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Toro 74936 Operator's Manual

60 in or 72 in turbo force side discharge mower
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Form No. 3368-204 Rev C
Z Master
®
G3 Riding Mower
with 60in or 72in TURBO FORCE
®
Side
Discharge Mower
Model No. 74936—Serial No. 311000001 and Up
Model No. 74938—Serial No. 311000001 and Up
Model No. 74960CP—Serial No. 311000001 and Up
Model No. 74961CP—Serial No. 311000001 and Up
G008971
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. 74938—Serial No. 311000001 and Up Model No. 74960CP—Serial No. 311000001 and Up Model No. 74961CP—Serial No. 311000001 and Up G008971 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

    Write the numbers in the Authorized Toro Dealer. space provided. Genuine Toro spark arresters are approved by the USDA Forestry Service. Note: It is a violation of California Public Resource Code Section 4442 to use or operate the engine on...

  • Page 3: Table Of Contents

    This manual uses 2 other words to highlight information. Engine Maintenance..........36 Important calls attention to special mechanical Servicing the Air Cleaner ........36 information and Note emphasizes general information Servicing the Engine Oil ........37 worthy of special attention. Servicing the Spark Plug ........

  • 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 • Be aware of the mower discharge direction and do • Be certain that the seat belt can be released quickly not point it at anyone. in the event of an emergency. • Do not operate the mower under the influence of •...
  • Page 6 • Keep all parts in good working condition and all hardware tightened. Replace all worn or damaged decals. • Use only Toro approved attachments. Warranty may be voided if used with unapproved attachments.

  • 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 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 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. 68-8340 1-403005 98-5954 103-2076 54-9220 58-6520 1. Grease 105-7798 66-1340...
  • Page 9 109-7232 109-7929 107-2102 107-3969 CP Models Only 110-2067 1. Warning—read the Operator's Manual. 2. Crushing hazard, mower—engage the parking brake, stop the engine, and remove the ignition key before working under the mower. 110-2068 1. Read the Operator's Manual.
  • Page 10 114-4466 1. Main, 25A 3. Charge, 25A 4. Auxiliary, 15A 2. PTO, 10A 116-0090 116-0157 114-9834 1. Power Take-off (PTO) 4. Continuous variable setting 2. Choke 5. Slow 3. Fast 116-0205 115-7445 1. Grease pulleys and spindles 116-0211 2. Maintenance interval—50 hours...
  • Page 11 116-3303 116-0752 1. Locked 2. Unlocked 116-4858 116-1654 Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 6. Keep bystandersa safe distance from the battery. 2. No fire, open flame, or 7. Wear eye protection; explosive gases can smoking.
  • Page 12 Manufacturer's Mark 1. Indicates the blade is identified as a part from the original machine manufacturer. 109-7069...

  • Page 13: 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 14: 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 15: 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 16: Checking The Engine Oil Level

    Checking the Engine Oil Level Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline. To minimize the Before you start the engine and use the machine, check chance of varnish deposits in the fuel system, use fuel the oil level in the engine crankcase;...

  • Page 17: 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 18: 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 19: 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 20: Using The Fuel Shut-Off Valve

    Using the Fuel Shut-Off Valve The fuel shut-off valve is located under the seat. Move the seat forward to access it. Close the fuel shut-off valve for transport, maintenance, and storage. Ensure the fuel shut-off valve is open when starting the engine.

  • Page 21: 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 22: 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 23: 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 24: 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 25: Adjusting The Flow Baffle Cam Locks

    Adjusting the Flow Baffle Cam Locks This procedure is applicable only to machines with the flow baffle locks. Certain models will have nuts and bolts in-place of the flow baffle locks and can be adjusted the same. The mower discharge flow can be adjusted for different types of mowing conditions.

  • Page 26: Positioning The Seat

    Position A • Allows increased ground speed in heavy conditions. • This position is similar to the benefits of the Toro This is the full rear position. The suggested use for this SFS mower. position is a follows. • Use for short, light grass mowing conditions.

  • Page 27: Unlatching The Seat

    1. To adjust, move the lever sideways to unlock seat (Figure 36). 2. Slide the seat to the desired position and release lever to lock in position. Changing the Seat Suspension The seat can be adjusted to provide a smooth and comfortable ride.

