Form No. 3329–858 Z147 Z Master with 44in SFS Side Discharge Mower Model No. 74161—Serial No. 240000001 and Up Operator’s Manual Register your product at www.Toro.
Warning Starting and Stopping the Engine . . . . . . . . . . . . Operating the Power Take Off (PTO) . . . . . . . . . The Safety Interlock System . . . . . . . . . . . . . . . . Testing the Safety Interlock System . . . . . . . . . . Driving Forward or Backward . . . . . . . . . . . . . . . Stopping the Machine . . . . . . . . . . . . . . . . . . . . . Adjusting the Height-of-Cut . . . . . . . . . . . . . . . . Adjusting Anti-Scalp Rollers . . . . . . . . . . . . . . . . Positioning the Seat . . . . . . .
Introduction Safety Read this manual carefully to learn how to operate and maintain your product properly. The information in this manual can help you and others avoid injury and product damage. Although Toro designs and produces safe products, you are responsible for operating the product properly and safely. Improper use or maintenance by the operator or owner can result in injury.
• Use extreme care when loading or unloading the machine into a trailer or truck. • Use extra care when handling gasoline and other fuels. They are flammable and vapors are explosive. • Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision. • Use only an approved container • Never remove gas cap or add fuel with engine running. Allow engine to cool before refueling. Do not smoke. Slope Operation • Never refuel or drain the machine indoors.
• Check the area to be mowed and never fold the ROPS in areas where there are slopes, drop offs or water. • Lower the rollbar only when absolutely necessary. Do not wear the seat belt with the roll bar folded down. • Check carefully for overhead clearances (i.e. branches, doorways, electrical wires) before driving under any objects and do not contact them. Maintenance and storage • Disengage drives, lower implement, set parking brake, stop engine and remove key or disconnect spark plug wire.
Slope Chart 7
Safety and Instruction 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.
93-7818 43-8480 1. Warning—read the Operator’s Manual for instructions on torquing the blade bolt/nut to 115–149 N⋅m (85–110 ft-lb). 98-3798 66-1340 98-4387 67-5360 1. Warning—wear hearing protection.
65–2690 104-4163 1. Explosion hazard 2. No fire, open flames, or smoking. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 5. Read the Operator’s Manual. 6. Keep bystanders a safe distance from the battery. 104-8569 103–2644 107-2112 99-3943 1.
103-1997 104-4164 1. Contains lead; do not discard. 2. Recycle 3. Wear eye protection; explosive gases can cause blindness and other injuries 4. No sparks, flame, or smoking 12 5. Sulfuric acid can cause blindness or severe burns. 6. Flush eyes immediately with water and get medical help fast. 7. Maximum fill line 8. Minimum fill line 9.
107-2102 13
Gasoline and Oil Warning Gasoline is harmful or fatal if swallowed. Long-term exposure to vapors can cause serious injury and illness. Recommended Gasoline Use UNLEADED Regular Gasoline suitable for automotive use (85 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available. • Avoid prolonged breathing of vapors. • Keep face away from nozzle and gas tank or conditioner opening. • Keep gas away from eyes and skin.
Operation 2 Note: Determine the left and right sides of the machine from the normal operating position. 1 Using the Rollover Protection System (ROPS) m–6836 Figure 2 Warning 1. Full down position To avoid injury or death from rollover: keep the roll bar in the raised locked position and use the seat belt. Important Always use the seat belt with the roll bar in the raised position. Ensure that the rear part of the seat is secured with the seat latch.
7. Tighten the front handles against the center roll bar ends (Fig. 3). 2 1 1 m–6897 Figure 4 1. Front handle 3 Think Safety First m–6478 Figure 5 Please read all safety instructions and symbols in the safety section. Knowing this information could help you or bystanders avoid injury. 1. Safe Zone—use the Z Master here on slopes less than 15 degrees or flat areas. 2. Use walk behind mower and/or hand trimmer near drop–offs and water. 3.
Controls To use the right side fuel tank rotate the fuel shut off valve 1/4 turn to the right from the off location. This uses fuel from the right side tank only. When the right fuel tank is empty, move the fuel shut off valve 1/4 turn to the left from the off position. Become familiar with all the controls (Fig. 7) before you start the engine and operate the machine. 1 8 8 Close fuel shut off valve, on front panel before transporting or storing machine. 2 2 1 Figure 9 1.
