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Toro Z Master Professional 500 Series Operator's Manual

Riding mower 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. 74915—Serial No. 402100000 and Up
Form No. 3417-777 Rev B
Professional 5000
®
Side Discharge
*3417-777* B

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Summary of Contents for Toro Z Master Professional 500 Series

  • Page 1 Form No. 3417-777 Rev B Z Master ® Professional 5000 Series Riding Mower with 60in TURBO FORCE ® Side Discharge Mower Model No. 74915—Serial No. 402100000 and Up *3417-777* B Register at www.Toro.com. Original Instructions (EN)

  • Page 2: Figure 1

    Whenever you need service, genuine Toro parts, or WARNING additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model CALIFORNIA and serial numbers of your product ready. Figure 1 Proposition 65 Warning identifies the location of the model and serial numbers on the product.

  • Page 3: Table Of Contents

    (Figure 2), which signals a hazard that may cause Using the Drive-Wheel-Release Valves .... 29 serious injury or death if you do not follow the Transporting the Machine ......... 30 recommended precautions. Maintenance ............32 Recommended Maintenance Schedule(s) ... 32 Pre-Maintenance Procedures ......

  • Page 4: Safety

    Safety Servicing the Cutting Blades ......60 Removing the Mower Deck....... 61 Replacing the Grass Deflector ......62 This machine has been designed in accordance with Cleaning .............. 63 ANSI B71.4-2012. Cleaning under the Mower Deck ....... 63 Disposing of Waste........... 63 Storage ..............

  • Page 5: Slope Indicator

    Slope Indicator g011841 Figure 3 You may copy this page for personal use. 1. The maximum slope you can operate the machine on is 15 degrees. Use the slope chart to determine the degree of slope of hills before operating. Do not operate this machine on a slope greater than 15 degrees. Fold along the appropriate line to match the recommended slope.

  • Page 6: Safety And Instructional Decals

    Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or missing. decal93-7818 93-7818 decalbatterysymbols 1. Warning—read the Operator's Manual for instructions on Battery Symbols torquing the blade bolt/nut to 115 to 149 N∙m (85 to 110 ft-lb).
  • Page 7 decal106-5517 106-5517 1. Warning—do not touch the hot surface. decal110-2068 110-2068 1. Read the Operator's Manual. decal112-9028 112-9028 1. Warning—stay away from moving parts; keep all guards in place. decal116-4858 116-4858 decal107-3069 107-3069 1. Warning–there is no rollover protection when the roll bar is down.
  • Page 8 decal116-8726 116-8726 1. Read the Operator’s Manual for the recommended hydraulic fluid. decal126-4398 126-4398 decal117-3848 117-3848 1. Read the Operator’s 3. Unlock Manual. 1. Thrown object hazard—keep bystanders a safe distance 2. Lock away from the machine. 2. Thrown object hazard, mower-do not operate the machine without the deflector, discharge cover, or grass collection system in place.
  • Page 9 decal127-0326 127-0326 1. Read the Operator's 3. Remove the key from Manual. the ignition and read the Operator's Manual before performing maintenance or servicing the machine. decal136-5508 2. Height-of-cut 136-5508 1. Belt routing decal127-6663 127-6663 1. Warning—read the 2. Crushing hazard—1) Operator's Manual.
  • Page 10 decal125-9383 125-9383 1. Check the hydraulic fluid every 50 operating hours. 3. Check the tire pressure every 50 operating hours. 2. Read the Operator’s Manual for information on lubricating 4. Read the Operator’s Manual before servicing or performing the machine. maintenance.
  • Page 11 decal132-0871 132-0871 Note: This machine complies with the industry standard stability test in the static lateral and longitudinal tests with the maximum recommended slope indicated on the decal. Review the instructions for operating the machine on slopes in the Operator’s Manual as well as the conditions in which you would operate the machine to determine whether you can operate the machine in those conditions on that day and at that site.

