Toro 74901 Z Master 5000, Operator'S Manual

Page 1: ...essional 5000 Series Riding Mower with 48in or 52in TURBO FORCE Side Discharge Mower Model No 74901 Serial No 313000001 and Up Model No 74903 Serial No 313000001 and Up g019752 Register at www Toro com Original Instructions EN 3375 587 A ...

Page 2: ...riding lawn mower is intended to be used by residential homeowners or professional hired operators It is designed primarily for cutting grass on well maintained lawns on residential or commercial properties It is not designed for cutting brush or for agricultural uses Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage Y...

Page 3: ... Servicing the Spark Plug 37 Check Spark Arrester if equipped 39 Fuel System Maintenance 39 Replacing the Fuel Filter 39 Servicing the Fuel Tank 40 Electrical System Maintenance 40 Servicing the Battery 40 Servicing the Fuses 42 Drive System Maintenance 43 Checking the Seat Belt 43 Checking the Rollover Protection System ROPS Knobs 43 Adjusting the Tracking 43 Checking the Tire Pressure 44 Checkin...

Page 4: ...y are functioning properly Operation Lightning can cause severe injury or death If lightning is seen or thunder is heard in the area do not operate the machine seek shelter Never run an engine in an enclosed area Only operate in good light keeping away from holes and hidden hazards Be sure all drives are in neutral and parking brake is engaged before starting engine Only start engine from the oper...

Page 5: ...top engine and remove key or disconnect spark plug wire Wait for all movement to stop before adjusting cleaning or repairing Clean grass and debris from cutting unit drives mufflers and engine to help prevent fires Clean up oil or fuel spillage Let engine cool before storing and do not store near flame Shut off fuel while storing or transporting Do not store fuel near flames or drain indoors Park ...

Page 6: ... degrees Use the slope chart to determine the degree of slope of hills before operating Do not operate this machine on a slope greater than 15 degrees Fold along the appropriate line to match the recommended slope 2 Align this edge with a vertical surface a tree building fence pole etc 3 Example of how to compare slope with folded edge 6 ...

Page 7: ...afety decals and instructions are easily visible to the operator and are located near any area of potential danger Replace any decal that is damaged or lost 1 403005 54 9220 58 6520 1 Grease 66 1340 68 8340 98 5954 103 2076 105 7798 7 ...

Page 8: ...107 2102 109 7232 110 2067 110 2068 1 Read the Operator s Manual 114 4466 1 Main 25A 3 Charge 25A 2 PTO 10A 4 Auxiliary 15A 8 ...

Page 9: ...115 7445 1 Grease pulleys and spindles 2 Maintenance interval 50 hours 116 0090 116 0157 116 0205 116 0211 116 0752 1 Latch 2 Unlatch 9 ...

Page 10: ...er 2 Empty 7 PTO 3 Half 8 Parking brake 4 Full 9 Neutral 5 Battery 10 Operator presence switch 116 2643 116 4858 116 3303 116 5944 120 5898 1 Choke 4 Slow 2 Fast 5 Power take off PTO Blade control switch 3 Continuous variable setting 10 ...

Page 11: ...ve gases can cause blindness and other injuries 3 Caustic liquid chemical burn hazard 8 Battery acid can cause blindness or severe burns 4 Wear eye protection 9 Flush eyes immediately with water and get medical help fast 5 Read the Operator s Manual 10 Contains lead do not discard Manufacturer s Mark 1 Indicates the blade is identified as a part from the original machine manufacturer 109 7069 11 ...

Page 12: ...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 Safety Interlock Indicators There are symbols on the hour meter and the indicate with a black triangle that the interlock component is in the correct position Figure 6 Battery Indicator Light If the ignition key is turned to ...

Page 13: ...der the seat when transporting or storing the mower Attachments Accessories A selection of Toro approved attachments and accessories are available for use with the machine to enhance and expand its capabilities Contact your Authorized Service Dealer or Distributor or go to www Toro com for a list of all approved attachments and accessories Specifications Note Specifications and design are subject ...

Page 14: ...ring fueling static electricity can be released causing a spark which can ignite the gasoline vapors A fire or explosion from gasoline can burn you and others and can damage property Always place gasoline containers on the ground away from your vehicle before filling Do not fill gasoline containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners m...

