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Summary of Contents for Toro 72980
- Page 1 Form No. 3447-510 Rev B Z Master ® Professional 6000 Series Riding Mower With 60in or 72in TURBO FORCE ® Side Discharge Mower Model No. 72980—Serial No. 400000000 and Up Model No. 72982—Serial No. 400000000 and Up *3447-510* Register at www.Toro.com. Original Instructions (EN)
- Page 2 Automotive Engineers (SAE) J1940 or J2723. As additional information, contact an Authorized Service configured to meet safety, emission, and operating Dealer or Toro Customer Service and have the model requirements, the actual engine torque on this class and serial numbers of your product ready.
- Page 3 information and Note emphasizes general information worthy of special attention. The safety-alert symbol (Figure 2) appears both in this manual and on the machine to identify important safety messages that you must follow to avoid accidents. This symbol will appear with the word Danger, Warning, or Caution.
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Page 4: Table Of Contents
Contents Servicing the Electronic Fuel-Injection System............44 Replacing the Fuel Filter ........44 Safety ............... 5 Servicing the Fuel Tank........44 General Safety ........... 5 Electrical System Maintenance ......45 Slope Indicator ........... 6 Electrical System Safety ........45 Safety and Instructional Decals ......7 Servicing the Battery......... -
Page 5: Safety
Safety General Safety This product is capable of amputating hands and feet and of throwing objects. Always follow all safety instructions to avoid serious personal injury or death. • Read and understand the contents of this Operator’s Manual before starting the engine. •... -
Page 6: Slope Indicator
Slope Indicator g011841 Figure 3 You may copy this page for personal use. 1. The maximum slope you can 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 7: 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 missing. decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery. 1. - Page 8 decal116-1716 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 decal107-3069 107-3069 1. Warning–there is no rollover protection when the roll bar is decal116-5988 down.
- Page 9 decal120-5899 120–5899 1. Power Takeoff (PTO) 3. Continuous-variable setting 2. Slow 4. Fast decal117-0346 decal126-2055 117-0346 126-2055 1. Fuel leak hazard—read the Operator's Manual; do not 1. Wheel lug nut—torque to 129 N∙m (95 ft-lb). attempt to remove the roll bar; do not weld, drill, or modify the roll bar in any way.
- Page 10 decal127-0326 127-0326 1. Read the Operator's 3. Remove the key and Manual. read the Operator's Manual before performing maintenance. 2. Height of cut decal136-5508 136-5508 1. Belt routing decal133-8062 133-8062 decal131-1180 131-1180 1. Read the Operator's 3. Bagging setting Manual. 4.
- Page 11 decal125-9383 125-9383 1. Check hydraulic fluid every 50 operating hours. 3. Check the tire pressure every 50 operating hours. 2. Read the Operator’s Manual for information on lubricating 4. Read the Operator’s Manual before servicing or performing the machine. maintenance.
- Page 12 decal132-0871 132-0871 Note: This machine complies with the industry standard stability test in the static lateral and longitudinal tests with the maximum recommended slope indicated on the decal. Review the instructions for operating the machine on slopes in the Operator’s Manual as well as the conditions in which you would operate the machine to determine whether you can operate the machine in the conditions on that day and at that site.
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Page 13: Product Overview
Controls Product Overview Become familiar with all the controls before you start the engine and operate the machine. Control Panel g027333 Figure 4 g013112 1. Deck-lift pedal 6. Roll bar Figure 5 2. Transport lock 7. Seat belt 1. Blade-control switch 4. - Page 14 Blade-Control Switch (Power Hour Meter Takeoff) The hour meter records the number of hours the engine has operated. It operates when the engine The blade-control switch, represented by a is running. Use these times for scheduling regular power-takeoff (PTO) symbol, engages and maintenance (Figure disengages power to the mower blades...
- Page 15 Electronic-Control Unit Malfunction-Indicator Light For Models with an EFI Engine Only The electronic-control unit (ECU) continuously monitors the operation of the EFI system. If a problem or fault within the system is detected, the malfunction-indicator light (MIL) illuminates. The MIL is the red light located in the right console panel.
