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Toro 78922 Operator's Manual

With 48in or 52in turbo force side discharge mower
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Form No. 3370-984 Rev A
Z Master
®
6000 Series Riding
Mower
with 48in or 52in TURBO FORCE
®
Side
Discharge Mower
Model No. 74922—Serial No. 312000001 and Up
Model No. 78922—Serial No. 312000001 and Up
Model No. 78924—Serial No. 312000001 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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Summary of Contents for Toro 78922

  • Page 1 Model No. 74922—Serial No. 312000001 and Up Model No. 78922—Serial No. 312000001 and Up Model No. 78924—Serial No. 312000001 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

    If you require a spark arrestor, contact your Authorized Toro Dealer. Genuine Toro spark arresters are approved by the USDA Forestry Service. Note: It is a violation of California Public Resource...

  • Page 3: Table Of Contents

    Contents Electrical System Maintenance........ 41 Servicing the Battery........... 41 Servicing the Fuses ..........43 Introduction..............2 Drive System Maintenance ........43 Safety ................4 Checking the Seat Belt ........43 Safe Operating Practices ........4 Checking the Rollover Protection System Slope Indicator.............

  • 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: Slope Operation

    • 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 9 110-2067 110-2068 1. Read the Operator's Manual. 107-2102 114-4466 1. Main, 25A 3. Charge, 25A 2. PTO, 10A 4. Auxiliary, 15A 116-1716 1. Fuel 6. Hour meter 109-7232 2. Empty 7. PTO 3. Half 8. Parking brake 4. Full 9. Neutral 5.
  • Page 10 116-0205 115-7445 1. Grease pulleys and spindles 2. Maintenance interval—50 hours 116-0211 116-0090 116-0752 116-0157 1. Locked 2. Unlocked...
  • Page 11 Battery Symbols 116-1654 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; smoking. explosive gases can 116-2643 cause blindness and other injuries 3.
  • Page 12 109-7069...

  • 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

    Releasing 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 G016995 head is recommended.

  • Page 19: Operating The Throttle

    Operating the Throttle Important: Do not engage starter for more than 5 seconds at a time. If the engine fails The throttle control can be moved between Fast and to start allow a 15 second cool-down period Slow positions (Figure 15). between attempts.

  • Page 20: Starting And Stopping The Engine

    Starting and Stopping the Engine Starting the Engine 1. Raise the ROPS up and lock into place, sit on the seat and fasten the seat belt. 2. Move the motion controls to neutral locked position. G008947 Figure 20 3. Set the parking brake; refer to Setting the Parking Brake.

  • 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

    Testing the Safety Interlock System Using the Motion Control Levers Service Interval: Before each use or daily Test the safety interlock system before you use the machine each time. If the safety system does not operate as described below, have an Authorized Service Dealer repair the safety system immediately.

  • 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 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 Anti-Scalp Rollers

    Adjusting the Anti-Scalp Rollers Whenever you change the height-of-cut, it is recommended to adjust the height of the anti-scalp rollers. 1. Disengage the blade control switch (PTO), move the motion control levers to the neutral locked position and set the parking brake. 2.

  • Page 26: Positioning The Flow Baffle

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

  • Page 27: Positioning The Seat

    Positioning the Seat WARNING The engine and hydraulic drive units can become The seat can move forward and backward. Position the very hot. Touching a hot engine or hydraulic drive seat where you have the best control of the machine units can cause severe burns.

  • Page 28: 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 complete grass catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris.

  • Page 29: 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 39). The lower rear section of the tractor frame extends back between the rear wheels and serves as a stop for tipping backward.

  • Page 30: Cutting Speed

    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 31: Maintenance

    • Check the torque for wheel lug nuts. Every 500 hours • 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. • Check the battery. Monthly •...

  • Page 32: Lubrication

    Lubrication Where to Grease the Mower Service Interval: Every 50 hours—Grease the mower Greasing and Lubrication deck spindles and idler arm. Yearly—Grease the pump belt idler Grease more frequently when operating conditions are arm. extremely dusty or sandy. Yearly—Grease the front caster Grease Type: No.

  • Page 33: Lubricate Caster Wheel Hubs

    Lubricate Caster Wheel Hubs Service Interval: Yearly 1. Stop the engine, wait for all moving parts to stop, and remove the key. Engage the parking brake. Figure 42 Figure 44 1. Seal guard 2. Spacer nut with wrench flats 6. Remove the dust cap and adjust the caster pivots. Keep the dust cap off until greasing is done.

  • Page 34: Engine Maintenance

    Engine Maintenance 13. Torque the nut to 75-80 in-lb (8-9 N-m), loosen, then re-torque to 20-25 in-lb (2-3 N-m). Make sure axle does not extend beyond either nut. WARNING 14. Reinstall the seal guards over the wheel hub and Contact with hot surfaces may cause personal insert wheel into caster fork.

  • Page 35: Servicing The Engine Oil

    Servicing the Engine Oil Oil Type: Detergent oil (API service SF, SG, SH, SJ, or SL) Oil Capacity: with a filter change, 71 ounces (2.1 L); without a filter change, 61 ounces (1.8 L) Viscosity: See the table below. Figure 45 1.

  • Page 36: 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. G008804 1. Park the machine so that the rear is slightly lower than the front to ensure the oil drains completely.

  • Page 37: Changing The Engine Oil Filter

    4. 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 49). G008804 G008796 Figure 49 5. Start the engine and drive to a flat area. Check the oil level again.

