Form No. 3329–882 Z147 Z–Master with 112cm Mower Model No. 74161TE—Serial No. 240000001 and Up Operator’s Manual Register your product at www.Toro.
This spark ignition system complies with Canadian ICES-002. Recommended Maintenance Schedule . . . . . . . . Servicing the Cutting Blades . . . . . . . . . . . . . . . . Servicing the Air Cleaner . . . . . . . . . . . . . . . . . . Servicing the Engine Oil . . . . . . . . . . . . . . . . . . . Servicing the Spark Plug . . . . . . . . . . . . . . . . . . . Servicing the Fuel Filter . . . . . . . . . . . . . . . . . . . Servicing the Fuel Tank . . . . . . . . . . . . . . . . . . . .
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. Safe Operation Practices for Ride-on (riding) Rotary Lawnmower Machines This machine meets or exceeds European Standards in effect at the time of production.
• lack of awareness of the effect of ground conditions, especially slopes; • Watch out for traffic when crossing or near roadways. • Stop the blades rotating before crossing surfaces other than grass. • incorrect hitching and load distribution. • When using any attachments, never direct discharge of material toward bystanders nor allow anyone near the machine while in operation. Preparation • While mowing, always wear substantial footwear and long trousers.
• Check carefully for overhead clearances (i.e. branches, doorways, electrical wires) before driving under any objects and do not contact them. Slope Operation • Do not mow slopes greater than 15 degrees. • Do not mow near drop–offs, ditches, steep banks or water. Wheels dropping over edges can cause rollovers, which may result in serious injury, death or drowning. Maintenance and Storage • Keep all nuts, bolts and screws tight to be sure the equipment is in safe working condition.
Sound Pressure This unit has a maximum sound pressure level at the operator ’s ear of 87 dBA, based on measurements of identical machines per Directive 98/37/EC. Sound Power This unit has a guaranteed sound power level of 100 dBA, based on measurements of identical machines per Directive 2000/14/EC. Vibration This unit does not exceed a hand/arm vibration level of 3.9 m/s2, based on measurements of identical machines per Directive 98/37/EC. This unit does not exceed a whole body vibration level of 0.
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. 93-7828 1. Thrown object hazard, mower—do not operate the mower with the deflector up or removed; keep the deflector in place. 2. Cutting/dismemberment hazard of hand or foot, mower blade—stay away from moving parts. 93-7316 1. Thrown object hazard—stay a safe distance from the machine. 2.
98-1977 1. Entanglement hazard, belt—stay away from moving parts. 99-8937 1. Right side fuel tank open 2. Fuel tank shut off 99-3943 3. Left side fuel tank open 99-8939 1. Engine 1. Read the Operator’s Manual. 2. Height of cut 3. Remove the ignition key and read the instructions before servicing or performing maintenance. 99-8936 1. Machine speed 2. Fast 3. Slow 4. Neutral 5. Reverse 99-8941 1.
99-8942 1. Height of cut 99-8940 1. Read the instructions before servicing or performing maintenance. 2. Hydraulic oil 99-8944 1. Explosion hazard—wear eye protection. 2. Caustic liquid/chemical burn hazard—to perform first aid, flush with water. 3. Fire hazard—no fire, open flames, or smoking. 4. Poison hazard—keep children away from the battery. 3. 4. 5. 6. Engine Tire pressure Hourly interval Grease 104-4163 98-1977 1. Explosion hazard 2. No fire, open flames, or smoking. 3.
105-6183 1. 2. 3. 4. Read the Operator’s Manual. Rotate the bypass valve out to push the machine. Rotate the bypass valve in to drive the machine. Use a wrench to rotate the bypass valve. 107-2131 1. Hydraulic oil level 2. Warning—do not touch the hot surface. 107-2132 106-5517 1. Warning—engage the parking brake and chock the wheels when parking on a hill. 1. Warning—do not touch the hot surface. 107-1866 1.
106-6590 1. 2. 3. 4. Disengage Parking brake Engage Warning—read the Operator’s Manual; do not use drugs or alcohol; receive training; wear hearing protection; and, before leaving the machine, set the control levers in the Neutral position, engage the parking brake, and remove the ignition key. 5. 6. 7. 8. 9. 10. Power takeoff (PTO) Engine—stop Engine—run Engine—start Choke Read the Operator’s Manual. 11. 12. 13. 14.
