Form No. 3380-752 Rev A Z Master® Commercial 2000 Series Riding Mower with 48in, 52in, or 60in TURBO FORCE® Side Discharge Mower Model No. 74141—Serial No. 314000001 and Up Model No. 74143—Serial No. 314000001 and Up Model No. 74145—Serial No. 314000001 and Up Register at www.Toro.com.
Introduction 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. 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.
Servicing the Spark Plug ..........................................33 Checking the Spark Arrester (if equipped) ..................34 Fuel System Maintenance ...........................................35 Replacing the Fuel Filter..........................................35 Servicing the Fuel Tank ...........................................35 Electrical System Maintenance ....................................36 Servicing the Battery...............................................36 Servicing the Fuses .........
Preparation Safety • Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job. 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 pay attention to the safety alert symbol , which means Caution, Warning, or Danger—“personal safety instruction.” Failure to comply with the instructions may result in personal injury or death.
Maintenance and Storage • Keep pets and bystanders away from an operating machine. • Disengage drives, set the parking brake, stop the engine, • Slow down and use caution when making turns and and remove the key or disconnect spark-plug wire. Wait for all movement to stop before adjusting, cleaning, or repairing. crossing roads and sidewalks. Stop the blades if you are not mowing. • Be aware of the mower-discharge direction and do not • Park the machine on a level surface. point it at anyone.
General Operation Using the Rollover Protection System (ROPS) • Be sure that the area is clear of bystanders before mowing. Stop the machine if anyone enters the area. • The ROPS is an integral and effective safety device. Keep the ROPS in the raised and locked position and use the seat belt when operating the machine. • Do not touch equipment or attachment parts which may be hot from operation. Allow all of the parts to cool before attempting to maintain, adjust, or service the machine.
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.
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. 10. Contains lead; do not discard.
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 5). Throttle Control 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.
Specifications Note: Specifications and design are subject to change without notice. Width: 48-inch Deck 52-inch Deck 60-inch Deck Without Deck 115.1 cm (45.3 inches) 119.4 cm (47 inches) 134.6 cm (50.5 inches) Deflector Up 130.8 cm (51.5 inches) 135.4 cm (53.3 inches) 156.0 cm (61.4 inches) Deflector Down 160.3 cm (63.1 inches) 171.8 cm (67.2 inches) 191.3 cm (75.3 inches) Length: 48-inch Deck 52-inch Deck 60-inch Deck Roll Bar - Up 199.6 cm (78.6 inches) 201.7 cm (79.4 inches) 210.
Operation DANGER 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 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 additional load on the engine. Allow 40 to 50 hours of break-in time for new machines to develop full power and best performance. Filling the Fuel Tank Note: Do not fill the fuel tank completely full. Fill the fuel tank to the bottom of the filler neck.
DANGER Operating on wet grass or steep slopes can cause sliding and loss of control. Wheels dropping over edges can cause rollovers, which may result in serious injury, death or drowning. There is no rollover protection when the roll bar is down. Always keep the roll bar in the raised and locked position and use the seat belt. Read and follow the rollover protection instructions and warnings. To avoid loss of control and possibility of rollover: • Do not operate near drop-offs or near water.
Operating the Mower Blade-control Switch (PTO) The use of protective equipment for eyes, ears, feet, and head is recommended. 1 2 The blade-control switch (PTO) starts and stops the mower blades and any powered attachments. Engaging the Blade-control Switch (PTO) G009027 Figure 9 1. Wear safety glasses Note: Engaging the blade-control switch (PTO) with the throttle position at half or less will cause excessive wear to the drive belts. 2.
Operating the Throttle Operating the Ignition Switch 1. Turn the ignition key to the Start position (Figure 16). The throttle control can be moved between Fast and Slow positions (Figure 14). Note: When the engines starts, release the key. Always use the Fast position when turning on the mower deck with the blade-control switch (PTO). 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.
Using the Fuel Shut-off Valve The fuel shut-off valve is located behind the seat. Close the fuel shut-off valve for transport, maintenance, and storage. Ensure that the fuel shut-off valve is open when starting the engine. G017428 1 2 Figure 18 6. Turn the ignition key to the Start position (Figure 19). Note: When the engines starts, release the key. G008948 Figure 17 1. On position Important: Do not engage starter for more than 5 seconds at a time.
Stopping the Engine Using the Safety-interlock System CAUTION Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. CAUTION 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.
Driving Forward (forward or reverse); the engine should stop. Repeat for other motion control. 5. Sitting on the seat, disengage the parking brake, move the blade-control switch (PTO) to the Off position, and move the motion-control levers to neutral-lock position. Try starting the engine; the engine should not crank. 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.
