Form No. 3375-663 Rev B Z Master® Professional 5000 Series Riding Mower with 52in TURBO FORCE® Side Discharge Mower Model No. 74906—Serial No. 313000001 and Up g019752 Register at www.Toro.com.
Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready. Figure 1 identifies the location of the model and serial numbers on the product. Write the numbers in the space provided. WARNING CALIFORNIA Proposition 65 Warning This product contains a chemical or chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
Contents Drive System Maintenance .........................................42 Checking the Seat Belt.............................................42 Checking the Rollover Protection System (ROPS) Knobs...............................................................42 Adjusting the Tracking ............................................43 Checking the Tire Pressure ......................................43 Checking the Wheel Lug Nuts ..................................44 Checking the Wheel Hub Slotted Nut .......
Operation Safety • 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. Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means CAUTION, WARNING, or DANGER-“personal safety instruction.
Safe handling of fuels • Use care when checking blades. Wrap the blade(s) or wear gloves, and use caution when servicing them. Only replace blades. Never straighten or weld them. • To avoid personal injury or property damage, use extreme care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive. • Keep hands and feet away from moving parts. If possible, do not make adjustments with the engine running.
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. 2. Align this edge with a vertical surface, a tree, building, fence pole, etc. 3. Example of how to compare slope with folded edge.
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.
110-2067 110-2068 1. Read the Operator's Manual. 107-2102 114-4466 109-7232 8 1. Main, 25A 3. Charge, 25A 2. PTO, 10A 4.
116-0205 115-7445 1. Grease pulleys and spindles 2. Maintenance interval—50 hours 116-0211 116-0090 116-0752 116-0157 1. Latch 9 2.
116-1654 116-3303 116-1716 1. Fuel 2. Empty 3. Half 4. Full 5. Battery 6. Hour meter 7. PTO 8. Parking brake 9. Neutral 10. Operator presence switch 116-5944 116-2643 121–7589 1. Fast 2. Variable speed control 116-4858 10 3. Slow 4.
Manufacturer's Mark 1. Indicates the blade is identified as a part from the original machine manufacturer. 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 smoking. 7. Wear eye protection; explosive gases can cause blindness and other injuries 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 8. Battery acid can cause blindness or severe burns. 9.
Hour Meter Product Overview The hour meter records the number of hours the engine has operated. It operates when the engine is running. 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).
Ignition Switch Specifications This switch is used to start the mower engine and has three positions: Start, Run and Off. Note: Specifications and design are subject to change without notice. Motion Control Levers Width: 52 inch Deck The motion control levers are used to drive the machine forward, reverse, and turn either direction. Neutral Lock Position The neutral lock position is used with the safety interlock system to engage and to determine neutral position.
Operation Length: 52 inch Deck Roll Bar - Up 201 cm (79 inches) Roll Bar - Down 206 cm (81 inches) Note: Determine the left and right sides of the machine from the normal operating position. Adding Fuel Height: Roll Bar - Up Roll Bar - Down 70.5 inches (179.1 cm) 119 cm (47 inches) • For best results, use only clean, fresh, unleaded gasoline with an octane rating of 87 or higher ((R+M)/2 rating method).
1. Park the machine on level ground. DANGER 2. Shut the engine off and set the parking brake. In certain conditions during 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.
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. Allow 40 to 50 hours of break-in time for new machines 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.
Think Safety First 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. Please read all safety instructions and symbols in the safety section. Knowing this information could help you or bystanders avoid injury. Wear hearing protection when operating this machine. DANGER Operating on wet grass or steep slopes can cause sliding and loss of control.
Releasing the Parking Brake 1 Operating the Throttle The throttle control can be moved between the Fast and Slow positions (Figure 15). 2 Always use the fast position when turning on the mower deck with the blade control switch (PTO). G016995 Figure 12 G008946 Operating the Mower Blade Control Switch (PTO) Figure 15 The blade control switch (PTO) starts and stops the mower blades and any powered attachments. Operating the Ignition Switch 1. Turn the ignition key to the Start position (Figure 16).
Using the Fuel Shut-Off Valve Starting and Stopping the Engine The fuel shut-off valve is located under the seat. Move the seat forward to access the valve. Starting the Engine Close the fuel shut-off valve for transport, maintenance, and storage. 1. Raise the ROPS up and lock it into place, sit on the seat, and fasten the seat belt. Ensure that the fuel shut-off valve is open when starting the engine. 2. Move the motion controls to the neutral locked position. 1 3.
