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Toro 74991 Z Master Professional 5000 Series Operator's Manual
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Toro 74991 Z Master Professional 5000 Series Operator's Manual

With 60in turbo force side discharge mower
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Original Instructions (EN)
Z Master
®
Series Riding Mower
with 60in TURBO FORCE
Mower
Model No. 74991—Serial No. 316000001 and Up
Form No. 3400-705 Rev B
Professional 5000
®

Side Discharge

g029833
*3400-705* B

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Summary of Contents for Toro 74991 Z Master Professional 5000 Series

  • Page 1: Side Discharge

    Form No. 3400-705 Rev B Z Master ® Professional 5000 Series Riding Mower with 60in TURBO FORCE ® Side Discharge Mower Model No. 74991—Serial No. 316000001 and Up g029833 *3400-705* B Register at www.Toro.com. Original Instructions (EN)
  • Page 2 You may contact Toro directly at www.Toro.com for product WARNING safety and operation training materials, accessory information, help finding a dealer, or to register your product. CALIFORNIA Proposition 65 Warning Whenever you need service, genuine Toro parts, or additional This product contains a chemical or chemicals...

  • Page 3: Table Of Contents

    Drive System Maintenance .........46 Safety ................4 Checking the Seat Belt..........46 Safe Operating Practices........... 4 Checking the Rollover-Protection-System (ROPS) Toro Mower Safety ..........6 Knobs...............46 Slope Indicator ............7 Adjusting the Tracking ..........47 Safety and Instructional Decals ......... 8 Checking the Tire Pressure ........48 Product Overview ............14...

  • Page 4: Safety

    Operator’s Manual. Modifications to this machine should only be made by either the manufacturer or an Authorized Operation Toro Dealer. • Lightning can cause severe injury or death. If lightning This product is capable of amputating hands and feet. Follow is seen or thunder is heard in the area, do not operate all safety instructions to avoid serious injury or death.

  • Page 5: Maintenance And Storage

    Maintenance and Storage • Slow down and use caution when making turns and crossing roads and sidewalks. Stop the blades if you are • Disengage drives, set the parking brake, shut off the not mowing. engine, and remove the key or disconnect spark-plug wire. •...

  • Page 6: Toro Mower Safety

    • Do not store the machine or a fuel container inside where The following list contains safety information specific to Toro there is an open flame, such as near a water heater or products and other safety information that you must know.

  • 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. 58-6520 1. Grease 106-2655 1. Warning—do not touch or approach moving belts; remove the ignition key and read the instructions before servicing or performing maintenance.
  • Page 9 110-2068 1. Read the Operator's Manual. 112-9028 1. Warning—stay away from moving parts; keep all guards in place. 107-3069 1. Warning—there is no rollover protection when the roll bar is down. 114-4466 2. To avoid injury or death from a rollover accident, keep the roll bar in the fully raised and locked position and wear 1.
  • Page 10 115-9625 1. Parking 2. Parking brake—engaged brake—disengaged 116-1716 117-0346 1. Fuel 6. Hour meter 1. Fuel leak hazard—read the Operator's Manual; do not 2. Empty 7. PTO attempt to remove the roll bar; do not weld, drill, or modify 8. Parking brake 3.
  • Page 11 117-3864 1. Read the Operator’s 2. Fill to bottom of filler neck; Manual. warning—do not overfill the tank. 126-4398 1. Read the Operator’s 3. Unlock manual 2. Lock 121–7586 1. Fast 3. Slow 2. Variable speed control 4. Power takeoff (PTO) 126-2055 1.
  • Page 12 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.
  • Page 13 132-0871 1. Warning—read the Operator’s Manual; do not operate the 4. Ramp hazard—when loading onto a trailer, do not use dual machine unless you are trained; wear hearing protection. ramps; only use a singular ramp wide enough for the machine and that has an incline less than 15 degrees;...

  • Page 14: Product Overview

    Fuel Gauge Product Overview The fuel gauge is located with the hour meter, and the bars light up when the ignition switch is on (Figure The indicator light appears when the fuel level is low—approximately 3.8 L (1 US gallon) remaining in the fuel tank.

  • Page 15: Specifications

    A selection of Toro approved attachments and accessories is 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.

