Toro Z MASTER G3 Operator's Manual
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Toro Z MASTER G3 Operator's Manual

Toro Z MASTER G3 Operator's Manual

152cm turbo force side discharge mower
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Form No. 3360-647 Rev C
Z Master G3 with a 152cm TURBO
FORCE
®
Side Discharge Mower
Model No. 74925TE—Serial No. 290000001 and Up
To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com.
Original Instructions (EN)

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  • Page 1 Z Master G3 with a 152cm TURBO FORCE ® Side Discharge Mower Model No. 74925TE—Serial No. 290000001 and Up To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com. Original Instructions (EN)

  • Page 2: Table Of Contents

    Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Introduction..............2 Dealer or Toro Customer Service and have the model Safety ................4 and serial numbers of your product ready. Figure 1 Safe Operating Practices ........4 identifies the location of the model and serial numbers Toro Riding Mower Safety ........
  • Page 3 Using the Z Stand®..........30 Replacing the Grass Deflector......62 Operating Tips ........... 31 Cleaning ..............63 Maintenance............... 32 Cleaning Under the Mower ......... 63 Recommended Maintenance Schedule(s) ....32 Waste Disposal ........... 63 Lubrication............. 33 Storage............... 64 Greasing and Lubrication ........33 Cleaning and Storage ..........

  • Page 4: Safety

    Preparation Safety • While mowing, always wear substantial footwear and This machine meets or exceeds European Standards in long trousers. Do not operate the equipment when effect at the time of production. However, improper barefoot or wearing open sandals. use or maintenance by the operator or owner can •...

  • Page 5: Toro Riding Mower Safety

    The following list contains safety information specific to – stop the engine and remove the key. Toro products or other safety information that you must know that is not included in the CEN standard. • Disengage drive to attachments, stop the engine, and disconnect the spark plug wire(s) or remove the •...

  • Page 6: Sound Pressure

    • Do not mow slopes when grass is wet. Slippery conditions reduce traction and could cause sliding and loss of control. • Do not make sudden turns or rapid speed changes. • Use a walk behind mower and/or a hand trimmer near drop-offs, ditches, steep banks or water.

  • Page 7: Slope Chart

    Slope Chart...

  • 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. 58-6520 1. Grease 99-8939 1. Read the Operator’s 3. Remove the ignition key and read the instructions Manual.
  • Page 9 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; smoking. explosive gases can cause blindness and other injuries 3.
  • Page 10 112-9028 1. Warning—stay away from moving parts; keep all guards in 114–4469 place. 1. Stored energy hazard—lower the mower deck and lock the height-of-cut position at 76 mm before servicing or performing maintenance. 114–4499 1. Wheel lug nuts 3. Read the instructions before servicing or performing maintenance;...
  • Page 11 115-7445 1. Grease pulleys and spindles 2. Maintenance interval—50 hours 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. 117-3811 2. Hydraulic oil 1.
  • Page 12 117-3847 117-3848 1. Sliding and loss of control hazard and tipping hazard, 1. Thrown object hazard—keep bystanders a safe distance drop-offs—do not operate the machine near drop-offs, from the machine. slopes greater than 15 degrees, or water; keep a safe 2.

  • Page 13: Product Overview

    Product Overview Figure 3 1. Height-of-cut deck lift 7. Seat belt pedal 2. Transport lock 8. Fuel cap 3. Parking brake lever 9. Mower deck 4. Controls 10. Caster wheel 5. Motion control levers 11. Z Stand 6. Roll bar...

  • Page 14: Controls

    Controls Become familiar with all the controls before you start the engine and operate the machine (Figure 3 and Figure 4). Figure 5 1. Fuel gauge (bars) 4. Safety interlock symbols 2. Battery light 5. Low fuel indicator light 3. Hour meter G008951 Figure 4 1.

  • Page 15: Specifications

    Contact your Authorized Service Dealer or Distributor or go to www.Toro.com for a list of all approved attachments Adding Fuel and accessories. Use unleaded regular gasoline suitable for automotive use (85 pump octane minimum).

  • Page 16: Filling The Fuel Tank

    Important: Do not use fuel additives containing methanol or ethanol. In certain conditions during fueling, static Add the correct amount of gas stabilizer/conditioner electricity can be released causing a spark to the gas. which can ignite the gasoline vapors. A fire Note: A fuel stabilizer/conditioner is most effective or explosion from gasoline can burn you and when mixed with fresh gasoline.