Important: Do not engage starter for more than 5 seconds at a time. If the engine fails to start allow a 15 second cool-down period between attempts. Failure to follow these instructions can burn out the starter motor. Note: You may need to start the engine several times when starting the engine for the first time after the fuel system has been without fuel completely.
• The blade control switch (PTO) is disengaged. • The motion control levers are in the neutral locked 5. Sitting on the seat, disengage the parking brake, move the blade control switch (PTO) to off and move the motion control levers to neutral lock position. Try starting the engine; the engine should not crank. position.
Driving Forward Note: The engine will kill if the traction control levers are moved with the parking brake engaged. To stop, pull the motion control levers to the neutral position. 1. Release the parking brake; refer to Releasing the Parking Brake (page 18) in Operation. 2. Move the levers to the center, unlocked position. 3. To go forward, slowly push the motion control levers forward (Figure 23). G008953 Figure 24 G008952 Figure 23 Driving Backward 1. Move the levers to the center, unlocked position.
Stopping the Machine To stop the machine, move the traction control levers to neutral and move them to the locked position, disengage the power take off (blade control switch (PTO), and turn the ignition key to the Off position. Set the parking brake when you leave the machine; refer to Setting the Parking Brake (page 17) in Operation. Remember to remove the key from the ignition switch. CAUTION Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended.
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 relocating the clevis pin into different hole locations. 1. Move the transport lock to the lock position. 2. Push on the deck lift pedal with your foot and raise the mower deck to the transport position (also the 140 mm (5-1/2 inch) cutting height position) (Figure 26). 3. To adjust, rotate the pin 90 degrees and remove the pin from the height-of-cut bracket (Figure 26).
Adjusting the Flow Baffle The mower discharge flow can be adjusted for different types of mowing conditions. Position the nut and baffle to give the best quality of cut. 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. G012120 Figure 31 3. To adjust the baffle, loosen the nut (Figure 30). 4.
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 36). G012122 Figure 33 Figure 36 The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable. 1. Seat suspension knob To adjust, move the lever sideways to unlock seat (Figure 34).
Using the Drive Wheel Release Valves WARNING Hands may become entangled in the rotating drive components below the engine deck, which could result in serious injury. Stop the engine, remove the key, and allow all moving parts to stop before accessing the drive wheel release valves. WARNING The engine and hydraulic drive units can become very hot. Touching a hot engine or hydraulic drive units can cause severe burns.
Transporting Machines Loading Machines Use a heavy-duty trailer or truck to transport the machine. Ensure that the trailer or truck has all necessary brakes, lighting, and marking as required by law. Please carefully read all the safety instructions. Knowing this information could help you, your family, pets, or bystanders avoid injury. Use extreme caution when loading units on trailers or trucks.
Mow at Correct Intervals Normally, mow every four days. 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. As the grass growth rate slows in mid summer, mow less 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.
Maintenance Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 8 hours • Change the engine oil. After the first 100 hours • • • • After the first 250 hours • Change the hydraulic filters and hydraulic oil when using any type of oil. Before each use or daily • • • • • • • • • Check the safety system. Check the engine oil level. Check the seat belt. Check the rollover protection system (ROPS) knobs. Clean the engine screen and the oil cooler.
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 Where to Grease the Mower Greasing and Lubrication Service Interval: Every 50 hours—Grease the mower deck spindles and idler arm. Yearly—Grease the pump belt idler arm. Grease more frequently when operating conditions are extremely dusty or sandy.
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 44 Figure 42 1. Seal guard 6. Remove the dust cap and adjust the caster pivots. Keep the dust cap off until greasing is done. Refer to Adjusting the Caster Pivot Bearing (page 44) in Maintenance. 2. Spacer nut with wrench flats 2. Raise the front of the machine up and support it with jack stands. 7. Remove the hex plug.
Engine Maintenance Note: Make sure axle does not extend beyond either nut. 15. Install the seal guards over the wheel hub and insert wheel into caster fork. Install caster bolt and tighten nut fully. WARNING Contact with hot surfaces may cause personal injury. 16. Raise the machine up and remove the jack stands. Keep hands, feet, face, clothing and other body parts away the muffler and other hot surfaces. Important: To prevent seal and bearing damage, check the bearing adjustment often.
8. Gently slide the primary filter out of the air cleaner body (Figure 46). 3. Carefully slide the primary filter over the inner filter (Figure 46). Note: Avoid knocking the filter into the side of the body. Note: Ensure that the primary filter is fully seated by pushing on its outer rim while installing it. 9. Remove the inner filter only if you intend to replace it. Important: Do not press on the soft inside area of the filter. Important: Never attempt to clean the inner filter.