  • Page 12: Product Overview

    Controls Product Overview Become familiar with all the controls before you start the engine and operate the machine. Control Panel g233557 Figure 5 g027333 Figure 4 1. Blade-control switch 4. Hour (power takeoff) meter/Safety-interlock 1. Height-of-cut deck-lift 6. Roll bar display pedal 2.

  • Page 13: Specifications

    Safety-Interlock Indicators To ensure optimum performance and continued safety certification of the machine, use only genuine Toro There are symbols on the hour meter that indicate with replacement parts and accessories. Replacement a black bar that the interlock component is positioned...

  • Page 14: Before Operation

    Operation • Do not fill containers inside a vehicle or on a truck or trailer bed with a plastic liner. Always place containers on the ground, away from your vehicle Note: Determine the left and right sides of the before filling. machine from the normal operating position.

  • Page 15: Adding Fuel

    Adding Fuel Note: Do not fill the fuel tank completely full. The empty space in the tank allows the fuel to expand. Recommended Fuel • For best results, use only clean, fresh (less than 30 days old), unleaded gasoline with an octane rating of 87 or higher ((R+M)/2 rating method).

  • Page 16: Using The Rollover-Protection System

    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 seat is secured to the machine. WARNING There is no rollover protection when the roll bar is in the down position.

  • Page 17: Using The Safety-Interlock System

    Using the Safety-Interlock Testing the Safety-Interlock System System Service Interval: Before each use or daily WARNING Test the safety-interlock system before you use the machine each time. If the safety system does not If the safety-interlock switches are operate as described below, have an Authorized disconnected or damaged, the machine could Service Dealer repair the safety system immediately.

  • Page 18: Positioning The Seat

    Positioning the Seat Changing the Seat Suspension The seat can move forward and backward. Position the seat where you have the best control of the The seat is adjustable to provide a smooth and machine and are most comfortable (Figure 10).
  • Page 19 The • Use only accessories and attachments approved machine could suddenly roll over if a wheel goes by Toro. over the edge or the edge collapses. Keep a safe • This machine produces sound levels in excess distance (twice the width of the machine) between of 85 dBA at the operator’s ear and can cause...

  • Page 20: Operating The Parking Brake

    Operating the Parking • Avoid starting, stopping, or turning the machine on slopes. Avoid making sudden changes in speed or Brake direction; turn slowly and gradually. • Do not operate a machine under any conditions Always engage the parking brake when you stop the where traction, steering, or stability is in question.

  • Page 21: Operating The Mower Blade-Control Switch (Pto)

    Operating the Mower Operating the Choke Blade-Control Switch (PTO) Use the choke to start a cold engine. Pull up the choke knob to engage the choke The blade-control switch (PTO) starts and stops the before using the key switch (Figure 20).

  • Page 22: Starting The Engine

    Starting the Engine Shutting Off the Engine Important: Do not engage starter for more than 5 CAUTION seconds at a time. If the engine fails to start, wait 15 seconds between attempts. Failure to follow Children or bystanders may be injured if they these instructions can burn out the starter motor.

  • Page 23: Using The Motion-Control Levers

    Using the Motion-Control WARNING Levers The machine can spin very rapidly. You may lose control of the machine and cause personal injury or damage to the machine. • Use caution when making turns. • Slow the machine down before making sharp turns.

  • Page 24: Using The Side Discharge

    Driving Backward Using the Side Discharge Move the levers to the center, unlocked position. The mower has a hinged grass deflector that disperses clippings to the side and down toward the To go backward, slowly pull the motion-control turf. levers rearward (Figure 25).

  • Page 25: Adjusting The Height Of Cut

    Adjusting the Height of Cut Adjusting the Height-of-Cut Pin The height-of-cut is adjusted from 25 to 140 mm (1 to 5-1/2 inches) in 6 mm (1/4 inch) increments by Using the Transport Lock relocating the clevis pin into different hole locations. The transport lock has 2 positions, and is used with Move the transport lock to the lock position.