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Page 16: Specifications
To ensure optimum performance and continued safety certification of the machine, use only genuine Toro replacement parts and accessories. Replacement parts and accessories made by other manufacturers could be dangerous, and such use could void the... -
Page 17: Before Operation
Fuel Safety Operation • Fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and Note: Determine the left and right sides of the others and can damage property. machine from the normal operating position. –... -
Page 18: Adding Fuel
Adding Fuel Note: Do not fill the fuel tank completely full. The empty space in the tank allows the fuel to expand. Recommended Fuel • For best results, use only clean, fresh (less than 30 days old), unleaded gasoline with an octane rating of 87 or higher ((R+M)/2 rating method). -
Page 19: Performing Daily Maintenance
Performing Daily Lower the roll bar to the down position (Figure Maintenance Before starting the machine each day, perform the Each Use/Daily procedures listed in Maintenance (page 35). Breaking in a New Machine New engines take time to develop full power. Mower decks and drive systems have higher friction when new, placing additional load on the engine. -
Page 20: Using The Safety-Interlock System
Using the Safety-Interlock Test the safety-interlock system before you use the machine each time. If the safety system does not System operate as described below, have an Authorized Service Dealer repair the safety system immediately. Sit on the seat, engage the parking brake, and WARNING move the blade-control switch (PTO) to the O If the safety-interlock switches are... -
Page 21: Unlatching The Seat
Unlatching the Seat Changing the Seat Suspension To unlatch the seat, push the seat latch forward (Figure 11). The seat is adjustable to provide a smooth and comfortable ride. Position the seat where you are most comfortable. To adjust it, turn the knob in front either direction to provide the best comfort (Figure 12). - Page 22 Rollover Protection System • Use only accessories and attachments approved (ROPS) Safety by Toro. • The ROPS is an integral safety device. Do not • This machine produces sound levels in excess remove any of the ROPS components from the of 85 dBA at the operator’s ear and can cause...
- Page 23 If possible, keep the deck lowered to the ground Authorized Service Dealer to inspect the ROPS. while operating on slopes. Raising the deck while operating on slopes can cause the machine to • Use only Toro approved accessories and become unstable. attachments for the ROPS. Slope Safety •...
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Page 24: Operating The Parking Brake
Operating the Parking Brake Always engage the parking brake when you stop the machine or leave it unattended. Engaging the Parking Brake g008945 Figure 17 Park the machine on a level surface. Disengaging the Blade-Control Switch (PTO) g027334 Figure 15 g009174 Figure 18 Disengaging the Parking Brake... -
Page 25: Starting The Engine
Starting the Engine Shutting Off the Engine Important: Do not engage the starter for more CAUTION than 5 seconds at a time. If the engine fails to start, wait 15 seconds between attempts. Failure Children or bystanders may be injured if they to follow these instructions can burn out the move or attempt to operate the machine while starter motor. -
Page 26: Using The Motion-Control Levers
Using the Motion-Control WARNING Levers The machine can spin very rapidly. You may lose control of the machine and cause personal injury or damage to the machine. • Use caution when making turns. • Slow the machine down before making sharp turns. -
Page 27: Using The Side Discharge
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 a complete grass-catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris. -
Page 28: Adjusting The Height Of Cut
Adjusting the Height of Cut Adjusting the Height-of-Cut Pin The height-of-cut is adjusted from 25 to 140 mm (1 to 5-1/2 inches) in 6 mm (1/4 inch) increments by Using the Transport Lock relocating the clevis pin into different hole locations. The transport lock has 2 positions, and is used with Move the transport lock to the lock position. -
Page 29: Adjusting The Anti-Scalp Rollers
Adjusting the Anti-Scalp Rollers Whenever you change the height-of-cut, adjust the height of the anti-scalp rollers. Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. -
Page 30: Positioning The Flow Baffle
Positioning the Flow Baffle The following figures are recommendations only. Adjustments vary by grass type, moisture content, and the height of the grass. Note: If the engine power draws down and the mower ground speed is the same, open the baffle. Position A This is the fully-rear position. -
Page 31: Operating Tips
It is best to cut only about a third of the grass blade. genuine Toro replacement blade. Cutting more than that is not recommended unless grass is sparse, or it is late fall when grass grows After Operation more slowly. -
Page 32: Using The Fuel-Shutoff Valve
Using the Fuel-Shutoff Using the Drive-Wheel-Release Valve Valves The fuel-shutoff valve is located under the seat. Move the seat forward to access it. WARNING Close the fuel-shutoff valve for transport, maintenance, and storage. Hands may become entangled in the rotating drive components below the engine deck, Ensure that the fuel-shutoff valve is open when which could result in serious injury. -
Page 33: Transporting The Machine
Selecting a Trailer WARNING Loading a machine onto a trailer or truck increases the possibility of tip-over and could cause serious injury or death (Figure 35). • Use only a full-width ramp; do not use individual ramps for each side of the machine. - Page 34 If using a trailer, connect it to the towing vehicle and connect the safety chains. If applicable, connect the trailer brakes and lights. Lower the ramp, ensuring that the angle between the ramp and the ground does not exceed 15 degrees (Figure 35).