107-3069 1. Warning—in a roll over accident without the roll bar raised and seat belt used, you will be injured or killed; in a roll over accident with the roll bar raised and seat belt used, you may be uninjured. 2. To mow under obstacles, lower the roll bar and do not wear the seat belt; at all other times, always raise the roll bar and wear the seat belt. 3. Read the Operator’s Manual, and slow down and turn gradually.
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 The unit has two fuel tanks. One tank is on the left side and one on the right side. Each tank connects to the fuel shut off valve in the control panel. From there a common fuel line leads to the engine (Fig. 7). Become familiar with all the controls (Fig. 7) before you start the engine and operate the machine. 1 8 8 To use the left side fuel tank rotate the fuel shut off valve to the LH, lefthand location.
6. Thoroughly clean mower deck. All debris must be removed to ensure baffle will fit properly against mower deck. 1 7. Repair all bent or damaged areas of mower deck and replace any missing parts. 2 Installing or Removing Blades 1. Remove blades and anti-scalp cups from spindles. Save for use when side discharging. 2. Install new recycler blades without anti-scalp cups. m–4121 Important The sail part of the blades (i.e., the turned up section) must face the inside of the mower. Figure 10 1.
Installing and Removing Kickers 2. Place the left side baffle and the right side baffle inside the cutting chamber so the extended lugs are interlocked. Secure them with 4 locknuts (5/16 inch) and 4 lock washers (Fig. 12). 3 The following instructions are for removing and installing kickers. The kickers are used for mulching only. The following procedures are written as though you were to install the kickers. Reverse the procedures to remove them. 3 Important The kickers are used only for mulching.
5. Rotate the blades to ensure that there is at least an 1/8 inch (3 mm) clearance between the blades and kickers. 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. Note: If a kicker interferes with a blade, reposition it further up into the mower. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 6. Turn mower deck over and install belt covers. 3.
2 Warning 1 A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders. 2 • Always replace a bent or damaged blade with a new blade. • Never file or create sharp notches in the edges or surfaces of the blade. 1 m–4201 m–2719 Figure 16 Figure 17 1. PTO—On 2. PTO—Off Starting and Stopping the Engine 1. Choke—On 2. Choke—Off Starting the Engine 1. Sit down on the seat and move the motion controls to neutral locked position. 1 1 2 2.
• You are sitting on the seat. Operating the Power Take Off (PTO) • The parking brake is engaged. • The power take off (PTO) is disengaged. The power take off (PTO) switch engages and disengages power to the electric clutch. • The motion control levers are in neutral locked position.
Driving Backward Warning 1. Move levers to the center, unlocked position. Machine can spin very rapidly. Operator may lose control of machine and cause personal injury or damage to machine. 2. To go backward, slowly pull the motion control levers rearward (Fig. 21). To go straight, apply equal pressure to both motion control levers (Fig. 21). • Use caution when making turns. • Slow the machine down before making sharp turns.
1 2 3 1 4 3 2 5 m–4122 m–4167 Figure 22 1. Height-of-cut lever 2. Clevis pin Figure 23 3. Hairpin cotter 1. Gage wheel 2. Stud 3. Washer 4. Nut 5. Wheel nut and washer. Do not remove. 5. Lower height-of-cut lever onto clevis pin. Center Rollers Adjusting Anti-Scalp Rollers 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. Whenever you change the height-of-cut it is recommended to adjust the height of the anti-scalp rollers. 1.
Positioning the Seat Pushing the Machine by Hand The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable. Important Always push the machine by hand. Never tow the machine because hydraulic damage may occur. 1. To adjust, move the lever sideways to unlock seat (Fig. 25). To Push the Machine 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2.
Danger Warning Without the grass deflector, discharge cover, or complete grass catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris. Contact with rotating mower blades and thrown debris will cause injury or death. Driving on street or roadway without turn signals, lights, reflective markings, or a slow moving vehicle emblem is dangerous and can lead to accidents causing personal injury. Do not drive machine on a public street or roadway.
Tips for Mowing Grass Warning Fast Throttle Setting Loading a unit onto a trailer or truck increases the possibility of backward tip–over and could cause serious injury or death. For best mowing and maximum air circulation, operate the engine at fast. Air is required to thoroughly cut grass clippings, so do not set the height-of-cut so low as to totally surround the mower by uncut grass. Always try to have one side of the mower free from uncut grass, which allows air to be drawn into the mower.