  • Page 26: Adjusting The Anti-Scalp Rollers

    Adjusting the Anti-Scalp Rollers Whenever you change the height-of-cut, adjust the height of the anti-scalp rollers. Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

  • Page 27: Positioning The Flow Baffle

    Position B Use this position when bagging. Always align it with the blower opening. g027727 Figure 31 Positioning the Flow Baffle The following figures are only recommendations g005833 for use. Adjustments vary by grass type, moisture Figure 33 content, and the height of the grass. Note: If the engine power draws down and the mower ground speed is the same, open up the baffle.

  • Page 28: Operating Tips

    It is best to cut only about a third of the grass blade. genuine Toro replacement blade. Cutting more than that is not recommended unless grass is sparse, or it is late fall when grass grows more slowly.

  • Page 29: After Operation

    Using the After Operation Drive-Wheel-Release After Operation Safety Valves General Safety WARNING Hands may become entangled in the rotating • Clean grass and debris from the cutting units, drive components below the engine deck, mufflers, and engine compartment to help prevent fires.

  • Page 30: Transporting The Machine

    Transporting the Machine Use a heavy-duty trailer or truck to transport the machine. Use a full-width ramp. Ensure that the trailer or truck has all the necessary brakes, lighting, and marking as required by law. Please carefully read all the safety instructions. Knowing this information could help you or bystanders avoid injury.
  • Page 31 If using a trailer, connect it to the towing vehicle and connect the safety chains. If applicable, connect the trailer brakes and lights. Lower the ramp, ensuring that the angle between the ramp and the ground does not exceed 15 degrees (Figure 37).

  • Page 32: Maintenance

    Every 500 hours • Adjust the caster-pivot bearing. • 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). • Check the battery charge.

  • Page 33: Pre-Maintenance Procedures

    CAUTION If you leave the key in the switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the switch before you perform any maintenance. Pre-Maintenance Lubrication Procedures Greasing the Machine Maintenance Safety Grease more frequently when operating conditions are extremely dusty or sandy.

  • Page 34: Greasing The Mower Deck

    Greasing the Mower Deck Remove the dust cap and adjust the caster pivots. Service Interval: Yearly—Grease the pump-belt-idler Note: Keep the dust cap off until greasing is arm. done. Yearly—Grease the front caster pivots (more Remove the hex plug. often in dirty or dusty conditions). Yearly—Repack the front caster-wheel bearings Thread a grease fitting into the hole.

  • Page 35: Lubricating The Caster-Wheel Hubs

    Lubricating the Pack the bearings with a general-purpose grease. Caster-Wheel Hubs Insert 1 bearing and 1 new seal into the wheel. Note: Service Interval: Yearly Replace the seals. If the axle assembly is missing both spacer nuts, Park the machine on a level surface, disengage apply a thread-locking adhesive to 1 spacer nut the blade-control switch, and engage the parking and thread it onto the axle with the wrench flats...
  • Page 36 This engine is equipped with a replaceable, Remove the inner filter only if you intend to high-density paper and foam air-cleaner element. replace it. Check the air cleaner daily or before starting the Important: Never attempt to clean the inner engine.

  • Page 37: Servicing The Engine Oil

    Installing the Filters Servicing the Engine Oil Important: To prevent engine damage, always operate the engine with both air filters and the Engine Oil Specifications cover installed. Oil Capacity: with a filter change—1.8 L (61 fl oz); If you are installing new filters, check each filter without a filter change—1.6 L (54 fl oz) for shipping damage.
  • Page 38 Changing the Engine Oil Service Interval: Every 100 hours (more often in dirty or dusty conditions). Note: Dispose of the used oil at a recycling center. Start the engine and let it run for 5 minutes. Note: This warms the oil so that it drains better. Park the machine so that the drain side is slightly lower than the opposite side to ensure that the oil drains completely.
  • Page 39 Changing the Engine-Oil Filter Slowly pour approximately 80% of the specified oil into the filler tube and slowly add the Service Interval: Every 200 hours—Change the additional oil to bring it to the Full mark (Figure engine-oil filter (more often in dirty 50).