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Page 35: Maintenance
Keep your hands and feet away from moving • To ensure optimum performance, use only parts or hot surfaces. If possible, do not make genuine Toro replacement parts and accessories. adjustments with the engine running. Replacement parts and accessories made by •... -
Page 36: Lubrication
• Adjust the parking brake. • After the initial change—change the hydraulic-system filters and fluid when using Toro® HYPR-OIL™ 500 fluid. (Change it more often under dirty or dusty conditions) • Replace the safety air filter (more often in dirty or dusty conditions). -
Page 37: Greasing The Mower Deck
Greasing the Mower Deck Note: Keep the dust cap off until greasing is done. Service Interval: Yearly—Grease the pump-belt-idler Remove the hex plug. arm. Thread a grease fitting into the hole. Park the machine on a level surface, disengage Pump grease into the fitting until it oozes out the blade-control switch, and engage the parking around the top bearing. -
Page 38: Greasing The Caster-Wheel Hubs
Greasing the Caster-Wheel With the open end of the wheel facing up, fill the area inside the wheel around the axle full of Hubs general-purpose grease. Insert the second bearing and new seal into the Service Interval: Yearly wheel. Park the machine on a level surface, disengage Apply a thread-locking compound to the second the blade-control switch, and engage the parking spacer nut, and thread it onto the axle with the... -
Page 39: Engine Maintenance
Engine Maintenance Engine Safety • Keep your hands, feet, face, clothing, and other body parts away from the muffler and other hot surfaces. Allow engine components to cool before performing maintenance. • Do not change the engine governor speed or overspeed the engine. -
Page 40: Servicing The Engine Oil
(Figure 43). change Note: Ensure that the primary filter is fully Viscosity: Toro Synthetic 10W-50 for all temperatures seated by pushing on the outer rim while installing it. Checking the Engine-Oil Level Important: Do not press on the soft, inside area of the filter. - Page 41 If the oil level is low, open the oil-fill cap (Figure 46). g389245 Figure 46 1. Oil-fill cap g389246 Slowly add the specified engine oil into the tank. Figure 44 Important: Do not overfill. 1. Dipstick 2. Full line After adding oil, check the oil level. Fully install the dipstick and ensure that it latches Fully install the dipstick and ensure that it latches (Figure...
- Page 42 Changing the Engine Oil and Filter Remove the engine-oil filter (Figure 48). Note: Dispose of the used oil at a recycling center. Start the engine and let it run for 5 minutes. Note: This warms the oil so that it drains better. Park the machine so that the drain side is slightly lower than the opposite side to ensure that the oil drains completely.
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Page 43: Servicing The Spark Plug(S)
Servicing the Spark Plug(s) Set the gap to 0.75 mm (0.03 inch). Service Interval: Every 100 hours or yearly, whichever comes first—Replace or clean and gap the spark plug. Ensure that the air gap between the center and side electrodes is correct before installing the spark plug. Use a spark plug wrench for removing and installing the spark plug and a gapping tool or feeler gauge to check and adjust the air gap. -
Page 44: Fuel System Maintenance
Fuel System Maintenance DANGER In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. Refer to Fuel Safety (page 17) for a complete list of fuel related precautions. Servicing the Electronic Fuel-Injection System g333362... -
Page 45: Electrical System Maintenance
Electrical System Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the Maintenance operating position. Remove the battery as shown in Figure Electrical System Safety • Disconnect the battery before repairing the machine. - Page 46 Charging the Battery Installing the Battery Note: Position the battery in the tray with the terminal WARNING posts opposite from the hydraulic tank (Figure 55). Charging the battery produces gasses that can explode. Never smoke near the battery and keep sparks and flames away from the battery.