Long Grass 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. When Stopping If the machine’s forward motion must be stopped while mowing, a clump of grass clippings may drop onto your lawn. To avoid this, move onto a previously cut area with the blades engaged.
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 engine 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 • • •
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 plugs 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.
Front Warning Contact with sharp blade can cause serious injury. Wear gloves or wrap sharp edges of the blade with a rag. Hold the blade end using a rag or thickly-padded glove. Remove the blade bolt, flat washer, split lock washer, and blade from the spindle shaft (Fig. 32). m–1078 Figure 30 1 2 3 4 MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE 5 m–4318 m–2539 Figure 32 Figure 31 1. Sail area of blade 2. Blade 3. Flat washer 4. Rotate the opposite ends of the blades forward. 5.
blade is not balanced, file some metal off the end of the sail area only (Fig. 32). Repeat this procedure until the blade is balanced. 3 5 4 1 2 1 m–1855 Figure 34 1. Blade 2 2. Balancer 6 m–4289 Installing the Blades Figure 35 1. Cover 2. Foam element 3. Paper element 1. Install the blade onto the spindle shaft (Fig. 32). Important The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting. 4. Wing nut 5. Air cleaner base 6. Latches 4.
Checking the Engine Oil Level Important Never clean the paper element with pressurized air or liquids, such as solvent, gas, or kerosene. Replace the paper element if it is damaged or cannot be cleaned thoroughly. 1. Park the machine on a level surface. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Clean around the oil dipstick (Fig. 38) so dirt cannot fall into the filler hole and damage the engine.
5. When oil has drained completely, close the drain valve (Fig. 39). Note: Dispose of the used oil at a certified recycling center. 1 2 M–4288 Figure 40 1 1. Oil filter m–4674 2. Adapter Figure 39 4. Install the replacement oil filter to the adapter. Turn the oil filter clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 3/4 turn (Fig. 40). 1. Oil drain valve 6. Slowly pour approximately 80% of the specified oil into the filler cap (Fig. 38).
Installing the Spark Plugs 1. Install the spark plugs. Make sure the air gap is set correctly. 1 2. Tighten the spark plugs to 11 ft.-lb. (15 N.m). 3. Push the wires onto the spark plugs (Fig. 41). 2 Servicing the Fuel Filter Replace the fuel filter after every 200 operating hours or yearly, whichever occurs first. M–4294 Figure 41 1. Spark plug wire installed Replacing the Fuel Filter 2. Spark plug Never install a dirty filter if it is removed from the fuel line. Checking the Spark Plugs 1.
Note: Now is the best time to install a new fuel filter because the fuel tank is empty. 2 6. Install the fuel line onto the fuel filter. Slide the hose clamp close to the fuel filter to secure the fuel line (Fig. 44). 1 3 M–4294 Figure 43 1. Filter 1 2. Hose clamp Servicing the Fuel Tank 4 2 Draining The Fuel Tank M–4294 Figure 44 1. Fuel shut-off valve 2. Fuel filter Danger In certain conditions, gasoline is extremely flammable and highly explosive.
1 2 3 4 m–4295 Figure 46 Figure 45 1. Air intake screen 2. Fan housing 3. Cylinder cover 4. Cylinder cover Grease Front Caster Pivots Lubricate the front caster pivots once a year. Greasing and Lubrication 1. Remove the dust cap and adjust the caster pivots. Keep dust cap off until greasing is done. Lubricate the machine when shown on the Check Service Reference Aid decal (Fig. 46). Grease more frequently when operating conditions are extremely dusty or sandy. 2. Adjust the caster pivot bearing.
Checking the Tire Pressure 5. Grease the fittings on the push arms (Fig. 47). Maintain the air pressure in the front and rear tires as specified. Uneven tire pressure can cause uneven cut. Check the pressure at the valve stem after every 50 operating hours or monthly, whichever occurs first (Fig. 48). Check the tires when they are cold to get the most accurate pressure reading. Pressure: 13 psi (90 kPa) drive wheels and caster wheels. 1 M–4269 m–1872 Figure 48 Figure 47 1.