  • Page 40: Servicing The Spark Plug

    Servicing the Spark Plug Service Interval: Every 200 hours—Check the spark plug(s). Every 500 hours—Replace the spark plug(s). Type: Champion XC12YC Air Gap: 0.76 mm (0.03 inch) g206628 Figure 53 Removing the Spark Plug Park the machine on a level surface, disengage Installing the Spark Plug the blade-control switch (PTO), and engage the parking brake.

  • Page 41: Checking The Spark Arrester

    Checking the Spark Fuel System Arrester Maintenance For Machines with a Spark Replacing the Fuel Filter Arrester Service Interval: Every 200 hours (more often in Service Interval: Every 50 hours dusty, dirty conditions). Important: Install the fuel line hoses and secure WARNING with plastic ties the same as they were originally Hot exhaust-system components may ignite...

  • Page 42: Servicing The Fuel Tank

    Electrical System Open the fuel-shutoff valve. Maintenance Servicing the Fuel Tank Do not attempt to drain the fuel tank. Ensure that an Electrical System Safety Authorized Service Dealer drains the fuel tank and services any components of the fuel system. •...
  • Page 43 Charging the Battery Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. WARNING Remove the battery as shown in Figure Charging the battery produces gasses that can explode. Never smoke near the battery and keep sparks and flames away from the battery.

  • Page 44: Servicing The Fuses

    Installing the Battery Drive System Note: Position the battery in the tray with the terminal Maintenance posts opposite from the hydraulic tank (Figure 56). Checking the Seat Belt Service Interval: Before each use or daily Inspect the seat belt for wear, cuts, and proper operation of the retractor and buckle.

  • Page 45: Adjusting The Tracking

    Adjusting the Tracking Disengage the blade-control switch (PTO). Drive to an open flat area, move the motion-control levers to the N EUTRAL position. Move the throttle midway between fast and slow. Move both motion-control levers all the way forward until they both hit the stops in the T-slot. Check which way the machine tracks.

  • Page 46: Checking The Tire Pressure

    Checking the Tire Pressure Service Interval: Every 50 hours/Monthly (whichever comes first) Maintain the air pressure in the rear tires at 90 kPa (13 psi). Uneven tire pressure can cause uneven cut. Check the tires when they are cold to get the most accurate pressure reading.

  • Page 47: Using The Clutch Shim

    Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Using an air compressor, blow out any debris from under the brake pole and around the brake spacers (Figure 67). g001297 g010868 Figure 65...
  • Page 48 Note: Do not discard the shim until the clutch is functioning properly. g010873 Figure 71 1. Feeler gauge g010871 Figure 69 1. Shim • If the gap is less than 0.25 mm (0.01 inch), then install the shim; refer to Using the Clutch Shim (page 47).

  • Page 49: Cooling System Maintenance

    Cleaning the Cooling System Engine-Cooling Fins and Maintenance Shrouds Cleaning the Engine Screen Service Interval: Every 100 hours/Yearly (whichever comes first) and Engine-Oil Cooler Park the machine on a level surface, disengage Service Interval: Before each use or daily the blade-control switch (PTO), and engage the parking brake.

  • Page 50: Checking And Cleaning The Hydraulic-Unit Shrouds

    Checking and Cleaning the Brake Maintenance Hydraulic-Unit Shrouds Adjusting the Parking Service Interval: Before each use or daily Brake Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the Service Interval: After the first 100 hours parking brake.

  • Page 51: 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 52 g027730 Figure 78 1. Position the belt cover 3. Ensure that the tab is under the metal catch 2. Slide the belt cover under the side catches g009038 Figure 77 1. Clutch pulley 5. Square hole in the idler arm for the ratchet 2.