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Page 47: Servicing The Fuses
Servicing the Fuses Drive System Maintenance 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. Checking the Seat Belt The fuses are located on the console to the right of the seat (Figure 56). -
Page 48: Adjusting The Tracking
Adjusting the Tracking Disengage the blade-control switch (PTO). Drive to an open flat area, move the motion-control levers to the N EUTRAL position. Move the throttle midway between the F positions. Move both motion-control levers all the way forward until they both hit the stops in the T-slot. Check which way the machine tracks. -
Page 49: Checking The Tire Pressure
Checking the Tire Pressure Checking the Wheel Lug Nuts Service Interval: Every 50 hours/Monthly (whichever comes first) Check and torque the wheel lug nuts to 122 to 129 Maintain the air pressure in the rear tires at 90 kPa N∙m (90 to 95 ft-lb). (13 psi). -
Page 50: Adjusting The Caster-Pivot Bearing
Adjusting the Caster-Pivot Removing the Clutch Shim Bearing Some later model year units have been built with clutches that contain a brake shim. When the clutch Service Interval: Every 500 hours/Yearly (whichever brake has worn to the point where the clutch no longer comes first) engages consistently, you can remove the shim to extend the clutch life. - Page 51 Verify that 12 V is present at the clutch connector the rotor and the armature face on both when the blade-control switch (PTO) switch is sides of the brake pole as shown in Figure engaged. Figure Measure the gap between the rotor and Note: Due to the way the rotor and the armature.
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Page 52: Cooling System Maintenance
Cleaning the Cooling System Engine-Cooling Fins and Maintenance Shrouds Cooling System Safety Service Interval: Every 100 hours/Yearly (whichever comes first) • Swallowing engine coolant can cause poisoning; keep out of reach from children and pets. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the •... -
Page 53: Checking And Cleaning The Hydraulic-Unit Shrouds
Checking and Cleaning the Brake Maintenance Hydraulic-Unit Shrouds Adjusting the Parking Service Interval: Before each use or daily Brake Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the Service Interval: After the first 100 hours parking brake. -
Page 54: Belt Maintenance
Belt Maintenance Tighten the jam nut on the rear linkage (Figure 72). Ensure that the wheel hub moves freely between Inspecting the Belts the caliper brake pads. Repeats steps for the right side. Service Interval: Every 50 hours Rotate the drive wheel release handle to Replace the belt if it is worn. - Page 55 g027730 Figure 75 1. Position the belt cover. 3. Ensure that the tab is under the metal catch. 2. Slide the belt cover under the side catches. g009038 Figure 74 1. Clutch pulley 5. Square hole in the idler arm for the ratchet 2.
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Page 56: Replacing The Hydraulic Pump-Drive Belt
Replacing the Hydraulic Controls System Pump-Drive Belt Maintenance Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the Adjusting the parking brake. Control-Handle Position Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the There are 2 height positions for the control operating position. -
Page 57: Adjusting The Motion-Control Linkage
Raise the rear of the machine up and support it with jack stands (or equivalent support) just high enough to allow the drive wheels to turn freely. Remove the electrical connection from the seat safety switch, located under the bottom cushion of the seat. -
Page 58: Adjusting The Motion-Control Damper
Adjusting the Move the motion-control levers to the REVERSE position and while applying slight pressure to Motion-Control the lever, allow the reverse-indicator springs to bring the levers back to neutral. Neutral-Lock Pivot Note: The wheels should stop turning or slightly creep in reverse. -
Page 59: Hydraulic System Maintenance
Use cardboard or paper to find hydraulic leaks. • Safely relieve all pressure in the hydraulic system before performing any work on the hydraulic system. Hydraulic-Fluid Specifications Hydraulic-Fluid Type: Toro ® HYPR-OIL ™ hydraulic fluid or Mobil ® 1 15W-50. -
Page 60: Changing The Hydraulic Fluid And Filters
Mobil 1 15W50 fluid. (Change it more often under dirty or dusty conditions) Every 500 hours—After the initial change—change the hydraulic-system filters and fluid when using Toro ® HYPR-OIL ™ 500 fluid. (Change it more often under dirty or... -
Page 61: Mower Deck Maintenance
Mower Deck Maintenance Blade Safety • Inspect the blades periodically for wear or damage. • Use care when checking the blades. Wrap the g006530 blades or wear gloves, and use caution when Figure 85 servicing the blades. Only replace or sharpen the 1. - Page 62 Checking for Bent Blades Note: The machine must be on a level surface for the following procedure. Raise the mower deck to the highest height-of-cut position. While wearing thickly padded gloves, or other adequate hand protection, slowly rotate the blade into a position that allows you to measure g014974 the distance between the cutting edge and the Figure 88...