Driving Backward 1. Move the levers to the center, unlocked position. 2. To go backward, slowly pull the motion-control levers rearward (Figure 23). G008953 Figure 23 Stopping the Machine To stop the machine, move the traction-control levers to neutral, and then 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).
Adjusting the Height-of-Cut Pin Mower deck size Height-of-cut range Increments 48-inch deck 38 to 127 mm (1-1/2 6 mm (1/4 inch) to 5 inches) 52-inch and 60-inch 38 to 140 mm (1-1/2 6 mm (1/4 inch) decks to 5-1/2 inches) 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.
Using the Drive-wheel-release Valves 6. To run the machine, move the bypass levers to the forward position (Figure 29). Using the Side Discharge WARNING The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. Hands may become entangled in the rotating drive components below the engine deck, which could result in serious injury. DANGER Stop the engine, remove the key, and allow all moving parts to stop before accessing the drive-wheel-release valves.
Transporting Machines WARNING Loading a unit onto a trailer or truck increases the possibility of backward tip-over and could cause serious injury or death. Use a heavy-duty trailer or truck to transport the machine. 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, your family, pets or bystanders avoid injury.
Cutting Long Grass Operating Tips If the grass is ever allowed to grow slightly longer than normal, or if it contains a high degree of moisture, raise the cutting height higher than usual and cut the grass at this setting. Then cut the grass again using the lower, normal setting. Using the Fast Throttle Setting For best mowing and maximum air circulation, operate the engine at the Fast throttle position.
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. Inspect the blades. Clean the mower deck.
Lubrication Greasing the Mower Greasing and Lubrication Service Interval: Every 50 hours—Grease the mower deck idler arm. Yearly—Grease the front caster pivots (more often in dirty or dusty conditions). Grease more frequently when operating conditions are extremely dusty or sandy. 1. Disengage the blade-control switch (PTO), move the motion-control levers to the neutral-locked position, and set the parking brake. Grease Type: No. 2 general-purpose lithium base or molybdenum-base grease 2.
Lubricating the Caster-wheel Hubs 14. Torque the nut to 8 to 9 N-m (75 to 80 in-lb), loosen, then torque to 2 to 3 N-m (20 to 25 in-lb). Note: Make sure axle does not extend beyond either nut. Service Interval: Yearly 1. Stop the engine, wait for all moving parts to stop, remove the key, and engage the parking brake. 15. Install the seal guards over the wheel hub, and insert wheel into the caster fork. 16. Install the caster bolt and tighten the nut fully.
Engine Maintenance 6. Remove the safety filter only if you intend to replace it. Important: Do not attempt to clean the safety filter. If the safety filter is dirty, then the primary filter is damaged. Replace both filters. WARNING Contact with hot surfaces may cause personal injury. 7. Inspect the primary filter for damage by looking into the filter while shining a bright light on the outside of the filter. Holes in the filter will appear as bright spots. If the filter is damaged, discard it.
Servicing the Engine Oil Oil Type: Detergent oil (API service SF, SG, SH, SJ, or SL) Crankcase Capacity: with a filter change, 2.1 L (71 oz); without a filter change, 1.8 L (61 oz) 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. Start the engine and let it run for 5 minutes. Note: 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.
Checking the Spark Plug Checking the Spark Arrester (if equipped) Important: Do not clean the spark plug(s). Always replace the spark plug(s) when it has: a black coating, worn electrodes, an oily film, or cracks. Service Interval: Every 50 hours If you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means the air cleaner is dirty. WARNING Hot exhaust system components may ignite gasoline vapors even after the engine is stopped.
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 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. Servicing the Battery 3. Disconnect the negative battery cable (black) from the negative (-) battery terminal (Figure 46). Service Interval: Monthly 4.
Installing the Battery 1. Position the battery in the tray with the terminal posts opposite from the hydraulic tank (Figure 46). 2. Install the positive (red) battery cable to positive (+) battery terminal. 3. 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 the seat belt for wear, cuts, and proper operation of retractor and buckle. Replace it before operating if it is 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 122 to 136 N-m (90 to 100 ft-lb). 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.
Adjusting the Electric Clutch Service Interval: Every 500 hours—Check the electric clutch. Cooling System Maintenance The clutch is adjustable to ensure proper engagement and proper braking. Cleaning the Engine Screen Service Interval: Before each use or daily 1. Insert a 0.38 to 0.53 mm (0.015–0.02 inch) feeler gauge through one inspection slot in the side of the assembly. Before each use remove any build-up of grass, dirt or other debris from the engine screen.