  • Page 17: Checking The Engine Oil Level

    Checking the Engine Oil Level 3. Lower the roll bar to the down position (Figure 7). Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking the Engine Oil Level. Breaking In a New Machine New engines take time to develop full power.

  • Page 18: Operating The Parking Brake

    Operating on wet grass or steep slopes can This machine produces sound levels in excess cause sliding and loss of control. of 85 dBA at the operators ear and can cause hearing loss through extended periods of Wheels dropping over edges can cause rollovers, exposure.

  • Page 19: Operating The Mower Blade Control Switch (Pto)

    Disengaging the Blade Control Switch (PTO) G009174 Figure 13 Operating the Throttle G008944 Figure 11 The throttle control can be moved between Fast and Slow positions (Figure 14). Always use the fast position when turning on the mower deck with the blade control switch (PTO). Operating the Mower Blade Control Switch (PTO) The blade control switch (PTO) starts and stops the...

  • Page 20: Operating The Ignition Switch

    Close the fuel shut-off valve for transport, maintenance, and storage. Ensure the fuel shut-off valve is open when starting the engine. G008959 Figure 15 Figure 17 1. On 2. Off 1. On 3. Hose going to the engine 2. Off Operating the Ignition Switch 1.

  • Page 21: Stopping The Engine

    Stopping the Engine Children or bystanders may be injured if they move or attempt to operate the tractor 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. Let the engine idle at slow throttle (turtle) for 60 seconds before turning the ignition switch off.

  • Page 22: The Safety Interlock System

    The Safety Interlock System operate as described below, have an Authorized Service Dealer repair the safety system immediately. 1. Sitting on the seat, engage the parking brake and move the blade control switch (PTO) to on. Try If safety interlock switches are disconnected starting the engine;...
  • Page 23 Using the Motion Control Levers G008952 Figure 23 Figure 22 Driving Backward 1. Motion control 4. Backward 1. Move the levers to the center, unlocked position. lever-neutral lock position 2. Center, unlocked position 5. Front of machine 2. To go backward, slowly pull the motion control 3.

  • Page 24: 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 25: Adjusting The Anti-Scalp Rollers

    4. Select a hole in the height-of-cut bracket corresponding to the height-of-cut desired and, insert the pin (Figure 26). 5. Push on the deck lift, pull back on the transport lock, and slowly lower the mower deck. Figure 27 1. Anti-scalp roller 4.

  • Page 26: Adjusting The Flow Baffle Cam Locks

    Adjusting the Flow Baffle Cam Position A Locks This is the full rear position. The suggested use for this position is a follows. This procedure is applicable only to machines with • Use for short, light grass mowing conditions. the flow baffle locks. Certain models will have nuts and bolts in-place of the flow baffle locks and can be •...

  • Page 27: Positioning The Seat

    Using the Drive Wheel Release • Allows increased ground speed in heavy conditions. • This position is similar to the benefits of the Toro Valves SFS mower. Hands may become entangled in the rotating drive components below the engine deck, which could result in serious injury.

  • Page 28: Using The Side Discharge

    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.

  • Page 29: Loading Machines

    Loading Machines Use extreme caution when loading units on trailers or Loading a unit onto a trailer or truck increases trucks. One full width ramp that is wide enough to the possibility of backward tip-over and could extend beyond the rear tires is recommended instead of cause serious injury or death.

  • Page 30: Using The Z Stand

    Using the Z Stand® The Z Stand® raises the front end of the machine to allow you to clean the mower and remove the blades. The machine could fall onto someone and cause serious injury or death. Figure 39 • Use extreme caution when operating the 1.

  • Page 31: Operating Tips

    Alternate mowing direction to keep the grass standing down any nicks and sharpen the blades as necessary. If straight. This also helps disperse clippings which a blade is damaged or worn, replace it immediately with enhances decomposition and fertilization. a genuine TORO replacement blade.

  • Page 32: Maintenance

    Every 500 hours • Adjust the caster pivot bearing. • Check the park brake adjustment. • Change the hydraulic filters and hydraulic oil when using Toro Pro-Series oil. • Check the battery. Monthly • Grease the pump belt idler arm.