  • Page 28: Using The Drive Wheel Release Valves

    Using the Drive Wheel Release Valves WARNING Hands may become entangled in the rotating drive components below the engine deck, which could result in serious injury. Stop the engine, remove the key, and allow all moving parts to stop before accessing the drive wheel release valves.

  • Page 29: Transporting Machines

    Transporting Machines Using the Z Stand® (CP Models Only) Use a heavy-duty trailer or truck to transport the machine. Ensure that the trailer or truck has all The Z Stand® raises the front end of the machine to necessary brakes, lighting, and marking as required by allow you to clean the mower and remove the blades.
  • Page 30 Figure 41 1. Z Stand (Positioned in 3. Latch resting on pivot tab slot) Figure 42 2. Crack in side walk or turf 3. Locked position 1. Z Stand 2. Latch 4. Unlocked position 4. Set the foot of stand on the ground and rest the latch on the pivot tab (Figure 41).

  • Page 31: 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 43). The lower rear section of the tractor frame extends back between the rear wheels and serves as a stop for tipping backward.
  • Page 32 If a blade is damaged or worn, replace it immediately with Mow at Correct Intervals a genuine TORO replacement blade. Normally, mow every four days. But remember, grass grows at different rates at different times. So to maintain the same cutting height, which is a good practice, mow more often in early spring.

  • Page 33: Maintenance

    • Check the torque for wheel lug nuts. • Adjust the caster pivot bearing. Every 500 hours • Check the park brake adjustment. • Change the hydraulic filters and hydraulic oil when using Toro® HYPR-OIL™ 500 hydraulic oil. • Replace the inner air filter. Every 600 hours •...

  • Page 34: 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 35: Lubricate Caster Wheel Hubs

    2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Grease the mower deck idler pulley pivot until grease come out the bottom (Figure 45). 4. Grease the three spindle bearings until grease comes out the lower seals (Figure 45).

  • Page 36: Engine Maintenance

    Engine Maintenance adhesive to one spacer nut and thread onto the axle with the wrench flats facing outward. Do Not thread spacer nut all of the way onto the end of the axle. WARNING Leave approximately 1/8 inch (3 mm) from the outer surface of the spacer nut to the end of the axle inside Contact with hot surfaces may cause personal the nut.

  • Page 37: Servicing The Engine Oil

    Figure 49 1. Air cleaner body 4. Air cleaner latch 2. Inner air filter 5. Air cleaner cover G016165 3. Primary air filter Figure 50 1. Air cleaner cover 3. Breathe valve. Servicing the Primary Filter 2. Throttle mechanism • If the primary filter is dirty, bent, or damaged, replace it.
  • Page 38 Note: Check the oil when the engine is cold. WARNING Contact with hot surfaces may cause personal injury. G008804 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 39 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: Every 150 hours (more often in dirty to bring it to the Full mark (Figure 54). or dusty conditions) Note: Dispose of the used oil at a recycling center.

  • Page 40: Servicing The Spark Plug

    Servicing the Spark Plug Service Interval: Every 200 hours—Check, clean and regap the spark plug. Every 600 hours—Replace the spark plugs. G015196 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 the spark plug(s) and a gapping tool/feeler gauge to check and adjust the air gap.
  • Page 41 Checking the Spark Plug Important: Replace the spark plug(s) when it has: a black coating, worn electrodes, an oily film, cracks or reuse is questionable. 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 42: 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 150 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 43: 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 44 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 45: 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 46: 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 47: 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 65). 8. Tighten the stop plate (Figure 65). Figure 66 Checking the Wheel Hub Slotted Nut Service Interval: After the first 100 hours Every 500 hours...

  • Page 48: Adjusting The Caster Pivot Bearing

    Figure 68 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 69 nut. 1.
  • Page 49 2. Using an air compressor, blow out any debris from under the brake pole and around the brake spacers. Figure 73 1. Shim C. Using a pneumatic line, blow out any debris Figure 71 from under the brake pole and around the brake spacers.

  • Page 50: 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 Servicing the Engine Oil check in step F. F. Perform the following safety check: Cooler a.

  • Page 51: Cleaning The Engine Cooling Fins And Shrouds

    insure adequate cooling and correct engine speed and will reduce the possibility of overheating and mechanical damage to the engine. Cleaning the Engine Cooling Fins and Shrouds Service Interval: Every 150 hours/Yearly (whichever comes first) 1. Disengage the PTO and set the parking brake. 2.

