Form No. 3375-549 Rev B Z Master® Commercial 2000 Series Riding Mower with 48in, 52in, or 60in TURBO FORCE® Side Discharge Mower Model No. 74141—Serial No. 313000001 and Up Model No. 74143—Serial No. 313000001 and Up Model No. 74145—Serial No. 313000001 and Up Register at www.Toro.com.
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. The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
Introduction This rotary-blade, 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. Figure 2 1. Safety alert symbol This manual uses 2 other words to highlight information.
Contents Checking the Wheel Lug Nuts ..................................39 Adjusting the Caster Pivot Bearing ............................39 Adjusting the Electric Clutch....................................39 Cooling System Maintenance ......................................40 Cleaning the Engine Screen......................................40 Cleaning the Engine Cooling Fins and Shrouds.............................................................40 Belt Maintenance ...........................................
Safety 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." Failure to comply with the instruction may result in personal injury or death. • – Never remove gas cap or add fuel with engine running. Allow engine to cool before refueling. Do not smoke.
• Let engine cool before storing and do not store near • Do not mow slopes when grass is wet. Slippery flame. conditions reduce traction and could cause sliding and loss of control. • Shut off fuel while storing or transporting. Do not store • Do not make sudden turns or rapid speed changes. • Use a walk behind mower and/or a hand trimmer near fuel near flames or drain indoors. • Park machine on level ground. Never allow untrained drop-offs, ditches, steep banks or water.
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 Manufacturer's Mark 1. Indicates the blade is identified as a part from the original machine manufacturer. 58-6520 1.
116-0205 109-7232 116-1654 112-3858 1. Read the Operator's Manual. 2. Read the instructions before servicing or performing maintenance. 3. Remove the ignition key before adjusting the height of cut. 4. Height of cut settings. 116-3303 114-4466 1. Main, 25A 3. Charge, 25A 2. PTO, 10A 4.
119-2501 116-5944 1. Choke 2. Fast 3. Slow 4. PTO (Power Take-off) 117–1158 1. Bypass lever position for operating the machine. 2. Bypass lever position for pushing the machine. 120-2522 117-8639 1. Belt routing 2.
121–3223 Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 6. Keep bystandersa safe distance from the battery. 2. No fire, open flame, or 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. Flush eyes immediately with water and get medical help fast. 5. Read the Operator's Manual. 107-2102 10.
Throttle Control Product Overview The throttle control is variable between Fast and Slow. Choke Use the choke to start a cold engine. Pull the choke knob up to engage it. Blade Control Switch (PTO) The blade control switch (PTO) is used to engage the electric clutch and drive the mower blades. Pull the switch up to engage the blades and release. To disengage the blades, push the blade control switch (PTO) down or move a motion control lever into the neutral lock position.
Specifications Operation Note: Specifications and design are subject to change without notice. Note: Determine the left and right sides of the machine from the normal operating position. Width: 48 inch Deck 52 inch Deck 60 inch Deck Adding Fuel Without Deck 45.3 inches (115.1 cm) 47.0 inches (119.4 cm) 50.5 inches (134.6 cm) • For best results, use only clean, fresh, unleaded gasoline Deflector Up 51.5 inches (130.8 cm) 53.3 inches (135.4 cm) 61.4 inches (156.0 cm) Deflector Down 63.
Filling the Fuel Tank DANGER Note: Do not fill the fuel tank completely full. Fill the fuel tank to the bottom of the filler neck. The empty space in the tank allows the gasoline to expand. 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 the seat is secured to the machine.
The use of protective equipment for eyes, ears, feet and head is recommended. DANGER Operating on wet grass or steep slopes can cause sliding and loss of control. 1 2 Wheels dropping over edges can cause rollovers, which may result in serious injury, death or drowning. G009027 There is no rollover protection when the roll bar is down. Figure 9 1. Wear safety glasses Always keep the roll bar in the fully raised and locked position and use the seat belt. 2.
Operating the Mower Blade Control Switch (PTO) Operating the Choke Use the choke to start a cold engine. 1. If the engine is cold, use the choke to start the engine. The blade control switch (PTO) starts and stops the mower blades and any powered attachments. 2. Pull up on the choke knob to engage the choke before using the ignition switch (Figure 15). Engaging the Blade Control Switch (PTO) 3. Push down on the choke to disengage the choke after the engine has started (Figure 15).
Operating the Ignition Switch 1. Turn the ignition key to the Start position (Figure 16). When the engines starts, release the key. 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. G017428 1 Note: Additional starting cycles may be required when starting the engine for the first time after the fuel system has been without fuel completely.