  • Page 38: 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 39: Check Spark Arrester (If Equipped)

    Checking the Spark Plug Check Spark Arrester (if equipped) Important: Never clean the spark plug(s). Always replace the spark plug(s) when it has: a black Service Interval: Every 50 hours coating, worn electrodes, an oily film, or cracks. If you see light brown or gray on the insulator, the WARNING engine is operating properly.

  • Page 40: Fuel System Maintenance

    Fuel 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. Replacing the Fuel Filter Servicing the Fuel Tank Service Interval: Every 500 hours/Yearly (whichever...

  • Page 41: Electrical System Maintenance

    Electrical System WARNING Maintenance Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in Servicing the Battery personal injury. • Always Disconnect the negative (black) battery Service Interval: Monthly cable before disconnecting the positive (red) cable.

  • Page 42: Installing The Battery

    Important: Always keep the battery fully charged (1.265 specific gravity). This is especially important to prevent battery damage when 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. G008804 2.

  • Page 43: 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 1. The fuses are located on right hand console next to the seat (Figure 58).

  • Page 44: Adjusting The Tracking

    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 60). 8. Tighten the stop plate (Figure 60). Figure 60 Left control lever shown Figure 59 1.

  • Page 45: Checking The Wheel Hub Slotted Nut

    Figure 63 1. 0.1 inch max 2. No more than two threads Figure 61 (0.1 inch max) should be showing here. Checking the Wheel Hub 4. If more than two threads (0.1 inch) are showing remove nut and install washer between hub and Slotted Nut nut.

  • Page 46: Using The Clutch Shim

    2. Using an air compressor, blow out any debris from under the brake pole and around the brake spacers. Figure 66 3. Check the condition of the wire harness leads, Figure 64 connectors, and terminals. Clean or repair as 1. Spring Washers 3.
  • Page 47 • If the gap is less than 0.010 inch, then reinstall the shim and reference the Troubleshooting section. • If the gap is sufficient, proceed to the safety check in step F. F. Perform the following safety check: a. Sit on the seat and start the engine. b.

  • 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). G008804 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 thereafter Check to make sure brake is adjusted properly. This procedure must be followed after the first 100 hours or when a brake component has been removed or replaced. 1.

  • Page 50: Belt Maintenance

    Belt Maintenance Inspecting the Belts Service Interval: Every 50 hours Check the belts for squealing when the belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks and cracks are signs of a worn mower belt. Replace the mower belt if any of these conditions are evident.

  • Page 51: Replacing The Hydraulic Pump Drive Belt

    Figure 77 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 76 Drive Belt 1. Clutch pulley 5. Square hole in the idler arm for the ratchet 1.

  • 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

    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 54: 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 82 for mounting options. Figure 83 1. Flanged nut 2. Jam nut Figure 82 RH Motion Control Shown 1.

  • 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. 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 56 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 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 10. Fine-tune the adjustment nut on the front deck lift assembly by turning it (Figure 89). To increase the height, turn the adjustment nut clockwise; to decrease, turn counterclockwise. g017029 Figure 90 1. Bolts at the bottom of the height-of-cut plate 13.

  • Page 59: Servicing The Cutting Blades

    File down any nicks and sharpen the blades as necessary. If a blade is damaged or worn, To increase the height, turn the adjustment nut replace it immediately with a genuine Toro replacement clockwise; to decrease, turn counterclockwise. blade. For convenient sharpening and replacement, you 17.

  • Page 60: Removing The Blades

    To ensure optimum and set the parking brake. performance and continued safety conformance of the machine, use genuine Toro replacement blades. 2. Stop the engine, remove the key, and wait for all Replacement blades made by other manufacturers may moving parts to stop before leaving the operating result in non-conformance with safety standards.
  • Page 61 Installing the Blades 1. Install the blade onto the spindle shaft (Figure 97). Important: The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting. Figure 95 2. Install the spring disk and blade bolt. The spring disk cone must be installed toward the bolt head 1.

  • Page 62: Removing The Mower Deck

    Removing the Mower Deck Before servicing or removing the mower deck, the spring loaded deck arms must be locked out. WARNING Deck lift arm assemblies have stored energy. Removing the deck with out releasing the stored energy can cause serious injury or death. Do Not attempt to disassemble the deck from the front frame without locking out the stored energy.

  • Page 63: Replacing The Grass Deflector

    g015594 Figure 100 1. Bolt 5. Spring installed 2. Spacer 6. Grass Deflector 3. Locknut 7. J hook end of spring 4. Spring 2. Place spacer and spring onto grass deflector. Place Figure 99 one J end of spring behind deck edge. 1.

  • Page 64: Cleaning

    Cleaning Storage Cleaning and Storage Cleaning Under the Mower 1. Disengage the power take off (blade control switch Service Interval: Before each use or daily (PTO), set the parking brake, and turn the ignition key to Off. Remove the key. 1.
  • Page 65 B. Run the engine to distribute conditioned fuel through the fuel system (5 minutes). C. Stop the engine, allow it to cool, and drain the fuel tank; refer to Servicing the Fuel Tank in the Maintenance Section. D. Restart the engine and run it until it stops. E.

  • Page 66: 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 67 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 68: Schematics

    Schematics Wire Diagram (Rev. A)
  • Page 69 Notes:...
  • Page 70 Notes:...
  • 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:

78924Z master 6000 series74922

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