Using the Blowout Baffles 7. After the engine starts, move the choke to off (Fig. 13). If the engine stalls or hesitates, move the choke back to on for a few seconds. Then move the throttle lever to desired setting. Repeat this as required. Blowout baffles are used when in side discharge mode only. Important Do not use blowout baffles while in recycling mode. 2 1 1. To install or remove blowout baffles, install or remove bolts as shown in Figure 11. 2 1 2 m–4201 m–2719 Figure 13 Figure 12 1.
The Safety Interlock System Important Make sure that the fuel shut off valve is closed before transporting or storing the machine, as fuel leakage may occur. Set the parking brake before transporting. Make sure to remove the key as the fuel pump may run and cause the battery to lose charge. Caution If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. Caution • Do not tamper with the interlock switches.
the engine is running, center either motion control and move (forward or reverse); the engine should stop. Repeat for other motion control. 2 3 5. Sitting on the seat, disengage the parking brake, move the PTO switch to off and move the motion control levers to neutral lock position. Try starting the engine; the engine should not crank. 1 4 Driving Forward or Backward m–2715 Figure 17 The throttle control regulates the engine speed as measured in rpm (revolutions per minute).
1. Raise the height-of-cut lever to the transport position (also the 4-1/2 inch (114 mm) cutting height position) (Fig. 18). 2. To adjust, remove hairpin cotter and clevis pin from height-of-cut bracket (Fig. 18). 1 3. Select hole in height-of-cut bracket corresponding to the height-of-cut desired, and insert clevis pin (Fig. 18). 1 4 4. Secure clevis pin with hairpin cotter (Fig. 18). 3 2 1 5 m–4167 Figure 19 2 1. Gage wheel 2. Stud 3. Washer 4. Nut 5. Wheel nut and washer. Do not remove.
Positioning the Seat Note: The machine will not drive unless by-pass valves are turned in. The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable. 1. To adjust, move the lever sideways to unlock seat (Fig. 21). 2. Slide the seat to the desired position and release lever to lock in position. 1 m–6279 Figure 22 1.
• Lock brake and block wheels. Warning • Securely fasten the machine to the trailer or truck with straps, chains, cable, or ropes. Loading a unit onto a trailer or truck increases the possibility of backward tip–over and could cause serious injury or death. • Secure a trailer to towing vehicle with safety chains. Warning • Use extreme caution when operating a unit on a ramp. • Use only a single, full width ramp; DO NOT use individual ramps for each side of the unit.
Tips for Mowing Grass Long Grass Fast Throttle Setting 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. For best mowing and maximum air circulation, operate the engine at fast.
Maintenance Recommended Maintenance Schedule Maintenance Service Interval After First 5 Hours Each Use Maintenance Procedure • Check hydraulic fluid level • Change engine oil • Change hydraulic filter • • • • Check oil level Check safety system Clean engine air intake1 Clean mower housing Every 5 Hours • Check cutting blades • Grease blade spindle bearings Every 25 Hours • • • • • • • • Every 40 Hours • Grease front tires Every 50 Hours • Check belts for wear/cracks Every 100 Hours • • • • Cha
Caution If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition and disconnect the wire from the spark plug(s) before you do any maintenance. Set the wire aside so that it does not accidentally contact the spark plug. Servicing the Cutting Blades Maintain sharp blades throughout the cutting season because sharp blades cut cleanly without tearing or shredding the grass blades.
1 MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE 2 3 4 5 m–2539 m–4318 Figure 26 Figure 27 1. Sail area of blade 2. Blade 3. Flat washer 2. Rotate the opposite ends of the blades forward. 3. Measure from a level surface to the cutting edge of the blades at the same position as in step 1 above. The difference between the dimensions obtained in steps 1 and 2 must not exceed 1/8 inch (3 mm). If this dimension exceeds 1/8 inch (3 mm), the blade is bent and must be replaced.
Installing the Blades 4. Carefully remove the foam element from the paper element (Fig. 30). 1. Install the blade onto the spindle shaft (Fig. 27). 5. Unscrew the wing nut and remove the paper element (Fig. 30). Important The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting. Cleaning the Foam Element 2. Install the flat washer, lock washer and blade bolt (Fig. 27). Torque the blade bolt to 85–110 ft-lb (115–150 N m). 1.
Installing the Foam and Paper Elements 4. Slide the oil dipstick fully into the filler tube, do not thread onto tube (Fig. 33). Pull the dipstick out and look at the end. If oil level is low, slowly pour only enough oil into the filler tube to raise the level to the full mark. Important To prevent engine damage, always operate the engine with the complete foam and paper air cleaner assembly installed. 1. Carefully slide the foam element into the paper air cleaner element (Fig. 30).
5. Fill the crankcase with the proper type of new oil; refer to Changing the Engine Oil, page 29. Servicing the Spark Plug 1 Check the spark plug(s) after every 100 operating 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.