  • Page 53: Replacing The Hydraulic Pump-Drive Belt

    Replacing the Hydraulic Controls System Pump-Drive Belt Maintenance Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the Adjusting the parking brake. Control-Handle Position Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the There are 2 height positions for the control operating position.

  • Page 54: Adjusting The Motion-Control Linkage

    Lower deck to the ground. Raise the rear of machine up and support it with jack stands (or equivalent support). Note: Raise the machine just high enough to allow the drive wheels to turn freely. Remove the electrical connection from the seat safety switch, located under the bottom cushion of the seat.

  • Page 55: Adjusting The Motion-Control Damper

    g008620 Figure 83 Right Motion Control Shown 1. Torque the locknut to 23 N∙m (17 ft-lb). The bolt must protrude past the end of the locknut after torquing. 2. Most resistance (firmest feel) 3. Damper 4. Medium resistance (medium feel) 5.

  • Page 56: Hydraulic System Maintenance

    Use cardboard or paper to find hydraulic leaks. • Safely relieve all pressure in the hydraulic system before performing any work on the hydraulic system. Servicing the Hydraulic System Hydraulic-Fluid Specifications Hydraulic-Fluid Type: Toro ® HYPR-OIL ™ hydraulic fluid or Mobil ® 1 15W-50. Important: Use the specified fluid.
  • Page 57 Mobil ® 1 fluid (more often in dirty or dusty conditions). 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).

  • Page 58: Mower Deck Maintenance

    Mower Deck On both sides of the deck, measure from the level surface to the front tip of the blade (Postion Maintenance A) as shown in Figure Note: The measurement should read 7.6 mm (3 inches) Leveling the Mower Deck Leveling the Deck Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the...
  • Page 59 Note: Loosen or tighten the single-point adjustment bolt enough to move the height-of-cut plate mounting bolts at least 1/3 the length of the available travel in their slots. This regains some up and down adjustment on each of the 4 deck links. g017036 Figure 92 g027344...

  • Page 60: Servicing The Cutting Blades

    Servicing the Cutting Blades To ensure a superior quality of cut, keep the blades sharp. For convenient sharpening and replacement, you may want to keep extra blades on hand. Blade Safety g006530 Figure 93 A worn or damaged blade can break, and a piece of the blade could be thrown toward you or bystanders, 1.

  • Page 61: Removing The Mower Deck

    Removing the Blades Replace the blades if they hit a solid object, or if the blade is out of balance or bent. g000553 Hold the blade end using a rag or thickly padded Figure 97 glove. 1. Blade 2. Balancer Remove the blade bolt, curved washer, and blade from the spindle shaft (Figure...

  • Page 62: Replacing The Grass Deflector

    Lift up the floor pan and insert a ratchet into the square hole in the deck idler (Figure 98). Rotate the deck idler clockwise and remove the mower belt (Figure 98). g010252 Figure 99 1. Right stabilizer 2. Deck strut (right side shown) 3.

  • Page 63: Cleaning

    Cleaning Cleaning under the Mower Deck Service Interval: Before each use or daily Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the g015594 operating position.

  • Page 64: Storage

    Storage Prepare the machine for storage when non-use occurs over 30 days. Prepare the machine for storage as follows: Storage Safety Add a petroleum-based stabilizer/conditioner to fuel in the • Shut off the engine, remove the key, wait for all tank.

  • Page 65: Troubleshooting

    Troubleshooting Problem Possible Cause Corrective Action The starter does not crank. 1. The blade-control switch is engaged. 1. Disengage the blade-control switch. 2. The parking brake is disengaged. 2. Engage the parking brake. 3. The motion-control levers are not in 3.
  • Page 66 Problem Possible Cause Corrective Action The machine pulls to the left or right (with 1. The tracking needs adjustment 1. Adjust the tracking. levers fully forward) 2. The tire pressure in the drive tires is 2. Adjust the tire pressure in the drive not correct.

  • Page 67: Schematics

    Schematics g224051 Electrical Schematic (Rev. A)

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74915

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