Checking the Engine Oil Level Service Interval: Before each use or daily Note: Check the oil when the engine is cold. WARNING G008804 Contact with hot surfaces may cause personal injury. 1 2 3 4 6 7 8 9 Keep hands, feet, face, clothing and other body parts away from the muffler and other 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. 5 1.
Changing the Engine Oil 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). Service Interval: After the first 8 hours Every 100 hours (more often in dirty or dusty conditions) 1 2 3 4 5 6 Note: Dispose of the used oil at a recycling center. 1. Start the engine and let it run five minutes. This warms the oil so it drains better. 2.
Changing the Engine Oil Filter Servicing the Spark Plug Service Interval: Every 200 hours Service Interval: Every 100 hours Note: Change the engine oil filter more frequently when operating conditions are extremely dusty or sandy. 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.
Installing the Spark Plug 4. Remove the spark plug. Tighten the spark plug(s) to 24.4-29.8 N-m (18-22 ft-lb). 1 2 G008803 3 Figure 53 G015200 Figure 55 5. Install the lefthand hydraulic unit shroud (Figure 52). Checking the Spark Plug Important: Never clean the spark plug(s). Always replace the spark plug(s) when it 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.
Check Spark Arrester (if equipped) Fuel System Maintenance Service Interval: Every 50 hours WARNING WARNING Fuel system components are under high pressure. The use of improper components can result in system failure, gasoline leakage and possible explosion. Hot exhaust system components may ignite gasoline vapors even after the engine is stopped. Hot particles exhausted during engine operation may ignite flammable materials. Fire may result in personal injury or property damage.
Electrical System Maintenance 1 2 Servicing the Battery 3 Service Interval: Monthly WARNING CALIFORNIA Proposition 65 Warning Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. G008963 Figure 56 1. Fuel filter 2. Hose clamp 3. Fuel line DANGER 5. Squeeze the ends of the hose clamps together and slide them away from the filter (Figure 56).
1. Disengage the blade control switch (PTO), move the motion control levers to the neutral locked position, and set the parking brake. 4. Secure the cables with 2 bolts, 2 washers, and 2 locknuts (Figure 57). 5. Slide the red terminal boot onto the positive (red) battery post. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 6. Install the clamp and secure it with the wing nut (Figure 57). 3.
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 59). Service Interval: Before each use or daily 2. To replace the fuses, pull out on the fuse to remove it. Visually inspect seat belt for wear, cuts, and proper operation of retractor and buckle.
8. Tighten the stop plate (Figure 61). g019756 Figure 61 Left control lever shown 1. Control lever 3. Stop plate 2. Bolt Figure 60 1. ROPS knob (locked position) 3. Roll bar in the upright position Checking the Tire Pressure 2. Pull the ROPS knob out and rotate it 90 degrees to change the roll bar position. 4. Roll bar in the folded position Service Interval: Every 50 hours/Monthly (whichever comes first) Maintain the air pressure in the rear tires at 90 kPa (13 psi).
Checking the Wheel Lug Nuts 5. Torque the slotted nut to 271 N-m (200 ft-lb). Check and torque the wheel lug nuts to 122-129 N-m (90-95 ft-lb). 6. Then tighten nut until the next set of slots line up with the cross hole in shaft. Do not loosen nut to align the slot. If required, tighten to the next set of slots. Checking the Wheel Hub Slotted Nut 7. Install a new cotter pin. Note: Do Not use anti-seize on wheel hub.
Using the Clutch Shim A. Loosen both brake mounting bolts one-half to one full turn as shown below. 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. Note: Do not remove the brake pole from the field shell/armature.
Cooling System Maintenance Cleaning the Engine Screen and Engine Oil Cooler Figure 70 Service Interval: Before each use or daily 1. Feeler gauge Remove any build-up of grass, dirt or other debris from the oil cooler (Figure 72). G008804 Figure 71 1. Feeler gauge • If the gap is less than 0.010 inch, then install Figure 72 the shim and refer to Maintenance (page 30). • If the gap is sufficient, proceed to the safety check in step F. F.
Brake Maintenance Check and Clean the Hydraulic Unit Shrouds Adjusting the Parking Brake Service Interval: Before each use or daily 1. Disengage the PTO and set the parking brake. Service Interval: After the first 100 hours 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Every 500 hours thereafter Check to make sure brake is adjusted properly.
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. Replacing the Mower Belt 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.
Figure 77 1. Position the belt cover. 3. Ensure that the tab is under the metal catch. 2. Slide the belt cover under the side catches. Replacing the Hydraulic Pump Drive Belt Figure 76 1. Clutch pulley 2. Mower belt 5. Square hole in the idler arm for the ratchet 6. Idler grease zerk 3. Spring loaded idler pulley 7. Belt guide 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. 4.