2 3 1 2 0.040 inch (1.0 mm) 1 m–3215 M–4294 Figure 37 1. Center electrode insulator 2. Side electrode Figure 38 3. Air gap (not to scale) 1. Filter 2. Hose clamp Installing the Spark Plug(s) Servicing the Fuel Tank 1. Install the spark plug(s). Make sure the air gap is set correctly. Draining The Fuel Tank 2. Tighten the spark plug(s) to 11 ft-lb (15 N.m). Danger 3. Push the wire(s) onto the spark plug(s) (Fig. 36).
6. Install the fuel line onto the fuel filter. Slide the hose clamp close to the fuel filter to secure the fuel line (Fig. 39). 1 2 3 1 3 4 2 4 M–4294 Figure 39 1. Fuel shut-off valve 2. Fuel filter 3. Hose clamp 4. Fuel line m–4295 Figure 40 1. Air intake screen 2. Fan housing 3. Cylinder cover 4. Cylinder cover Cleaning the Cooling System Greasing and Lubrication Clean the air intake screen from grass and debris before each use.
Where to Add Grease 2. Grease the fittings on the three spindle bearings (Fig. 42). Lubricate the grease fittings as shown on the Check Service Reference Aid decal (Fig. 41). 3. Grease the idler pulley pivot (Fig. 42). 4. Grease the fittings on the push arms (Fig. 42). 1 M–4269 Figure 42 Where to Add Light Oil or Spray Lubrication Figure 41 Lubricate the machine in the following areas with spray type lubricant or light oil. Lubricate every 160 hours. • Seat switch actuator.
Adjusting the Caster Pivot Bearing 1 Check after every 500 operating hours or at storage, which ever comes first. m–1872 Figure 43 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 1. Valve stem 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Adjusting the Wheel Hub Slotted Nut 3. Remove dust cap from caster and tighten lock nut (Fig. 45).
Hydraulic System Oil Capacity: 67 oz. (2.0 l) Warning Note: There are two ways of checking the hydraulic oil. One is when the oil is warm and one is when the oil is cold. The baffle inside the tank has two levels depending if the oil is warm or cold. Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • If hydraulic fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury.
4. Apply a thin coat hydro fluid to the rubber gasket on the replacement filter (Fig. 48). 4. Check hydraulic fluid level and add as required to maintain proper level. 5. Install the replacement hydraulic filter onto the filter adapter. Do not tighten. 5. Repeat this procedure on the opposite wheel. Warning 6.
5. Move lever to the neutral position but not locked (Fig. 49). 6. Pull lever back until the clevis pin (on arm below pivot shaft) contacts the end of the slot (just beginning to put pressure on the spring) (Fig. 50). 8 1 7. Check where the control lever is relative to notch in console (Fig. 49). It should be centered allowing lever to pivot outward to the neutral lock position. 4 3 9 2 3 2 6 2 7 1 9 m–6282 Figure 49 1. Neutral locked position 2. Control lever 8 1 3.
Warning Engine must be running so motion control adjustment can be performed. Contact with moving parts or hot surfaces may cause personal injury. Keep hands, feet, face, clothing and other body parts away from rotating parts, muffler and other hot surfaces. 1 3 2 This adjustment must be made with drive wheels turning. m–6283 Figure 51 1. Raise the frame and block up the machine so drive wheels can rotate freely. 1. Tracking knob 2. Pump rod 2.
8. Remove jumper wire from wire harness connector and plug connector into seat switch. 2. Measure the length of the spring. Measurement should be 2-3/4 inch (70 mm) between washers (Fig. 53). 9. Reinstall prop rod and lower the seat into position. 3. If adjustment is necessary, loosen the jam nut below the spring and tighten the nut directly below the yoke (Fig. 53). Turn the nut until the correct measurement is obtained. Tighten the two nuts together and repeat on opposite side of unit. 10.
2 Danger Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns. • Do not drink electrolyte and avoid contact with skin, eyes or clothing. Wear safety glasses to shield your eyes and robber gloves to protect your hands. • Fill the battery where clean water is always available for flushing the skin. • Follow all instructions and comply with all safety messages on the electrolyte container. 1 Figure 54 1. Main—20 amp 2.
9 5 4 11 Warning 2 Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. 7 6 7 • 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. 3 8 10 1.
Note: Do not run the machine with the battery disconnected, electrical damage may occur. 5. Wait five to ten minutes after filling the battery cells. Add distilled water, if necessary, until the electrolyte level is up to the upper line (Fig. 55) on the battery case. Leveling the Mower at Three Positions 6. Reinstall battery vent caps. Charging the Battery Important There are only three measuring positions needed to level the mower.