Page 15: ...chines to develop full power and best performance Using the Rollover Protection System ROPS WARNING To avoid injury or death from rollover keep the roll bar in the fully raised locked position and use the seat belt Ensure that the rear part of the seat is secured with the seat latch WARNING There is no rollover protection when the roll bar is in the down position Lower the roll bar only when absol...

Page 16: ...iding 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 Always keep the roll bar in the fully raised and locked position and use the seat belt Read and follow the rollover protection instructions and warnings To avoid loss of control and possibility of rollover Do not ope...

Page 17: ... 2 Figure 11 Releasing the Parking Brake G016995 1 2 Figure 12 Operating the Mower Blade Control Switch PTO The blade control switch PTO starts and stops the mower blades and any powered attachments Engaging the Blade Control Switch PTO Note Engaging the blade control switch PTO with the throttle position at half or less will cause excessive wear to the drive belts G008945 Figure 13 Disengaging th...

Page 18: ...t the starter motor Note Additional starting cycles may be required when starting the engine for the first time after the fuel system has been without fuel completely STA RT RU N STO P G008947 Figure 17 2 Turn the ignition key to stop to stop the engine 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 f...

Page 19: ...n without fuel completely STA RT RU N STO P G008947 Figure 20 1 Off 3 Start 2 Run Stopping the Engine CAUTION Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended Always remove the ignition key and set the parking brake when leaving the machine unattended even if just for a few minutes Let the engine idle at slow throttle turtle for 60 seconds...

Page 20: ...nd 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 Move either motion control lever out of neutral locked position Try starting the engine the engine should not crank Repeat for other control lever 3 Sitting on the seat engage the parking brake move the blade cont...

Page 21: ...brake engaged To stop pull the motion control levers to the neutral position 1 Release the parking brake refer to Releasing the Parking Brake in Operation 2 Move the levers to the center unlocked position 3 To go forward slowly push the motion control levers forward Figure 24 G008952 Figure 24 Driving Backward 1 Move the levers to the center unlocked position 2 To go backward slowly pull the motio...

Page 22: ...perate the machine while it is unattended Always remove the ignition key and set the parking brake when leaving the machine unattended even if just for a few minutes Adjusting the Height of Cut Using the Transport Lock The transport lock has two positions and is used with the deck lift pedal There is a lock position and a unlock position for the transport position The transport lock is used with t...

Page 23: ...ed and insert the pin Figure 27 5 Push on the deck lift pull back on the transport lock and slowly lower the mower deck 1 3 2 G017027 Figure 27 1 Deck lift pedal 3 Transport lock 2 Cut of height pin 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 ...

Page 24: ...fle The following figures are only recommendations for use Adjustments will vary by grass type moisture content and height of grass Note If the engine power draws down and the mower ground speed is the same open up the baffle Position A This is the full rear position The suggested use for this position is a follows Use for short light grass mowing conditions Use in dry conditions For smaller grass...

Page 25: ...r sideways to unlock seat Figure 35 g019754 Figure 35 Unlatching the Seat g019755 Figure 36 1 Seat latch 2 Seat Changing the Seat Suspension The seat can be adjusted 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 37 g019768 1 Figure 37 1 Seat suspension knob 25 ...

Page 26: ... valve levers vertically to push the machine This allows hydraulic oil to by pass the pump enabling the wheels to turn Figure 38 3 Disengage parking brake before pushing Figure 38 1 Vertical to push the machine 2 Horizontal to run the machine 4 Rotate the release valve levers horizontally to run the machine Figure 38 Using the Side Discharge The mower has a hinged grass deflector that disperses cl...

Page 27: ...t starts to tip backward If it is not possible to use one full width ramp use enough individual ramps to simulate a full width continuous ramp The ramp should be long enough so that the angles do not exceed 15 degrees Figure 40 A steeper angle may cause mower components to get caught as the unit moves from ramp to trailer or truck Steeper angles may also cause the unit to tip backward If loading o...

Page 28: ...Figure 40 1 Trailer 3 Not greater than 15 degrees 2 Full width ramp 4 Full width ramp side view 28 ...

Page 29: ... frequently If you cannot mow for an extended period first mow at a high cutting height then mow again two days later at a lower height setting Cutting Speed To improve cut quality use a slower ground speed in certain conditions Avoid Cutting Too Low If the cutting width of the mower is wider than the mower you previously used raise the cutting height to ensure that uneven turf is not cut too shor...