  • Page 16: Operation

    Operation DANGER In certain conditions during fueling, static Note: Determine the left and right sides of the machine electricity can be released, causing a spark that can from the normal operating position. ignite the gasoline vapors. A fire or explosion from gasoline can burn you and others and can damage Adding Fuel property.

  • Page 17: Checking The Engine-Oil Level

    Breaking in a New Machine of varnish deposits in the fuel system, use fuel stabilizer at all times. New engines take time to develop full power. Mower decks and drive systems have higher friction when new, placing Filling the Fuel Tank additional load on the engine.

  • Page 18: Entering The Operating Position

    Entering the Operating Position Use the mower deck as a step to get into the operating position (Figure g029797 Figure 9 1. Mower deck Think Safety First Please read all safety instructions and symbols in the safety section. Knowing this information could help you or bystanders avoid injury.

  • Page 19: Operating The Parking Brake

    Operating the Parking Brake Always set the parking brake when you stop the machine or leave it unattended. Setting the Parking Brake WARNING The parking brake may not hold a machine parked on a slope and could cause personal injury or property damage.

  • Page 20: Operating The Mower Blade-Control Switch (Pto)

    Operating the Mower Operating the Ignition Switch Blade-Control Switch (PTO) 1. Turn the ignition key to the S position (Figure 17). TART Note: When the engine starts, release the key. The blade-control switch (PTO) starts and stops the mower blades and any powered attachments. Important: Do not engage the starter for more than 5 seconds at a time.

  • Page 21: Starting And Shutting Off The Engine

    Starting and Shutting Off the Engine Starting the Engine 1. Raise the ROPS up, lock it into place, sit on the seat, and fasten the seat belt. 2. Move the motion-control levers to the N EUTRAL LOCK G008947 position. Figure 20 3.

  • Page 22: Using The Safety-Interlock System

    Testing the Safety-Interlock System Important: Make sure that you close the fuel-shutoff valve before transporting or storing the machine, as Service Interval: Before each use or daily fuel leakage may occur. Set the parking brake before transporting the machine. Make sure to remove the key Test the safety-interlock system before you use the machine as the fuel pump may run and cause the battery to lose each time.

  • Page 23: Driving Forward Or Backward

    Driving Forward or Backward Driving Forward Note: The engine shuts off if you move the traction-control The throttle control regulates the engine speed as measured levers with the parking brake engaged. in rpm (revolutions per minute). Place the throttle control in the F position for best performance.

  • Page 24: Shutting Off The Machine

    Driving Backward 1. Move the levers to the center, unlocked position. 2. To go backward, slowly pull the motion-control levers rearward (Figure 25). G008953 Figure 25 Shutting Off the Machine To shut off the machine, move the motion-control levers to neutral and then to the N position, disengage EUTRAL...

  • Page 25: Adjusting The Anti-Scalp Rollers

    Adjusting the Height-of-Cut Pin Adjusting the Anti-Scalp Rollers Adjust the height-of-cut from 25 to 140 mm (1 to 5-1/2 inches) in 6 mm (1/4 inch) increments by moving the clevis Whenever you change the height of cut, adjust the height pin into different hole locations.

  • Page 26: Adjusting The Flow-Baffle-Cam Locks

    Adjusting the Flow-Baffle-Cam Positioning the Flow Baffle Locks The following figures are only recommendations for use. Adjustments vary by grass type, moisture content, and height For Machines with Flow-Baffle Locks of grass. Only Note: If the engine power draws down and the mower You can adjust the mower-discharge flow for different types ground speed is the same, open up the baffle.

  • Page 27: Positioning The Seat

    • Tall, dense grass mowing conditions. • Wet conditions. • Lowering the engine power consumption. • Increased ground speed in heavy conditions. g030021 Figure 35 Figure 33 Note: This position is similar to the benefits of the Toro SFS mower.

  • Page 28: Adjusting The Myride™ Suspension System

    Adjusting the MyRide™ Adjust the rear-shock assemblies (Figure 37). Suspension System The MyRide™ suspension system adjusts to provide a smooth and comfortable ride. Adjusting the rear 2-shock assemblies is the easiest and quickest adjustment for changing the suspension system. Position the suspension system where you are most comfortable.