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 before turning the ignition switch off. g017429 Figure 18 6. Turn the ignition key to the Start position (Figure 16). When the engines starts, release the key.
The Safety Interlock System motion control levers to neutral lock position. Try starting the engine; the engine should not crank. CAUTION Driving Forward or Backward If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. • Do not tamper with the interlock switches. • Check the operation of the interlock switches daily and replace any damaged switches before operating the machine.
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 22). G008953 Figure 23 Stopping the Machine To stop the machine, move the traction control levers to neutral and move to locked position, disengage the power take off (blade control switch (PTO), and turn the ignition key to off.
Adjusting the Height-of-Cut Pin Mower deck size Height-of-cut range Increments 48 inch 1-1/2 to 5 inches (38 to 127 mm) 1/4 inch (6 mm) 52 inch and 60 inch 1-1/2 to 5-1/2 inches (38 to 140 mm) 1/4 inch (6 mm) The height-of-cut is adjusted by relocating the clevis pin into different hole locations. 1. Move the transport lock to the lock position. 2.
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. g017628 Figure 26 1. Anti-scalp roller 4. Flange Nut 2. Spacer 5. Bolt WARNING 3. Bushing The engine and hydraulic drive units can become very hot. Touching a hot engine or hydraulic drive units can cause severe burns.
5. To run the machine, move the bypass levers to the forward position (Figure 29). WARNING Using the Side Discharge Loading a unit onto a trailer or truck increases the possibility of backward tip-over and could cause serious injury or death. The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. • Use extreme caution when operating a unit on a ramp. • Ensure the ROPS is in the up position while using the seat belt when loading the machine.
Cutting a Lawn for the First Time all the safety instructions. Knowing this information could help you, your family, pets or bystanders avoid injury. Cut grass slightly longer than normal to ensure the cutting height of the mower does not scalp any uneven ground. However, the cutting height used in the past is generally the best one to use. When cutting grass longer than six inches tall, you may want to cut the lawn twice to ensure an acceptable quality of cut.
Keep the Underside of the Mower Clean Clean clippings and dirt from the underside of the mower after each use. If grass and dirt build up inside the mower, cutting quality will eventually become unsatisfactory. Blade Maintenance Maintain a sharp blade throughout the cutting season because a sharp blade cuts 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.
Maintenance Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 8 hours • Change the engine oil. • Check the torque on the wheel lug nuts. After the first 50 hours • Change the hydraulic system filter and 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. Check the mower blades. Clean the mower deck.
Lubrication Where to Grease the Mower Service Interval: Every 50 hours—Grease the mower deck idler arm. Greasing and Lubrication Yearly—Grease the front caster pivots (more often in dirty or dusty conditions). Grease more frequently when operating conditions are extremely dusty or sandy. Grease Type: No. 2 general purpose lithium base or molybdenum base grease 1. Disengage the blade control switch (PTO), move the motion control levers to the neutral locked position, and set the parking brake.
Lubricate the Caster Wheel Hubs 14. Service Interval: Yearly—Lubricate the caster wheel hubs (more often in dirty or dusty conditions). 1. Stop the engine, wait for all moving parts to stop, and remove the key. Engage the parking brake. Important: To prevent seal and bearing damage, check the bearing adjustment often. Spin the caster tire. The tire should not spin freely (more than 1 or 2 revolutions) or have any side play.
Engine Maintenance WARNING Contact with hot surfaces may cause personal injury. Keep hands, feet, face, clothing and other body parts away the muffler and other hot surfaces. Servicing the Air Cleaner Service Interval: Every 250 hours—Replace the primary air filter. Figure 36 Every 250 hours—Check the secondary air filter. Every 500 hours—Replace the secondary air filter. 1. Air cleaner body 4. Air cleaner cover 2. Primary air filter 5. Safety filter 3.
Servicing the Engine Oil Oil Type: Detergent oil (API service SF, SG, SH, SJ, or SL) Crankcase Capacity: with a filter change, 71 ounces (2.1 L); without a filter change, 61 ounces (1.8 L) Viscosity: See the table below. G008804 1 2 3 4 6 7 8 9 5 Figure 37 Note: Use of multi-grade oils (5W-20, 10W-30, or 10W-40) will increase oil consumption. Check the oil level more frequently when using them.
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 40). 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. Park the machine so that the rear is slightly lower than the front to ensure the oil drains completely. 2.