F ront 9. Tighten the jam nut under the rear support arm and tighten the bolt securing the chain to the rear support arm. 10. Adjust the opposite side if needed. Adjusting the Front–to–Rear Mower Pitch 1. Position the right blade front-to-rear (Fig. 61). B C m–1078 2. Measure the right blade at the A location (Fig. 61), from a level surface to the cutting edge of the blade tip (Fig. 62). Figure 58 3. Record this measurement. 4. Measure the right blade at the B location (Fig.
9. Tighten both swivel jam nuts against the front swivel to lock the height. 1 3 4 10. Check to make sure there is equal tension on the chains and adjust again if needed. Adjusting the Compression Spring 2 1. Raise the mower lift lever to the transport position (Fig. 63). m–6273 Figure 64 2. Check the distance between the two large washers, it needs to be 10–1/4 inches (260 mm) (Fig. 63). 1. Push arm 2. 15-5/16 inch (389 mm) nominal 3.
2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 1 5 3. Remove belt covers over outside spindles. 3 4. Loosen outer nut on spring eye bolt (Fig. 65). 1 4 5 3 4 2 7 2 M–4269 Figure 66 Top View 6 1. Deck belt 2. Idler arm 3. Outside pulley M–4197 4. Spring 5. Idler pulley Figure 65 Top View 1. 2. 3. 4. Outer nut Idler pulley Idler arm Spring eye bolt Replacing the Pump Drive Belt 5. Spring 6. 9–3/8 inch ± 1/8 inch (238±.
4 5 8 1 3 6 4 2 3 5 1 6 2 7 m–4119 Figure 67 1. Clutch strap 2. Bolt 3. Clutch electrical wire m–5037 4. Belt 5. Idler 6. Clutch Figure 68 1. 2. 3. 4. 5. Replacing the Grass Deflector Warning Bolt Spacer Locknut Spring Spring installed 6. Grass Deflector 7. Place behind deck edge before installing bolt 8. Hook end of spring Waste Disposal 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.
Mercury Tilt Switch Disposal Several states have passed laws concerning the disposal of devices containing mercury. In all the remaining states it is advisable to follow similar procedures. The laws state that these sealed devices contain mercury and should not be placed in the garbage until the mercury is removed and reused, recycled or otherwise managed to insure that it does not become part of solid waste or waters. Management and disposal practices must be within relevant federal, state or local laws.
BK BK GND PTO CLUTCH GY SW5 DK.GN SHOWN WITH LEVER IN NEUTRAL POSITION LT.GN (NEUTRAL) LT.BU SHOWN WITH LEVER IN NEUTRAL POSITION LT.BU SW4 (NEUTRAL) SHOWN WITH PARK BRAKE DISENGAGED SW3 (BRAKE) SHOWN IN OFF POSITION DK.
Cleaning and Storage A. Add a petroleum based stabilizer/conditioner to fuel in the tank. Follow mixing instructions from stabilizer manufacture. Do not use an alcohol based stabilizer (ethanol or methanol). 1. Disengage the power take off (PTO), set the parking brake and turn the ignition key to off. Remove spark plug wire. Remove the key. Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline and used at all times. 2.
Troubleshooting Problem Starter does not crank Engine will not start, starts hard, or fails to keep running. Engine g loses power. Engine g overheats. Possible Causes Corrective Action 1. Blade control (PTO) is engaged. 1. Move blade control (PTO) to disengage. 2. Parking brake is not on. 2. Set parking brake. 3. Operator is not seated. 3. Sit on the seat. 4. Battery is dead. 4. Charge the battery. 5. Electrical connections are corroded or loose. 5.
Problem Machine does not drive. Abnormal vibration. Uneven cutting g height. g Blades do not rotate. Possible Causes Corrective Action 1. Traction belt is worn, loose or broken. 1. Contact Authorized Service Dealer. 2. Traction belt is off pulley. 2. Contact Authorized Service Dealer. 3. Hydro fluid level low. 3. Add hydro fluid to reservoir. 1. Engine mounting bolts are loose. 1. Tighten engine mounting bolts. 2. Loose engine pulley, idler pulley, or blade pulley. 2.
The Toro Total Coverage Guarantee LCE A Limited Warranty Conditions and Products Covered Owner Responsibilities The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair the listed Toro Products if defective in materials or workmanship. The following time periods apply from the date of purchase: You must maintain your Toro Product by following the maintenance procedures described in the operator’s manual.