  • Page 29: Using The Drive-Wheel Release Valves

    Remove the key. To adjust the front-shock assembly, open the floor pan and 2. Rotate the release-valve levers vertically to push the adjust it by using a spanner wrench (Toro Part No. 132-5069) machine (Figure 39). or slip-joint pliers (Figure 38).

  • Page 30: Transporting The Machine

    Transporting the Machine Loading the Machine Use a heavy-duty trailer or truck to transport the machine. Use extreme caution when loading or the unloading machine Ensure that the trailer or truck has all necessary brakes, onto a trailer or a truck. Use a full-width ramp that is wider lighting, and marking as required by law.
  • Page 31 WARNING Loading a machine onto a trailer or truck increases the possibility of a tip-over and could cause serious injury or death. • Use extreme caution when operating a machine on a ramp. • Ensure that the ROPS is in the up position and use the seat belt when loading or unloading the machine.

  • Page 32: Operating Tips

    This also helps disperse clippings, which enhances blades as necessary. If a blade is damaged or worn, replace it decomposition and fertilization. immediately with a genuine Toro replacement blade. Mowing at Correct Intervals Normally, mow every 4 days. However, grass grows at different rates at different times.

  • Page 33: Maintenance

    • Adjust the caster-pivot bearing. Every 500 hours • Check the parking-brake adjustment. • Change the hydraulic filters and hydraulic fluid when using Toro® HYPR-OIL™ 500 hydraulic fluid (more often in dirty or dusty conditions). • Replace the inner air filter.

  • Page 34: Lubrication

    CAUTION If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition before you do any maintenance. Lubrication Adding Light Oil or Spray Lubrication Grease more frequently when operating conditions are extremely dusty or sandy.

  • Page 35: Greasing The Mower

    Greasing the Mower 5. Grease the drive-belt idler arm (Figure 45). 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—Repack the front caster-wheel bearings (more often in dirty or dusty conditions).

  • Page 36: Lubricating The Caster-Wheel Hubs

    Lubricating the Caster-Wheel 14. Torque the nut to 8 to 9 N∙m (75 to 80 in-lb), loosen the nut, then torque it to 2 to 3 N∙m (20 to 25 in-lb). Hubs Note: Make sure that the axle does not extend beyond Service Interval: Yearly either nut.

  • Page 37: Engine Maintenance

    Engine Maintenance 6. Release the latches on the air cleaner and pull the air-cleaner cover off the air-cleaner body (Figure 49). 7. Clean the inside of the air-cleaner cover with WARNING compressed air. Contact with hot surfaces may cause personal 8.

  • Page 38: Servicing The Engine Oil

    Servicing the Engine Oil Oil Type: Detergent oil (API service class SL, SM, SN, or higher) Oil Capacity: with a filter change, 1.9 L (2.0 US qt); with no filter change, 1.6 L (1.7 US qt) G029644 Viscosity: See the table below. Figure 50 Note: Use of synthetic oil having 5W-20 or 5W-30 rating is acceptable, up to 4 degrees C (40 degrees F).

  • Page 39: Changing The Engine Oil

    Changing the Engine Oil 5. Slowly pour approximately 80% of the specified oil into the filler tube and slowly add the additional oil to Service Interval: Every 100 hours (more often in dirty or bring it to the Full mark (Figure 53).

  • Page 40: Servicing The Spark Plug

    Changing the Engine-Oil Filter Servicing the Engine-Oil Cooler Service Interval: Every 200 hours (more often in dirty or Service Interval: Every 200 hours dusty conditions). 1. Keep the oil cooler free of debris by cleaning the fins with a brush. Note: Change the engine oil filter more frequently when operating conditions are extremely dusty or sandy.
  • Page 41 Removing the Spark Plug 1. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 2. Disengage the blade-control switch (PTO), move the motion-control levers to the N position, EUTRAL LOCK g029646 and set the parking brake.

  • Page 42: Checking The Spark Arrester (If Equipped)

    Installing the Spark Plug Fuel System Tighten the spark plug(s) to 24.4 to 29.8 N∙m (18 to 22 ft-lb). Maintenance WARNING Fuel-system components are under high pressure. The use of improper components can result in system failure, gasoline leakage, and possible explosion.

  • Page 43: Servicing The High-Pressure Fuel Filter

    Electrical System Maintenance Servicing the Battery Service Interval: Monthly 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 G008963 eyes and wear rubber gloves to protect your hands.