Servicing the Spark Plug Service Interval: Every 100 hours Make sure the air gap between the center and side electrodes is correct before installing the spark plug. Use a spark plug wrench for removing and installing the spark plug(s) and a gapping tool/feeler gauge to check and adjust the air gap. Install a new spark plug(s) if necessary. G008804 2 1 Type of Spark Plug: NGK® BPR4ES or equivalent Air Gap: 0.030 inch (0.75 mm) Removing the Spark Plug 3 1.
1 Check Spark Arrester (if equipped) 2 Service Interval: Every 50 hours WARNING 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. G008794 Figure 43 Installing the Spark Plug Do Not refuel or run engine unless spark arrester is installed. Tighten the spark plug(s) to 16 ft.-lb (22 N-m). 1 2 1.
Servicing the Fuel Tank Fuel System Maintenance Do not attempt to drain the fuel tank. Ensure that an Authorized Service Dealer drains the fuel tank and services any components of the fuel system. Replacing the Fuel Filter Service Interval: Every 500 hours/Yearly (whichever comes first) (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.
Electrical System Maintenance WARNING Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. Servicing the Battery • Always Disconnect the negative (black) battery cable before disconnecting the positive (red) cable. Service Interval: Monthly WARNING • Always Reconnect the positive (red) battery cable before reconnecting the negative (black) cable.
Installing the Battery 1. Position battery in the tray with the terminal posts opposite from the hydraulic tank (Figure 46). 2. First, install the positive (red) battery cable to positive (+) battery terminal. 3. Then install the negative (black) battery cable and ground wire to the negative (-) battery terminal. 4. Secure the cables with 2 bolts, 2 washers, and 2 locknuts (Figure 46). 5. Slide the red terminal boot onto the positive (red) battery post. 6.
Drive System Maintenance Checking the Seat Belt Service Interval: Before each use or daily Visually inspect seat belt for wear, cuts, and proper operation of retractor and buckle. Replace before operating if damaged. Checking the Rollover Protection System (ROPS) Knobs Service Interval: Before each use or daily WARNING To avoid injury or death from rollover: keep the roll bar in the fully raised locked position and use the seat belt. Ensure the seat is secured to the machine.
Checking the Wheel Lug Nuts Service Interval: After the first 8 hours Yearly Check and torque the wheel lug nuts to 90-100 ft-lb (122-136 N-m). Adjusting the Caster Pivot Bearing Service Interval: Every 500 hours/Yearly (whichever comes first) 1. Disengage the blade control switch (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.
Cooling System Maintenance The clutch is adjustable to ensure proper engagement and proper braking. 1. Insert a 0.015–0.021 inch (0.381–0.533 mm) feeler gauge through one inspection slot in the side of the assembly. Make sure it is between the armature and the rotor friction surfaces. Cleaning the Engine Screen Service Interval: Before each use or daily The gap needs to be at least .015 inches (0.381 mm) and not more than .021 inches (0.533 mm).
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.
8. Install the new belt around the engine pulley and the two drive pulleys. 2 3 1 4 5 6 Figure 57 1. Position the belt cover g017437 3. Ensure the tab is under the metal catch Figure 59 2. Slide belt cover under the side catches Replacing the Hydraulic Pump Drive Belt 1. Idler pulley 4. Pump drive belt 2. Idler spring post 5. Right hand hydraulic pump pulley 3. Engine pulley 6. Left hand hydraulic pump pulley 9. Install the clutch stop shown in Figure 58. 1.
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 wait for all moving parts to stop before leaving the operating position. 3. Loosen the bolts and flange nuts installed in the levers (Figure 60). 4.
13. Start engine. Brake must be engaged 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. 7. Slide the seat and seat plate forward to allow the front nuts to go through the key hole (Figure 62). 14. Run the unit at least 5 minutes with the drive levers at full forward speed to bring hydraulic oil up to operating temperature.
Adjusting the Motion Control Damper The top damper mounting bolt can be adjusted to obtain a more desired motion control lever resistance. See Figure 65 for mounting options. Figure 66 1. Flanged nut Figure 65 RH Motion Control Shown 1. Torque the lock nut to 200 in-lb (16.7 ft-lb). The bolt must protrude past end of locknut after torque. 2. Most resistance (firmest feel) 3. Damper 4. Medium resistance (medium feel) 5.
