Form No. 3372-548 Rev C Z Master® Riding Mower with 48in, 52in or 60in TURBO FORCE® Side Discharge Mower Model No. 74141—Serial No. 312000001 and Up Model No. 74143—Serial No. 312000001 and Up Model No. 74145—Serial No. 312000001 and Up To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com.
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. WARNING CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage.
Lubricate the Caster Wheel Hubs........................ 29 Engine Maintenance............................................... 30 Servicing the Air Cleaner .................................... 30 Servicing the Engine Oil ..................................... 31 Servicing the Spark Plug ..................................... 33 Check Spark Arrester (if equipped)...................... 34 Fuel System Maintenance ....................................... 35 Replacing the Fuel Filter .................................
Safety • Use extra care when handling gasoline and other fuels. They are flammable and vapors are explosive. 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.
• Be aware of the mower discharge direction and do not point it at anyone. • Do not operate the mower under the influence of alcohol or drugs. • Use extreme care when loading or unloading the machine into a trailer or truck. • Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision. • Be certain that the seat belt can be released quickly in the event of an emergency. • Be aware there is no rollover protection when the roll bar is down.
• Keep all parts in good working condition and all hardware tightened. Replace all worn or damaged decals. • Use only Toro approved attachments. Warranty may be voided if used with unapproved attachments.
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.
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. 114-4466 1. Main, 25A 3. Charge, 25A 2. PTO, 10A 4.
116-3303 117–1158 1. Bypass lever position for operating the machine. 2. Bypass lever position for pushing the machine. 116-4858 117-8639 1. Belt routing 2. Grease pulley, maintenance interval—50 hours 116-5988 1. Parking brake—engaged 2. Parking brake—disengaged 119-2501 1. Choke 2. Fast 10 3. Slow 4.
121–3223 120-2522 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.
Product Overview 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. Pull the switch up to engage the blades and release.
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) Deflector Up 51.5 inches (130.8 cm) 53.3 inches (135.4 cm) 61.4 inches (156.
Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline. To minimize the chance of varnish deposits in the fuel system, use fuel stabilizer at all times. 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.
Checking the Engine Oil Level Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking the Engine Oil Level. 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.
DANGER CAUTION Operating on wet grass or steep slopes can cause sliding and loss of control. This machine produces sound levels in excess of 85 dBA at the operators ear and can cause hearing loss through extended periods of exposure. Wheels dropping over edges can cause rollovers, which may result in serious injury, death or drowning. Wear hearing protection when operating this machine. There is no rollover protection when the roll bar is down.
Releasing the Parking Brake 1 Operating the Throttle 2 The throttle control can be moved between Fast and Slow positions (Figure 14). Always use the fast position when turning on the mower deck with the blade control switch (PTO). G017427 Figure 11 G008946 Operating the Mower Blade Control Switch (PTO) Figure 14 The blade control switch (PTO) starts and stops the mower blades and any powered attachments. Operating the Choke Use the choke to start a cold engine.
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 tractor 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 the motion control levers to neutral lock position. Now start the engine. While the engine is running, center either motion control and move (forward or reverse); the engine should stop. Repeat for other motion control. CAUTION If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. 5.
Using the Motion Control Levers G008952 Figure 22 Figure 21 Driving Backward 1. Motion control lever-neutral lock position 4. Backward 1. Move the levers to the center, unlocked position. 2. Center, unlocked position 5. Front of machine 2. To go backward, slowly pull the motion control levers rearward (Figure 23). 3. Forward Driving Forward Note: The engine will kill if the traction control levers are moved with the parking brake engaged.
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. Set the parking brake when you leave the machine; refer to Setting the Parking Brake 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 tractor while it is unattended.
Adjusting the Height-of-Cut Pin 1. Disengage the blade control switch (PTO), move the motion control levers to the neutral locked position and set the parking brake. 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) 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
G008962 Figure 28 1 2 3 4 Using the Drive Wheel Release Valves g017420 WARNING Figure 29 Hands may become entangled in the rotating drive components below the engine deck, which could result in serious injury. 5. To run the machine, move the bypass levers to the forward position (Figure 29). Stop the engine, remove the key, and allow all moving parts to stop before accessing the drive wheel release valves.
individual ramps for each side of the unit (Figure 30). The lower rear section of the tractor frame extends back between the rear wheels and serves as a stop for tipping backward. Having a full width ramp provides a surface for the frame members to contact if the unit starts to tip backward. If it is not possible to use one full width ramp, use enough individual ramps to simulate a full width continuous ramp. The ramp should be long enough so that the angles do not exceed 15 degrees (Figure 30).