  • Page 44: Charging The Battery

    Charging the Battery 5. Remove the wing nut securing the battery clamp (Figure 61). WARNING 6. Remove the clamp (Figure 61). Charging the battery produces gasses that can 7. Remove the battery (Figure 61). explode. Never smoke near the battery and keep sparks and flames away from battery.

  • Page 45: Servicing The Fuses

    Servicing the Fuses 2. Make sure that the booster battery is a good and fully charged lead-acid battery at 12.6 V or greater. The electrical system is protected by fuses. It requires no Note: Use properly sized jumper cables with short maintenance, however, if a fuse blows check the component lengths to reduce voltage drop between systems.

  • Page 46: Drive System Maintenance

    Drive System 4. Connect the other end of the positive cable to the positive terminal of the booster battery. Maintenance 5. Connect the black negative (–) cable to the other terminal (negative) of the booster battery. 6. Make the final connection on the engine block of the Checking the Seat Belt stalled vehicle (not to the negative battery post) away from the battery and stand back...

  • Page 47: Adjusting The Tracking

    Adjusting the Tracking 1. Disengage the blade-control switch (PTO). 2. Drive to an open, flat area and move the motion-control levers to the N position. EUTRAL LOCK 3. Move the throttle midway between the F and S positions. 4. Move both motion-control levers forward until they both hit the stops in the T-slot.

  • Page 48: Checking The Tire Pressure

    Checking the Tire Pressure Checking the Wheel Hub Slotted Nut Service Interval: Every 50 hours/Monthly (whichever comes first) Service Interval: After the first 100 hours Maintain the air pressure in the rear tires at 90 kPa (13 psi). Every 500 hours Uneven tire pressure can cause uneven cut.

  • Page 49: Adjusting The Caster-Pivot Bearing

    Adjusting the Caster-Pivot Using the Clutch Shim Bearing Some later model year units have been built with clutches that contain a brake shim. When the clutch brake has worn to the Service Interval: Every 500 hours/Yearly (whichever comes point where the clutch no longer engages consistently, you first) can remove the shim to extend the clutch life.
  • Page 50 5. Verify that 12 V is present at the clutch connector E. Using a 0.010 inch thick-feeler gauge, verify that when the you engage the blade-control switch (PTO). a gap is present between the rotor and armature face on both sides of the brake pole as shown in 6.

  • Page 51: Cooling System Maintenance

    Cooling System F. Perform the following safety check: i. Sit on the seat and start the engine. Maintenance ii. Make sure that the blades do not engage when the blade-control switch (PTO) is in the O position and the clutch is Cleaning the Engine Screen disengaged.

  • Page 52: Cleaning The Engine Cooling Fins And Shrouds

    Cleaning the Engine Cooling Cleaning the Hydraulic Units Fins and Shrouds Service Interval: Before each use or daily 1. Disengage the blade-control switch (PTO) and set the Service Interval: Every 100 hours/Yearly (whichever comes parking brake. first) 2. Shut off the engine, remove the key, and wait for all 1.

  • Page 53: Brake Maintenance

    Brake Maintenance 9. Disengage the parking brake. 10. Turn the wheel hub by hand in both directions relative to the caliper. Adjusting the Parking Brake Note: The wheel hub should move freely between Service Interval: After the first 100 hours the caliper.

  • Page 54: Belt Maintenance

    Belt Maintenance Inspecting the Belts Service Interval: Every 50 hours Replace the belt if it is worn. The signs of a worn belt include squealing while the belt is rotating; the blades slipping while cutting grass; and frayed edges, burn marks, and cracks on the belt.

  • Page 55: Replacing The Hydraulic-Pump Drive Belt

    Figure 83 Figure 84 1. Idler pulley 5. Left hydraulic-pump pulley Replacing the Hydraulic-Pump 2. Clutch pulley 6. Square hole in idler arm 3. Pump-drive belt 7. Idler spring Drive Belt 4. Right hydraulic-pump pulley 1. Disengage the blade-control switch (PTO) and set the parking brake.

  • Page 56: Controls System Maintenance

    Controls System Maintenance Adjusting the Control-Handle Position There are 2 height positions for the control levers—high and low. Remove the bolts to adjust the height. 1. Disengage the blade-control switch (PTO), move the motion-control levers to the N position, EUTRAL LOCK and set the parking brake.