Page 30: ...clean engine cooling fins and shrouds Every 200 hours Change the engine oil filter Every 250 hours Replace the primary air filter heavy duty air cleaner more often in dusty or sandy conditions Check the safety air filter heavy duty air cleaner Change the hydraulic filters and hydraulic oil when using Mobil 1 oil more often in dirty or dusty conditions Every 500 hours Replace the safety air filter ...

Page 31: ...out of the bearings 5 Wipe up any excess grease Where to Add Light Oil or Spray Lubrication Service Interval Every 100 hours Lubricate the deck lift pivots G017050 Figure 41 Where to Grease the Mower Service Interval Every 50 hours Grease the mower deck spindles and idler arm Yearly Grease the pump belt idler arm Yearly Grease the front caster pivots more often in dirty or dusty conditions Yearly ...

Page 32: ...eal into the wheel Note The seals must be replaced 8 If the axle assembly has had both spacer nuts removed or broken loose apply a thread locking 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 in...

Page 33: ... safety air filter heavy duty air cleaner Note Check the filters more frequently if the operating conditions are extremely dusty or sandy Removing the Filters 1 Disengage the PTO move the motion control levers to the neutral locked position and set the parking brake 2 Stop the engine remove the key and wait for all moving parts to stop before leaving the operating position 3 Release the latches on...

Page 34: ...ilters check each filter for shipping damage Do not use a damaged filter 2 If the safety filter is being replaced carefully slide it into the filter body Figure 46 3 Carefully slide the primary filter over the safety filter Figure 46 Note Ensure that the primary filter is fully seated by pushing on its outer rim while installing it Important Do not press on the soft inside area of the filter 4 Ins...

Page 35: ... hot surfaces Important Do not overfill the crankcase with oil because damage to the engine may result Do not run engine with oil below the low mark because the engine may be damaged 1 Disengage the PTO move the motion control levers to the neutral locked position and set the parking brake 2 Stop the engine remove the key and wait for all moving parts to stop before leaving the operating position ...

Page 36: ...op the engine remove the key and wait for all moving parts to stop before leaving the operating position Figure 49 G008804 G008793 1 2 3 4 4 5 Figure 49 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 2 3 4 5 6 1 Figure 50 6 Start the engine and drive to a flat area Check the oil level again C...

Page 37: ...stall a new spark plug s if necessary Type Champion RC12YC or equivalent Air Gap 0 030 inch 0 76 mm Removing the Spark Plug 1 Stop the engine remove the key and wait for all moving parts to stop before leaving the operating position 2 Disengage the PTO move the motion control levers to the neutral locked position and set the parking brake 3 Remove the lefthand hydraulic unit shroud in the order li...

Page 38: ... has a black coating worn electrodes an oily film or cracks 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 Set the gap to 0 030 inches 0 76 mm G008794 1 2 Figure 54 Installing the Spark Plug Tighten the spark plug s to 18 22 ft lb 24 4 29 8 N m 3 2 1 G015200 Figure 55 38 ...

Page 39: ... more often in dirty or dusty conditions The fuel filter is located near the engine on the front or rear side of the engine 1 Disengage the PTO move the motion control levers to the neutral locked position and set the parking brake 2 Stop the engine remove the key and wait for all moving parts to stop before leaving the operating position 3 Allow the machine to cool down 4 Stop the engine remove t...

Page 40: ... handling DANGER Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns Do not drink electrolyte and avoid contact with skin eyes or clothing Wear safety glasses to shield your eyes and rubber gloves to protect your hands Removing the Battery WARNING Battery terminals or metal tools could short against metal machine components causing sparks Sparks can cause th...

Page 41: ...e the positive red battery cable Figure 57 5 Remove the wing nut securing the battery clamp Figure 57 6 Remove the clamp Figure 57 7 Remove the battery G008804 G008964 1 2 3 4 Figure 57 1 Remove the wing nut and clamp 3 Remove the positive battery cable 2 Remove the negative battery cable before the positive 4 Remove battery Installing the Battery 1 Position battery in the tray with the terminal p...

Page 42: ...attery cables refer to Installing the Battery Note Do not run the machine with the battery disconnected electrical damage may occur Figure 58 1 Positive Battery Post 3 Red Charger Lead 2 Negative Battery Post 4 Black Charger Lead 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 ...