Mow at Correct Intervals Normally, mow every four days. But remember, 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 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 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. 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.
8. If the axle assembly has had both spacer nuts removed (or broken loose), apply a thread locking adhesive to one spacer nut and thread onto the axle with the wrench flats facing outward. Do Not thread spacer nut all of the way onto the end of the axle. Leave approximately 1/8 inch (3 mm) from the outer surface of the spacer nut to the end of the axle inside the nut. 9. Insert the assembled nut and axle into the wheel on the side of the wheel with the new seal and bearing. g014942 Figure 34 10.
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. 1. Air cleaner clamps 3. Primary air filter 2. Air cleaner cover 4. Secondary air filter Every 500 hours—Replace the secondary air filter.
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) G008804 Viscosity: See the table below. 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) 3 Removing the Spark Plug 4 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.
Fuel System Maintenance Note: It is important to reinstall the fuel line hoses and secure with plastic ties the same as they were originally installed at the factory to keep the fuel line away from components that could cause fuel line damage. Replacing the Fuel Filter Servicing the Fuel Tank Service Interval: Every 500 hours/Yearly (whichever comes first) (more often in dirty or dusty conditions). Do not attempt to drain the fuel tank.
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. • Always Disconnect the negative (black) battery cable before disconnecting the positive (red) cable. • 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. Figure 47 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.
7. If it tracks to the left, loosen the bolts and adjust the right stop plate rearward on the right T-slot until the machine tracks straight (Figure 50). 8. Tighten the stop plate (Figure 50). Figure 51 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.
Figure 53 1. Adjusting nut 2. Slot Figure 52 1. Spring Washers 3. Dust Cap 2. Lock Nut Adjusting the Electric Clutch Service Interval: Every 500 hours—Check the electric clutch. 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. The gap needs to be at least .015 inches (0.381 mm) and not more than .
Cooling System Maintenance Cleaning the Engine Screen Service Interval: Before each use or daily Before each use remove any build-up of grass, dirt or other debris from the engine screen. This will help insure adequate cooling and correct engine speed and will reduce the possibility of overheating and mechanical damage to the engine (Figure 54). Cleaning the Engine Cooling Fins and Shrouds Service Interval: Every 100 hours/Yearly (whichever comes first) Figure 54 1.
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. Figure 61 3. Loosen the bolts and flange nuts installed in the levers (Figure 60).
7. Slide the seat and seat plate forward to allow the front nuts to go through the key hole (Figure 62). 12. Temporarily install a jumper wire across the terminals in the connector of the main wiring harness. 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. 1 2 14.
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). 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 Failure to properly perform this procedure can result in irreparable damage to the transaxle drive system. Servicing the Hydraulic System Removing Hydraulic System Filters 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).
hydraulic filters and oil can result in irreparable damage to the transaxle drive system. 2 1 Bleeding the Hydraulic System 3 5 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. 4 6 g017625 1 Figure 70 1. Jacking points 3/4 G008748 2. Enter the operator's position. Start engine and move throttle control ahead to 1/2 throttle position. Disengage parking brake. A.
Mower Deck Maintenance 3 Leveling the Mower Deck 1 Setting Up the Machine Note: Ensure the mower deck is leveled before matching the height-of-cut (HOC). 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. g017419 Figure 71 3. Transport lock 1. Deck lift pedal 3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 2.
To increase the height, turn the adjuster screw clockwise; to decrease, turn counterclockwise. is too high, loosen the single point adjustment bolt by rotating it counterclockwise (Figure 75). 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 will regain some up and down adjustment on each of the four deck links. g017441 g017036 Figure 73 1. Whizlock nut 2.
Servicing the Cutting Blades Checking for Bent Blades 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. 1. Disengage the blade control switch (PTO), move the motion control levers to the neutral locked position and set the parking brake. 2.
performance and continued safety conformance of the machine, use genuine Toro replacement blades. Replacement blades made 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. Figure 79 2. Remove the blade bolt, curved washer, and blade from the spindle shaft (Figure 78). 1. Sharpen at original angle 2. Check the balance of the blade by putting it on a blade balancer (Figure 80).
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. 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.
B. Run the engine to distribute conditioned fuel through the fuel system (5 minutes). 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.
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.
The Toro Total Coverage Warranty A Limited Warranty (see warranty periods below) Conditions and Products Covered 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. The following time periods apply from the date of purchase by the original owner: Products 21 in.