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 2 drive pulleys. 2 3 1 4 5 6 Figure 57 1. Position the belt cover g017437 3. Ensure that the tab is under the metal catch Figure 59 2. Slide the 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 (Figure 58). 1.
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 60). 4.
5. Move the seat to the furthest forward position to expose the rear nuts. 11. Remove the electrical connection from the seat safety switch, located under the bottom cushion of the seat. Note: The switch is a part of the seat assembly. 6. Loosen the rear nuts. 12. Temporarily install a jumper wire across the terminals in the connector of the main wiring harness. Note: The nuts do not need to be removed. 7.
Adjusting the Motion Control Neutral-lock Pivot 21. Install the seat. 22. Remove the jack stands. 23. Raise the deck and install the height-of-cut pin. 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 66 for adjustment options. 24. Ensure that the machine does not creep in neutral with the parking brakes disengaged. 1. Loosen the jam nut. Adjusting the Motion-control Damper 2.
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 the engine, wait for all moving parts to stop, allow the 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). Important: Use oil specified.
Bleeding the Hydraulic System 3. Repeat for the other filter. 4. Install the filter guards over each filter as previously removed. 5. Use the 3 screws to secure the filter guards. 6. Verify that the vent plugs are removed before adding the oil. 7. Slowly pour the specified oil through the expansion reservoir until oil comes out of one of the vent-plug holes. 8. Stop and install that vent plug. 9. Torque the plug to 20 N-m (15 ft-lb). 10.
Mower Deck Maintenance 6. Insert the height adjustment pin into the 7.6 cm (3 inches) cutting height location. 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) as shown in Figure 72. 7. Release the transport lock and allow the deck to lower to the cutting height. Note: Ensure that the mower deck is leveled before matching the height-of-cut (HOC). 1.
g017036 Figure 75 1. Single-point adjustment bolt 14. Tighten the 2 bolts at the bottom of the height-of-cut plate (Figure 74). T g017441 Figure 73 1. Whizlock nut 2. Adjuster screw Note: In most conditions, the back blade tip should be adjusted 6.4 mm (1/4 inch) higher than the front. 3. Jam nut 4. Yoke 15. Torque the 2 bolts to 37 to 45 N-m (27 to 33 ft-lb). 16. On both sides of the deck, measure from the level surface to the back tip of the blade (postion B) as shown in Figure 72. 12.
Checking for Bent Blades Servicing the Cutting Blades 1. Disengage the PTO, move the motion-control levers to the neutral-locked position, and set the parking brake. 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. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. WARNING 3. Rotate the blades until the ends face forward and backward.
Removing the Blades Note: If the blade stays in a horizontal position, the blade is balanced and can be used. Blades must be replaced if a solid object is hit, if the blade is out of balance, or if the blade is bent. To ensure optimum performance and continued safety conformance of the machine, use genuine Toro replacement blades. Replacement blades made by other manufacturers may result in nonconformance with safety standards. Figure 80 1. Hold the blade end using a rag or a thickly-padded glove. 1.
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 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. 1. Stop the engine, wait for all moving parts to stop, remove the key, and engage the parking brake. 2.
Replacing the Grass Deflector WARNING An uncovered discharge opening could allow the lawn mower to throw objects in the operator's or bystander's direction and result in serious injury. Also, contact with the blade could occur. Do not operate the lawn mower unless you install a cover plate, a mulch plate, grass deflector or bagger. 1. Remove the locknut, the bolt, the spring, and the spacer holding the deflector to the pivot brackets (Figure 84). 2. Remove the damaged or worn grass deflector (Figure 84).
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. 2. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine and hydraulic system. Clean dirt and chaff from the outside of the engine-cylinder-head fins and blower housing. Service Interval: Before each use or daily 1.
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. Store the machine in a clean, dry garage or storage area.
Troubleshooting Problem The starter does not crank. The engine does 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 the disengaged position. 2. The parking brake is not on. 3. The motion-control levers are not in the 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.
Problem The machine does not drive. The machine vibrates abnormally. The machine produces an uneven cutting height. Possible Cause 1. The bypass valves are not closed tight. 1. Tighten the bypass valves. 2. The pump belt is worn, loose, or broken. 3. The pump belt is off a pulley. 4. The idler spring is broken or missing. 5. The hydraulic oil level is low or too hot. 2. Change the belt. 1. Install new cutting blade(s). 2. The blade mounting bolt is loose. 3. The engine mounting bolts are loose. 4.
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 Instructions for Obtaining Warranty Service 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.