Page 43: ...on 3 Roll bar in the upright position 2 Pull ROPS knob out and rotate 90 degrees to change roll bar position 4 Roll bar in the folded position Adjusting the Tracking 1 Disengage the blade control switch PTO 2 Drive to an open flat area move the motion control levers to the neutral locked position 3 Move the throttle midway between fast and slow 4 Move both motion control levers all the way forward...

Page 44: ...ice Interval After the first 100 hours Every 500 hours See Figure 63 to determine which slotted nut has been installed on the unit Figure 63 1 Style A black finish 3 Style B yellow zinc 2 03 inch 76 mm 4 24 inch 6 mm Style A black finish Torque the slotted nut to 211 260 ft lb 286 352 N m Note Do Not use anti seize on wheel hub Style B yellow zinc 1 Remove and discard the cotter pin 2 Torque the s...

Page 45: ...Nut Using the Clutch Shim Some later model year units have been built with clutches that contain a brake shim When the clutch brake has worn to the point where the clutch no longer engages consistently the shim can be removed to extend the clutch life Figure 66 1 Armature 5 Brake spacer 2 Field shell 6 Re gap shim 3 Rotor 7 Brake pole 4 Brake mounting bolt Removing the Clutch Shim 1 Stop the engin...

Page 46: ...the brake pole as shown Due to the way the rotor and armature faces wear peaks and valleys it is sometimes difficult to measure the true gap Figure 70 1 Feeler gauge Figure 71 1 Feeler gauge 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 i Sit on...

Page 47: ...y of overheating and mechanical damage to the engine Figure 72 Cleaning the Engine Cooling Fins and Shrouds Service Interval Every 100 hours Yearly whichever comes first 1 Disengage the PTO and set the parking brake 2 Stop the engine remove the key and wait for all moving parts to stop before leaving the operating position 3 Remove the air intake screen recoil starter and fan housing Figure 73 4 C...

Page 48: ...tion and set the parking brake 3 Stop the engine wait for all moving parts to stop and remove the key 4 Raise the back of the machine up and support the machine with jack stands DANGER Mechanical or hydraulic jacks may fail to support machine and cause a serious injury Use jack stand when supporting machine Do not use hydraulic jacks 5 Remove the rear tires from the machine 6 Remove any debris fro...

Page 49: ...cting the Belts Service Interval Every 50 hours Check the belts for squealing when the belt is rotating blades slipping when cutting grass frayed belt edges burn marks and cracks are signs of a worn mower belt Replace the mower belt if any of these conditions are evident Replacing the Mower Belt Squealing when the belt is rotating blades slipping when cutting grass frayed belt edges burn marks and...

Page 50: ...s are seated in the anchor grooves 12 Install the belt covers Figure 78 Figure 78 1 Position the belt cover 3 Ensure the tab is under the metal catch 2 Slide belt cover under the side catches Replacing the Hydraulic Pump Drive Belt 1 Disengage the PTO and set the parking brake 2 Stop the engine remove the key and wait for all moving parts to stop before leaving the operating position 3 Remove mowe...

Page 51: ...re 79 10 Install the mower belt Refer to Replacing the Mower Belt 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 2 Stop the engine remove the key and w...

Page 52: ...ngaged and motion control levers out to start engine Operator does 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 Note The motion control lever needs to be in neutral while making any necessary adjustments 7...

Page 53: ...r change Checking the Hydraulic Oil Service Interval Every 50 hours Check the hydraulic oil level 1 Position the machine on a level surface 2 Disengage the PTO move the motion control levers to the neutral locked position and set the parking brake 3 Stop the engine remove the key and wait for all moving parts to stop before leaving the operating position 4 Allow the engine and hydraulic system to ...

Page 54: ...hours Change the hydraulic filters and hydraulic oil when using any type of oil Every 250 hours Change the hydraulic filters and hydraulic oil when using Mobil 1 oil more often in dirty or dusty conditions Every 500 hours Change the hydraulic filters and hydraulic oil when using Toro HYPR OIL 500 hydraulic oil more often in dirty or dusty conditions To replace the hydraulic oil the filters need to...

Page 55: ...te 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 3 Stop the engine remove the key and wait for all moving parts to stop before leaving the operating position 4 Check tire pressure of the drive tires If needed ad...