  • Page 33: Lubrication

    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 34: Lubricate Caster Wheel Hubs

    2. Stop the engine, remove the key, and wait for all 8. Pump grease into the zerk until it oozes out around moving parts to stop before leaving the operating the top bearing. position. 9. Remove the grease zerk in the hole. Install the hex plug and dust cap (Figure 44).

  • Page 35: 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. Leave approximately 1/8 inch (3 mm) from the outer surface of the spacer nut to the end of the axle Contact with hot surfaces may cause personal inside the nut.

  • Page 36: Servicing The Engine Oil

    Servicing the Engine Oil Oil Type: Detergent oil (API service SG, SH, SJ, or SL) Oil Capacity: with a filter change, 77 ounces (2.3 L); without a filter change, 70 ounces (2.1 L) Viscosity: See the table below. Figure 46 1.

  • Page 37: Changing The Engine Oil

    Changing the Engine Oil Service Interval: After the first 8 hours Every 100 hours (more often in dirty or dusty conditions) Note: Dispose of the used oil at a recycling center. 1. Start the engine and let it run five minutes. This warms the oil so it drains better.

  • Page 38: Changing The Engine Oil Filter

    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 50). G008796 Figure 50 6. Start the engine and drive to a flat area. Check the oil level again.

  • Page 39: Servicing The Spark Plug

    Servicing the Spark Plug Service Interval: Every 100 hours Make sure the air gap between the center and side electrodes is correct before installing the spark plug. Use a spark plug wrench for removing and installing the spark plug(s) and a gapping tool/feeler gauge to check and adjust the air gap.

  • Page 40: Check Spark Arrester (If Equipped)

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

  • Page 41: Servicing The Fuel Tank

    Electrical System installed at the factory to keep the fuel line away from components that could cause fuel line damage. Maintenance Servicing the Fuel Tank Servicing the Battery Do not attempt to drain the fuel tank. Ensure that an Authorized Service Dealer drains the fuel tank and Service Interval: Monthly—Check the battery.

  • Page 42: Installing The Battery

    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.

  • Page 43: Servicing The Fuses

    Charging the Battery Servicing the Fuses The electrical system is protected by fuses. It requires no maintenance, however, if a fuse blows check the component/circuit for a malfunction or short. Charging the battery produces gasses that can explode. 1. The fuses are located on right hand console next to the seat (Figure 59).

  • Page 44: 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 45: Checking The Tire Pressure

    Checking the Wheel Hub Slotted Nut Service Interval: After the first 100 hours Every 500 hours 1. Remove the cotter pin. 2. Torque the slotted nut to 200 ft-lb (271 N-m). 3. Check the distance from the bottom of the slot in the nut to the inside edge of the hole.

  • Page 46: Using The Clutch Shim

    Removing the Clutch Shim 4. Tighten the locknut until the spring washers are flat and then back off a 1/4 turn to properly set the 1. Stop the engine, wait for all moving parts to stop, pre-load on the bearings (Figure 64). and remove the key.
  • Page 47 B. Using needle nose pliers, or by hand, take hold of the tab and remove the shim (Do Not discard the shim until proper clutch function has been confirmed). Figure 70 1. Feeler gauge • If the gap is less than 0.010 inch, then reinstall Figure 68 the shim and reference the Troubleshooting 1.

  • Page 48: Cooling System Maintenance

    Cooling System Maintenance Cleaning the Engine Screen and Engine Oil Cooler Service Interval: Before each use or daily Remove any build-up of grass, dirt or other debris from the oil cooler (Figure 71). Figure 72 1. Engine guard 4. Fan housing 2.

  • Page 49: Brake Maintenance

    Brake Maintenance Adjusting the Parking Brake Service Interval: After the first 100 hours Every 500 hours 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 50: Belt Maintenance

    Belt Maintenance standard nut. Do Not allow the cable to turn when the nuts are tightened. 15. Close the drive wheel release valve. Refer to Using Inspecting the Belts the Drive Wheel Valves in Operation. Service Interval: Every 50 hours 16.