  • Page 57: Adjusting The Motion-Control Damper

    Adjusting the Motion-Control 5. Start the engine. Damper Note: Engage the parking brake and move the motion-control levers out before starting the engine. You can adjust the top damper mounting bolt to obtain a You do not need to be in the seat because of the more desired motion-control lever resistance.

  • Page 58: Adjusting The Motion-Control Neutral-Lock Pivot

    See Figure 89 for adjustment EUTRAL LOCK options. System 1. Loosen the jam nut. Hydraulic Fluid Type: Toro ® HYPR-OIL ™ 500 hydraulic 2. Tighten or loosen the flanged nut to the desired feel. fluid or Mobil ® 1 15W-50.
  • Page 59 Every 500 hours—Change the hydraulic filters and ® ™ hydraulic fluid when using Toro HYPR-OIL 500 hydraulic fluid (more often in dirty or dusty conditions). To replace the hydraulic fluid, you need to remove the filters.

  • Page 60: Mower Deck Maintenance

    Mower Deck Maintenance Leveling the Mower Deck Setting Up the Machine Note: Ensure that the mower deck is level before matching the height of cut (HOC). 1. Position the mower on a flat surface. 2. Disengage the blade-control switch (PTO), move the motion-control levers to the N position, EUTRAL...
  • Page 61 6. Insert the height-adjustment pin into the 7.6 cm (3 inch) height-of-cut 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) as shown in Figure...

  • Page 62: Servicing The Cutting Blades

    Servicing the Cutting Blades To ensure a superior quality of cut, keep the blades sharp. For convenient sharpening and replacement, keep extra blades on hand. WARNING A worn or damaged blade can break, and a piece of the blade could be thrown at you or bystanders, resulting in serious personal injury or death.

  • Page 63: Removing The Blades

    Toro replacement blades. Replacement blades made by other 2. Shut off the engine, remove the key, and wait for all manufacturers may result in nonconformance with safety moving parts to stop before leaving the operating standards.
  • Page 64 Sharpening the Blades Installing the Blades 1. Use a file to sharpen the cutting edge at both ends of 1. Install the blade onto the spindle shaft (Figure 103). the blade (Figure 101). Important: The curved part of the blade must Note: Maintain the original angle.

  • Page 65: Removing The Mower Deck

    Removing the Mower Deck Before servicing or removing the mower deck, lock out the spring-loaded deck arms. WARNING Deck-lift-arm assemblies have stored energy. Removing the deck without 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 66: Replacing The Grass Deflector

    Replacing the Grass Deflector WARNING An uncovered discharge opening could allow the lawn mower to throw objects at you or bystanders, resulting in serious injury. Also, contact with the blade could occur. Do not operate the lawn mower unless you install a cover plate, mulch plate, grass deflector, or bagger.

  • Page 67: Cleaning

    Cleaning Storage Cleaning and Storage Cleaning under the Mower 1. Disengage the blade-control switch (PTO), set the Service Interval: Before each use or daily parking brake, and turn the ignition key to Off. Remove the key. 1. Disengage the blade-control switch (PTO), move the motion-control levers to the N position, EUTRAL...
  • Page 68 D. Restart the engine and run it until it stops. E. Dispose of fuel properly. Recycle as per local codes. Important: Do not store stabilizer/conditioned fuel over 90 days. 13. Check and tighten all bolts, nuts, and screws. Repair or replace any part that is damaged.

  • Page 69: Troubleshooting

    Troubleshooting Problem Possible Cause Corrective Action The malfunction indicator light (MIL) 1. The engine is too hot. 1. Turn the engine off and let it cool. comes on. 2. There is old gas in the gas tank. 2. Use new gas. 3.
  • Page 70 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 71 Problem Possible Cause Corrective Action The clutch does not engage. 1. The fuse is blown. 1. Replace the fuse. Check the coil resistance, battery charge, charging system, and wiring connections, and replace components if necessary. 2. There is low voltage supply at the 2.

  • Page 72: Schematics

    Schematics G0131 19 Wire Diagram (Rev. A)
  • Page 73 Notes:...
  • Page 74 Notes:...
  • Page 75 Notes:...
  • Page 76 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. If all other remedies fail, you may contact us at Toro Warranty Company.

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