  • Page 52: Brake Maintenance

    Brake Maintenance Adjusting the Parking Brake Service Interval: After the first 100 hours Every 500 hours 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. Check to make sure the brake is adjusted properly.

  • Page 53: Belt Maintenance

    Belt Maintenance 15. Close the drive wheel release valve. Refer to Using the Drive Wheel Valves in Operation. 16. Repeat on the opposite side of the machine. Inspecting the Belts 17. Install the rear tires and torque the lug nuts to 90-95 Service Interval: Every 50 hours ft-lb (122-129 N-m).

  • Page 54: Replacing The Hydraulic Pump Drive Belt

    Figure 83 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 Figure 82 Drive Belt 1. Clutch pulley 5. Square hole in the idler arm for the ratchet 1.

  • Page 55: 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 56: Adjusting The Motion Control Linkage

    not have to be in the seat because of the jumper wire being used. Run engine at full throttle and release brake. 6. Run the unit at least 5 minutes with the drive levers at full forward speed to bring hydraulic oil up to operating temperature.

  • Page 57: Adjusting The Motion Control Damper

    Adjusting the Motion Control Damper The top damper mounting bolt can be adjusted to obtain a more desired motion control lever resistance. See Figure 88 for mounting options. Figure 89 1. Flanged nut 2. Jam nut Figure 88 RH Motion Control Shown 1.

  • Page 58: Hydraulic System Maintenance

    Hydraulic System Maintenance Servicing the Hydraulic System Hydraulic Oil Type: Toro ® HYPR-OIL ™ ® hydraulic oil or Mobil 1 15W-50. Important: Use oil specified. Other fluids could cause system damage. Each Hydraulic System Oil Capacity: 52 ounces (1.5 l) per side with filter change Checking the Hydraulic Oil Service Interval: Every 50 hours—Check the hydraulic...
  • Page 59 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 60: 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 Figure 93 and set the parking brake.
  • Page 61 13. If the deck is too low, tighten the single point adjustment bolt by rotating it clockwise. If the deck is too high, loosen the single point adjustment bolt by rotating it counterclockwise (Figure 97). Note: Loosen or tighten the single point adjustment bolt enough to move the height-of-cut plate mounting bolts at least 1/3 the length of the available travel in their slots.

  • Page 62: Servicing The Cutting Blades

    (Figure 99). Measure from a level surface blades as necessary. If a blade is damaged or worn, to the cutting edge, position A, of the blades replace it immediately with a genuine Toro replacement (Figure 99). Note this dimension. blade. For convenient sharpening and replacement, you may want to keep extra blades on hand.
  • Page 63 Toro replacement blades. Replacement blades made by other manufacturers may result in non-conformance with safety standards. 1. Hold the blade end using a rag or thickly-padded glove. Figure 101 2. Remove the blade bolt, curved washer, and blade 1.

  • Page 64: Removing The Mower Deck

    Installing the Blades Removing the Mower Deck 1. Install the blade onto the spindle shaft (Figure 103). Before servicing or removing the mower deck, the spring loaded deck arms must be locked out. Important: The curved part of the blade must be pointing upward toward the inside of the WARNING mower to ensure proper cutting.

  • Page 65: Replacing The Grass Deflector

    Figure 105 1. Right stabilizer Figure 104 2. Deck strut (right side shown) 1. Clutch pulley 5. Square hole in the idler 3. Remove the rear deck lift attachment shoulder bolt and nut. arm for the ratchet 4. Remove the front deck lift attachment shoulder bolt and nut. 2.

  • Page 66: Cleaning

    Cleaning Cleaning Under the Mower Service Interval: Before each use or daily 1. Disengage the blade control switch (PTO), move the motion control levers to the neutral locked position and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

  • Page 67: Storage

    Storage B. Run the engine to distribute conditioned fuel through the fuel system (5 minutes). Cleaning and Storage C. Stop the engine, allow it to cool, and drain the fuel tank; refer to Servicing the Fuel Tank in the 1. Disengage the power take off (blade control switch Maintenance Section.

  • Page 68: 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 69 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 70: Schematics

    Schematics Wire Diagram (Rev. A)
  • Page 71 Notes:...
  • Page 72 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:

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