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 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 wait for all moving parts to stop before leaving the operating position. 3. Loosen the bolts and flange nuts installed in the levers (Figure 79). Figure 78 1.
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. Bring the motion control levers into the neutral position. Adjust pump control rod lengths by rotating the double nuts on the rod in the appropriate direction until the wheels slightly creep in reverse (Figure 81).
Adjusting the Motion Control Damper Adjusting the Motion Control Neutral Lock Pivot The top damper mounting bolt can be adjusted to obtain a more desired motion control lever resistance. See Figure 82 for mounting options. The flanged nut can be adjusted to obtain a more desired motion control lever resistance when moving it to the neutral lock position. See Figure 83 for adjustment options. 1. Loosen the jam nut. 2. Tighten or loosen the flanged nut to the desired feel.
Hydraulic System Maintenance Servicing the Hydraulic System Hydraulic Oil Type: Toro® HYPR-OIL™ 500 hydraulic oil or Mobil® 1 15W-50. 3 H 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 oil level. 1. Position the machine on a level surface. 2.
Replacing the Hydraulic Filters and Hydraulic Oil 1 Service Interval: After the first 250 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).
Mower Deck Maintenance 3 1 Leveling the Mower Deck Setting Up the Machine Note: Ensure the mower deck is leveled before matching the height-of-cut. 2 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. G017027 4. Check tire pressure of the drive tires.
10. If needed, loosen the whizlock nut on the side of the yoke and the jam nut on top. 13. If the deck is too low, tighten the single point adjustment bolt by rotating it clockwise. If the deck is too high, loosen the single point adjustment bolt by rotating it counterclockwise (Figure 91). Note: Fine tune the screw adjuster by turning it to get 7.6 mm (3 inch) height (see Figure 89).
Checking for Bent Blades Servicing the Cutting Blades 1. Disengage the blade control switch (PTO), move the motion control levers to the neutral locked position and set the parking brake. Maintain 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. 2.
Note: Repeat this procedure until the blade is balanced. 1. Hold the blade end using a rag or thickly-padded glove. 2. Remove the blade bolt, curved washer, and blade from the spindle shaft (Figure 94). Figure 96 1. Blade 2. Balancer Installing the Blades 1. Install the blade onto the spindle shaft (Figure 97). Important: The curved part of the blade must point upward toward the inside of the mower to ensure proper cutting. 2. Install the spring disk and blade bolt.
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. 1. Stop the engine, wait for all of the moving parts to stop, and remove the key. Engage the parking brake. 2.
Cleaning 8. Raise the deck struts and secure them in the up position. Slide the deck out to the right side of the machine. Cleaning Under the Mower Replacing the Grass Deflector Service Interval: Before each use or daily 1. Disengage the blade control switch (PTO), move the motion control levers to the neutral locked position, and set the parking brake.
Storage Cleaning and Storage 1. Disengage the power take off (blade control switch (PTO), set the parking brake, and turn the ignition key to Off. Remove the key. Stop the engine, allow it to cool, and drain the fuel tank; refer to Servicing the Fuel Tank (page 40) in the Maintenance Section. 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. 2.
Troubleshooting Problem The starter does not crank. The engine will not start, starts hard, or fails to keep running Possible Cause 1. The blade control switch (PTO) is engaged. 1. Move the blade control switch (PTO) to disengaged. 2. The parking brake is not on. 3. The drive levers are not in neutral lock position. 4. The operator is not seated. 5. The battery is dead. 6. The electrical connections are corroded or loose. 7. The fuse is blown. 8. The relay or switch is defective. 2.
Problem The machine does not drive. There is abnormal vibration. Mowing is resulting in uneven cutting height. Possible Cause 1. The by pass valves is not closed tight. 1. Tighten the by pass valves. 2. 3. 4. 5. 2. 3. 4. 5. The pump belt is worn, loose or broken. The pump belt is off a pulley. The idler sprint is broken or missing. The hydraulic oil level is low or too hot. 1. Install new cutting blade(s). 2. The blade mounting bolt is loose. 3. The engine mounting bolts are loose. 4.
Schematics Wire Diagram (Rev.
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The Toro Total Coverage Warranty Landscape Contractor Equipment (LCE) A Limited Warranty (see warranty periods below) Conditions and Products Covered This warranty includes the cost of parts and labor, but you must pay transportation costs. The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to the original purchaser to repair the Toro Products listed below if defective in materials or workmanship.