Page 56: ...ches 8 3 cm at B is correct 4 Measure at A and B on both sides 10 If needed loosen the whizlock nut on the side of the yoke and the jam nut on top Fine tune the screw adjuster by turning it to get 3 inch 7 6 mm height see Figure 90 To increase the height turn the adjuster screw clockwise to decrease turn counterclockwise Figure 90 1 Whizlock nut 3 Jam nut 2 Adjuster screw 4 Yoke 11 If the front de...

Page 57: ...ntain sharp blades throughout the cutting season because sharp blades cut cleanly without tearing or shredding the grass blades Tearing and shredding turns grass brown at the edges which slows growth and increases the chance of disease Check the cutter blades daily for sharpness and for any wear or damage File down any nicks and sharpen the blades as necessary If a blade is damaged or worn replace...

Page 58: ...with a new blade Never file or create sharp notches in the edges or surfaces of blade Removing the Blades Blades must be replaced if a solid object is hit if the blade is out of balance or is bent To ensure optimum performance and continued safety conformance of the machine use genuine Toro replacement blades Replacement blades made by other manufacturers may result in non conformance with safety ...

Page 59: ...Install the blade onto the spindle shaft Figure 98 Important The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting 2 Install the spring disk and blade bolt The spring disk cone must be installed toward the bolt head Figure 98 Torque the blade bolt to 85 110 ft lb 115 150 N m 59 ...

Page 60: ...nt frame without locking out the stored energy 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Remove the height adjustment pin and lower the deck to the ground 3 Place the height adjustment pin in the 3 inch 7 6 cm cutting height location This locks the deck lift arms in the lowest position when the deck is removed and the stored energy in the deck spring is ...

Page 61: ...ous injury Also contact with the blade could occur Never operate the lawn mower unless you install a cover plate a mulch plate grass deflector or bagger 1 Remove the locknut bolt spring and spacer holding the deflector to the pivot brackets Figure 101 Remove the damaged or worn grass deflector g015594 1 6 2 4 7 3 5 Figure 101 1 Bolt 5 Spring installed 2 Spacer 6 Grass Deflector 3 Locknut 7 J hook ...

Page 62: ... Section 4 Service the air cleaner refer to Servicing the Air Cleaner in the Maintenance Section 5 Grease the machine refer to Greasing and Lubrication in the Maintenance Section 6 Change the crankcase oil refer to Servicing the Engine Oil in the Maintenance Section 7 Check the tire pressure refer to Checking the Tire Pressure in the Maintenance Section 8 Change the hydraulic filters refer to Serv...

Page 63: ...abilizer conditioned fuel over 90 days 13 Check and tighten all bolts nuts and screws Repair or replace any part that is damaged 14 Paint all scratched or bare metal surfaces Paint is available from your Authorized Service Dealer 15 Store the machine in a clean dry garage or storage area Remove the key from the ignition switch and keep it out of reach of children or other unauthorized users Cover ...

Page 64: ...Replace seat if needed 9 Electrical connections are corroded loose or faulty 9 Check the electrical connections for good contact Clean connector terminals thoroughly with electrical contact cleaner apply dielectric grease and reconnect 10 Relay or switch is defective 10 Contact an Authorized Service Dealer 11 Faulty spark plug 11 Clean adjust or replace spark plug Engine will not start starts hard...

Page 65: ...utting blade s 3 Mower deck is not level 3 Level mower deck from side to side and front to rear 4 Underside of mower is dirty 4 Clean the underside of the mower 5 Tire pressure is not correct 5 Adjust the tire pressure Uneven cutting height 6 Blade spindle bent 6 Contact an Authorized Service Dealer 1 Mower deck belt is worn loose or broken 1 Install new deck belt 2 Mower deck belt is off pulley 2...

Page 66: ...Schematics Wire Diagram Rev A 66 ...

Page 67: ...Notes 67 ...

Page 68: ... item 3 to use the 24 hour Toro Dealer locator system 2 Bring the product and your proof of purchase sales receipt to the Service Dealer The dealer will diagnose the problem and determine if it is covered under warranty 3 If for any reason you are dissatisfied with the Service Dealer s analysis or with the assistance provided contact us at RLC Customer Care Department Toro Warranty Company 8111 Ly...