Hydraulic System Maintenance properly perform this procedure can result in irreparable damage to the transaxle drive system. Removing Hydraulic System Filters Servicing the Hydraulic System 1. Stop engine, wait for all moving parts to stop, and allow engine to cool. Remove the key and engage the parking brake. Hydraulic Oil Type: Toro® HYPR-OIL™ 500 hydraulic oil or 20W-50 engine oil. 2. Locate the filter and guards on each transaxle drive system (Figure 68).
1 2 3 4 5 Bleeding the Hydraulic System 1. Raise the rear of machine up and support with jack stands (or equivalent support) just high enough to allow drive wheels to turn freely. 6 g017625 1 Figure 70 1. Jacking points 2. Enter the operator's position. Start engine and move throttle control ahead to 1/2 throttle position. Disengage parking brake. 3/4 G008748 A. Move the bypass levers into the pushing the machine position; refer to the Pushing the Machine by Hand section in Operation.
Mower Deck Maintenance 6. Insert the height adjustment pin into the 3 inch (7.6 cm) cutting height location. 7. Release the transport lock and allow the deck to lower to the cutting height. Leveling the Mower Deck 8. Raise the discharge chute. Setting Up the Machine 9. On both sides of the deck, measure from the level surface to the front tip of the blade (Postion A). The measurement should read 3 inches (7.6 mm) (Figure 72).
bolts at least 1/3 the length of the available travel in their slots. This will regain some up and down adjustment on each of the four deck links. g017036 Figure 75 g017441 1. Single point adjustment bolt Figure 73 1. Whizlock nut 2. Adjuster screw 14. Tighten the two bolts at the bottom of the height of cut plate (Figure 74). Torque to 27-33 ft-lb (37-45 N-m). 3. Jam nut 4. Yoke Note: In most conditions, the back blade tip should be adjusted 1/4 inch (6.4 mm) higher than the front. 11.
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.
position, the blade is balanced and can be used. If the blade is not balanced, file some metal off the end of the sail area only (Figure 81). Repeat this procedure until the blade is balanced. by other manufacturers may result in non-conformance with safety standards. 1. To hold the spindle shaft, use an open end wrench (1-1/2) on the spindle shaft hex end. 2. Remove the blade bolt, curved washer, and blade from the spindle shaft (Figure 78). Figure 80 1. Blade 5 1 2 3 4 g017443 Figure 78 4.
Installing the Blades Removing the Mower Deck Important: The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting. Before servicing or removing the mower deck, the spring loaded deck arms must be locked out. 1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. 1. To hold the spindle shaft, use an open end wrench (1-1/2) on the spindle shaft hex end. 2.
6 2 4 7 3 1 5 g015594 Figure 84 2 g017417 1. Bolt 5. Spring installed 2. Spacer 6. Grass Deflector 3. Locknut 7. J hook end of spring 4. Spring Figure 83 2. Place spacer and spring onto grass deflector. Place one J end of spring behind deck edge. 1. Remove the rear deck lift attachment shoulder bolt and nut. 2. Remove the front deck lift attachment shoulder bolt and nut. Note: Make sure one J end of spring is installed behind deck edge before installing the bolt as shown in Figure 84. 8.
Cleaning Storage Cleaning Under the Mower 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. 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. 2. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine and hydraulic system.
C. Stop the engine, allow it to cool, and drain the fuel tank; refer to Servicing the Fuel Tank in the Maintenance Section. D. Restart the engine and run it until it stops. E. 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. 14. Paint all scratched or bare metal surfaces. Paint is available from your Authorized Service Dealer. 15.
Troubleshooting Problem Starter does not crank Engine will not start, starts hard, or fails to keep running Possible Cause 1. Blade control switch (PTO) is engaged. 1. Move blade control switch (PTO) to disengaged. 2. Parking brake is not on. 3. Drive levers are not in neutral lock position. 4. Operator is not seated. 5. Battery is dead. 6. Electrical connections are corroded or loose. 7. Fuse is blown. 8. Relay or switch is defective. 2. Set the parking brake. 3.
Problem Machine does not drive. Abnormal vibration. Uneven cutting height. Possible Cause 1. By pass valves is not closed tight. 1. Tighten the by pass valves. 2. 3. 4. 5. 2. 3. 4. 5. Pump belt is worn, loose or broken. Pump belt is off a pulley. Broken or missing idler spring. Hydraulic oil level is low or too hot. 1. Install new cutting blade(s). 2. Blade mounting bolt is loose. 3. Engine mounting bolts are loose. 4. Loose engine pulley, idler pulley, or blade pulley. 5. Engine pulley is damaged.
Schematics g018479 Wire Diagram (Rev.
Notes: 59
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.
