's manual for additional maintenance procedures.

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Содержание 74959

Страница 1: ...o 3380 781 Rev A Z Master Commercial 3000 Series Riding Mower with 72in TURBO FORCE Side Discharge Mower Model No 74959 Serial No 314000001 and Up Register at www Toro com Original Instructions EN 3380 781 A ...

Страница 2: ...l Toro parts The 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...

Страница 3: ...aintenance 31 Servicing the Air Cleaner 31 Servicing the Engine Oil 32 Servicing the Spark Plug 35 Check the Spark Arrester if equipped 36 Fuel System Maintenance 37 Replacing the Fuel Filter 37 Servicing the Fuel Tank 37 Electrical System Maintenance 38 Servicing the Battery 38 Servicing the Fuses 39 Drive System Maintenance 40 Checking the Seat Belt 40 Checking the Rollover Protection System ROP...

Страница 4: ...y 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 Only...

Страница 5: ...g at all 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...

Страница 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 ...

Страница 7: ...y 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 1 403005 54 9220 58 6520 1 Grease 66 1340 68 8340 98 5954 103 2076 105 7798 116 2643 7 ...

Страница 8: ...107 2102 109 7232 1 Fast 3 Neutral 2 Slow 4 Reverse 110 2067 110 2068 1 Read the Operator s Manual 114 4466 1 Main 25A 3 Charge 25A 2 PTO 10A 4 Auxiliary 15A 116 0205 8 ...

Страница 9: ...nd spindles 2 Maintenance interval 50 hours 116 0752 1 Latch 2 Unlatch 116 1654 116 1716 1 Fuel 6 Hour meter 2 Empty 7 PTO 3 Half 8 Parking brake 4 Full 9 Neutral 5 Battery 10 Operator presence switch 116 3303 116 4858 116 5944 9 ...

Страница 10: ...r 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 not discard Manufacturer s Mark 1 Indicates the blade is identified as a part from the original machine ma...

Страница 11: ...116 0090 125 9382 1 Read the Operator s Manual for more information on servicing the machine 109 7069 11 ...

Страница 12: ...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...

Страница 13: ...ies A selection of Toro approved attachments and accessories is available for use with 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 72 inch Deck Without Deck 150 1 cm 59 1 in...

Страница 14: ...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...

Страница 15: ...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...

Страница 16: ...es 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 c...

Страница 17: ...low 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 ...

Страница 18: ...Setting the Parking Brake page 16 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 g017006 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 cool...

Страница 19: ...e 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 controls...

Страница 20: ... 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...

Страница 21: ... you leave the machine refer to Setting the Parking Brake page 16 Remove the key from the ignition switch CAUTION Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended 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...

Страница 22: ...egrees 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 1 3 2 G017027 Figure 25 1 Deck lift pedal 3 Transport lock 2 Cut of height pin Adjusting the Anti scalp Rollers Whenever you cha...

Страница 23: ...lade 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 lever back o...

Страница 24: ... 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...

Страница 25: ...e parking brake before pushing g015123 Figure 34 1 Vertical to push the machine 2 Horizontal to run the machine 4 Rotate the release valve levers horizontally to run the machine Figure 34 Using the Side Discharge The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf DANGER Without a grass deflector discharge cover or complete grass catcher assembly mo...

Страница 26: ...ull width ramp 4 Full width ramp side view 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 wit...

Страница 27: ...quently 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 t...

Страница 28: ... 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...

Страница 29: ...o ooze out of 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 37 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...

Страница 30: ... 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...

Страница 31: ...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...

Страница 32: ...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 43 3 Carefully slide the primary filter over the inner filter Figure 43 Note Ensure that the primary fi...

Страница 33: ... 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 ...

Страница 34: ...top the engine remove the key and wait for all moving parts to stop before leaving the operating position Figure 46 G008804 G008793 1 2 3 4 4 5 Figure 46 5 Slowly pour approximately 80 of the specified oil into the filler tube and slowly add the additional oil to bring it to the Full mark Figure 47 G008796 2 3 4 5 6 1 Figure 47 6 Start the engine and drive to a flat area 7 Check the oil level agai...

Страница 35: ...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...