  • Page 51: Replacing The Hydraulic Pump Drive Belt

    Figure 78 1. Position the belt cover 3. Install the bolt 2. Slide belt cover under the side catches Replacing the Hydraulic Pump Figure 77 Drive Belt 1. Clutch pulley 5. Square hole in the idler 1. Disengage the PTO and set the parking brake. arm for the ratchet 2.

  • Page 52: Controls System Maintenance

    Controls System Maintenance Adjusting the Control Handle Position There are two height positions for the control levers; high and low. Remove the bolts to adjust the height for the operator. 1. Disengage the PTO, move the motion control levers to the neutral locked position, and set the parking brake.

  • Page 53: Adjusting The Motion Control Linkage

    4. Temporarily install a jumper wire across the terminals in the connector of the main wiring harness. 5. Start engine. Brake must be engaged and motion control levers out to start engine. Operator does not have to be in the seat because of the jumper wire being used.

  • Page 54: Adjusting The Motion Control Damper

    10. Raise the deck and re-install the height of cut pin. 11. Check that the machine does not creep in neutral with the park brakes disengaged. Adjusting the Motion Control Damper The top damper mounting bolt can be adjusted to Figure 84 obtain a more desired motion control lever resistance.

  • Page 55: 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 or equivalent. Other fluids could cause system damage. Each Hydraulic System Oil Capacity: 52 ounces (1.5...
  • Page 56 Replacing the Hydraulic Filters and Hydraulic Oil Service Interval: Every 250 hours Every 500 hours To replace the hydraulic oil, the filters need to be removed. Replace both at the same time. 1. Disengage the blade control switch (PTO), move the motion control levers to the neutral locked position and set the parking brake.

  • Page 57: Mower Deck Maintenance

    Mower Deck Maintenance Leveling the Mower Deck Setting Up the Machine Note: Ensure the mower deck is leveled before matching the height-of-cut (HOC). 1. Position mower on a flat surface. 2. Disengage the blade control switch (PTO), move the motion control levers to the neutral locked position and set the parking brake.
  • Page 58 6. Insert the height adjustment pin into the 3 inch (7.6 cm) cutting height location. 7. Release the transport lock and allow the deck to lower to the cutting height. 8. Raise the discharge chute. 9. On both sides of the deck, measure from the level surface to the front tip of the blade (Postion A).

  • Page 59: Servicing The Cutting Blades

    If a blade is damaged or worn, replace it immediately with a genuine Toro replacement blade. For convenient sharpening and replacement, you may want to keep extra blades on hand.

  • Page 60: Removing The Blades

    1. Disengage the blade control switch (PTO), move the performance and continued safety conformance of motion control levers to the neutral locked position the machine, use genuine Toro replacement blades. and set the parking brake. Replacement blades made by other manufacturers may 2.

  • Page 61: Removing The Mower Deck

    Sharpening the Blades When sharpening blade, pieces of blade could be thrown and cause serious injury. Wear proper eye protection when sharpening blade. 1. Use a file to sharpen the cutting edge at both ends of the blade (Figure 97). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges.

  • Page 62: Replacing The Grass Deflector

    Figure 101 1. Right stabilizer Figure 100 2. Deck strut (right side shown) 3. Remove the rear deck lift attachment shoulder bolt and nut. 1. Clutch pulley 5. Square hole in the idler 4. Remove the front deck lift attachment shoulder bolt and nut. arm for the ratchet 2.

  • Page 63: Cleaning

    Cleaning Note: Make sure the L end of the spring is installed behind the deck edge before installing the bolt as shown in Figure 102. Cleaning Under the Mower 3. Install the bolt and nut. Place the J hook end of the spring around the grass deflector (Figure 102).

  • Page 64: 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 65: Troubleshooting

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

  • Page 67: Schematics

    Schematics Wire Diagram (Rev. A)
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  • Page 71 Spypros Stavrinides Limited Cyprus 357 22 434131 Surge Systems India Limited India 91 1 292299901 T-Markt Logistics Ltd Hungary 36 26 525 500 Toro Australia Australia 61 3 9580 7355 Toro Europe BVBA Belgium 32 14 562 960 374-0102 Rev D...
  • Page 72 1. Contact your seller to arrange service of the product. If for any reason it is impossible for you to contact your seller, you may contact any Toro Authorized distributor to arrange service. 2. Bring the product and your proof of purchase (sales receipt) to your seller of the Service Dealer.

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74925te

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