- Page 63 Removing the Blades Note: If the blade stays in a horizontal position, the blade is balanced and can be used. Replace the blades if they hit a solid object, or if the Note: If the blade is not balanced, file some blade is out of balance or bent.
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Page 64: Leveling The Mower Deck
g298850 Figure 94 1. Top spindle nut 3. Blade bolt g027343 Figure 95 2. Flat of the spindle shaft 1. Deck-lift pedal 3. Transport lock 2. Height-of-cut pin Apply copper-based lubricant or grease to the threads of the blade bolt as needed to prevent seizing. - Page 65 g009196 Figure 96 1. 7.6 cm (3 inch) at position 3. Measure here from the A is correct blade tip to the hard surface 4. Measure at position A and 2. 8.3 cm (3-1/4 inch) at position B is correct B on both sides g027344 Figure 97...
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Page 66: Removing The Mower Deck
Removing the Mower Deck Note: Loosen or tighten the single-point adjustment bolt enough to move the height-of-cut plate mounting bolts at least 1/3 Lock out the spring-loaded deck arms before servicing the length of the available travel in their slots. or removing the mower deck. - Page 67 Raise the deck struts and secure them in the raised position. Slide the deck out to the right side of the machine. g009038 Figure 100 1. Clutch pulley 5. Square hole in the idler arm for the ratchet 2. Mower belt 6.
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Page 68: Replacing The Grass Deflector
Replacing the Grass Cleaning Deflector Cleaning under the Mower WARNING Deck An uncovered discharge opening could allow the machine to throw objects toward you or Service Interval: After each use bystanders, resulting in serious injury. Also, Park the machine on a level surface, disengage contact with the blade could occur. -
Page 69: Storage
Storage Check the condition of the blades; refer to Servicing the Cutting Blades (page 61). Prepare the machine for storage when non-use Storage Safety occurs over 30 days. Prepare the machine for storage as follows: • Shut off the engine, remove the key, and wait for all moving parts to stop before you leave the Add a petroleum-based operator’s position. -
Page 70: Troubleshooting
Troubleshooting Problem Possible Cause Corrective Action The malfunction-indicator light (MIL) 1. The engine is too hot. 1. Shut off the engine and let it cool. comes on. 2. There is old fuel in the fuel tank. 2. Use new fuel. 3. - Page 71 Problem Possible Cause Corrective Action The engine loses power. 1. The engine load is excessive. 1. Reduce the ground speed. 2. The air cleaner is dirty. 2. Clean the air-cleaner element. 3. The oil level in the crankcase is low. 3.
- Page 72 Problem Possible Cause Corrective Action The blades do not rotate. 1. The mower deck belt is damaged, 1. Install a new deck belt. worn, loose, or broken. 2. Install the mower belt on the deck 2. The mower deck belt is off the pulley. pulley and check the idler pulley, idler arm, and spring for correct position and function.
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Page 73: Schematics
Schematics g361552 Electrical Schematic (Rev. A) - Page 74 g008623 Hydraulic Schematic (Rev. A)
- Page 75 While the exposure from Toro products may be negligible or well within the “no significant risk” range, out of an abundance of caution, Toro has elected to provide the Prop 65 warnings. Moreover, if Toro does not provide these warnings, it could be sued by the State of California or by private parties seeking to enforce Prop 65 and subject to substantial penalties.