Страница 36: ...ipped 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 the k...

Страница 37: ...ng the operating position 5 Close the fuel shutoff valve under the seat Figure 53 Figure 53 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 53 7 Remove the filter from the fuel lines 8 Install a new filter and move the hose clamps close to the filter Figure 53 9 Open the fuel shutoff valve Note It is importan...

Страница 38: ...als and metal parts of the machine 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 Always Disconnect the negative black battery cable before disconnecting the positive red cable Always Reconnect the positive red battery cable before reconnecting the negative black cable 1 Disengag...

Страница 39: ...n the temperature is below 32 F 0 C 1 Charge battery for 10 to 15 minutes at 25 to 30 amps or 30 minutes at 10 amps 2 When the battery is fully charged unplug the charger from the electrical outlet then disconnect the charger leads from the battery posts Figure 55 3 Install the battery in the machine and connect the battery cables refer to Installing the Battery page 39 Note Do not run the machine...

Страница 40: ...led rearward to get both knobs fully engaged Figure 57 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...

Страница 41: ...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 60 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...

Страница 42: ...e 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 63 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 t...

Страница 43: ...eeler gauge Figure 67 1 Feeler gauge If the gap is less than 0 010 inch then reinstall the shim and reference the Troubleshooting page 60 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...

Страница 44: ...y of overheating and mechanical damage to the engine Figure 69 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 69 4 C...

Страница 45: ...osition and set 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 hydraulic jacks may fail to support machine and cause a serious injury Use jack stand when supporting machine Do not use hydraulic jacks 5 Remove the rear tires from the machine 6 Remove any debris ...

Страница 46: ...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 crack...

Страница 47: ...ring ends are seated in the anchor grooves 12 Install the belt covers Figure 74 Figure 74 1 Position the belt cover 3 Ensure the tab is under the metal catch 2 Slide belt cover under the side catches Replacing the Hydraulic Pump Drive Belt 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...

Страница 48: ...5 10 Install the mower belt Refer to Replacing the Mower Belt page 46 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...

Страница 49: ...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...

Страница 50: ...nce 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 80 for adjustment options 1 Loosen the jam nut 2 Tighten or loosen the flanged nut to the desired feel For more resist...

Страница 51: ...rvoir 9 Remove the dipstick and look at the end Figure 81 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...

Страница 52: ...n 3 Raise the machine and support it with jack stands Figure 82 Figure 82 1 Jack stands 4 Remove both the mower belt and the pump drive belt refer to Replacing the Mower Belt page 46 and Replacing the Hydraulic Pump Drive Belt page 47 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 83 G008968 1 2 Figure 8...

Страница 53: ...e 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 84 1 3 2 G017027 Figure 84 1 Deck lift pedal 3 Transport lock 2 Height of cut pin 6 Insert the height ad...

Страница 54: ...wn adjustment on each of the four deck links g017036 Figure 88 1 Single point adjustment bolt 14 Tighten the two bolts at the bottom of the height of cut plate Figure 87 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...

Страница 55: ... Area 4 Crack Checking for Bent Blades 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 Rotate the blades until the ends face forward and backward Figure 90 Measure from a level surface to the cutting edge pos...

Страница 56: ...if the same amount of material is removed from both cutting edges Figure 92 1 Sharpen at the original angle 2 Check the balance of the blade by putting it on a blade balancer Figure 93 Note If the blade stays in a horizontal position the blade is balanced and can be used Figure 93 1 Blade 2 Balancer 3 If the blade is not balanced file some metal off the end of the sail area only Figure 93 4 Repeat...

Страница 57: ... 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 95 6 Rotate the deck idler clockwise and remove the mower belt Figure 95 Figure 95 1 Clutch pulley 5 Square hole in the idler arm for the ratchet 2 Mower bel...

Страница 58: ...spring 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 97 4 Install the bolt and nut 5 Place one J hook end of spring around grass deflector Figure 97 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...

Страница 59: ...machine 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 54 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 f...

Страница 60: ...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...

Страница 61: ...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...

Страница 62: ...Schematics G020788 Electrical Schematic Rev A 62 ...

Страница 63: ...Notes 63 ...

Страница 64: ... 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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