1 3 4 3 2 5 1 2 M–4640 m–4638 Figure 49 1. Spring washers 2. Lock nut Figure 50 3. Dust cap 1. Slotted nut 2. Two threads or less showing Wheel Hub Slotted Nut 3. Hole in threaded shaft 4. Washer (if needed) 5. Slot Servicing the Hydraulic System Check after every 500 operating hours. The slotted nut needs to be torqued to 125 ft.-lb. (169.5 N m). Checking the Hydraulic Fluid 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake.
5. Run the machine at low idle for 15 minutes to allow any air to purge out of the system and warm the fluid. Refer to Starting and Stopping the Engine on page 22. • After the first 8 operating hours. 6. Recheck the fluid level while the fluid is warm. The fluid should be between cold and hot. Use summer filter above 32°F (0°C) 7. If required, add fluid to the hydraulic tank. 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake.
Checking the Hydraulic Lines 1 After every 100 operating hours, check hydraulic lines and hoses for leaks, loose fittings, kinked lines, loose mounting supports, wear, weather and chemical deterioration. Make necessary repairs before operating. 3 2 Note: Keep areas around hydraulic system clean from grass and debris build up. m–1256 Adjusting the Handle Neutral Figure 53 1. Hydraulic filter 2. Gasket 3.
Setting the Hydraulic Pump Neutral 9. Apply slight rearward pressure on the motion control lever, turn the head of the adjustment bolt in the appropriate direction until the control lever is centered in neutral lock position (Fig. 54). Note: Adjust handle neutral first. That has to be correct before the following adjustment can be made. Note: Keeping rearward pressure on the lever will keep the pin at the end of the slot and allow the adjustment bolt to move the lever to the appropriate position.
Warning Electrical system will not perform proper safety shut off with jumper wire installed. • Remove jumper wire from wire harness connector and plug connector into seat switch when adjustment is completed. • Never operate this unit with jumper installed and seat switch bypassed. 1 2 3 7. After both pump neutrals are set, shut off the machine. 8. Remove jumper wire from wire harness connector and plug connector into seat switch. m–6283 Figure 56 1. Tracking knob 2. Pump rod 9.
2 3 4 5 7 6 1 4 1 3 m–6280 Figure 57 1. Pump rod 2. Turn this way to track left 2 M–4120 Figure 58 3. Tracking knob 4. Turn this way to track right 1. 2. 3. 4. Brake lever Spring, 2.75 inch (70 mm) Adjusting nuts Collar on brake rod 5. 3/16–1/4 inch (5–7 mm) 6. Jam nut and yoke 7. Trunion Adjusting the Parking Brake Check parking brake for proper adjustment. Servicing the Fuse 1. Disengage brake lever (lever down). Service Interval/Specification 2. Measure the length of the spring.
Servicing the Battery Danger Warning Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns. Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. • 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.
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. 60) 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.
Front 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. 66). B C m–1078 2. Measure the right blade at the A location (Fig. 66), from a level surface to the cutting edge of the blade tip (Fig. 67). Figure 63 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. 68). m–6273 Figure 69 2. Check the distance between the two large washers, it needs to be 10–1/4 inches (260 mm) (Fig. 68). 1. Push arm 2. 15-5/16 inch (389 mm) nominal 3.
Cleaning Under the Deck 1 4 5 3 2 Remove grass build up under deck daily. 7 1. Position mower on a flat surface. 2. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 6 M–4197 4. Raise deck to the transport position. Figure 70 5. Lift the front of unit and support unit using jack stands. Top View 1. 2. 3. 4.
Replacing the Grass Deflector 1 5 Warning 3 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. 4 2 Never operate the lawn mower unless you install a cover plate, a mulch plate, or a grass chute and catcher. M–4269 Figure 71 Top View 1. Deck belt 2. Idler arm 3. Outside pulley 1.
BK BK GND (NEUTRAL) SW5 DK.GN SHOWN WITH LEVER IN NEUTRAL POSITION LT.GN SHOWN WITH LEVER IN NEUTRAL POSITION LT.BU DK.GN LT.
Cleaning and Storage B. Run engine to distribute conditioned fuel through the fuel system (5 minutes). 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. C. Stop engine, allow to cool and drain the fuel tank; refer to Servicing the Fuel Tank, page 37. D. Restart engine and run it until it stops. 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 disengaged. 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 Abnormal vibration. Machine does not drive. Abnormal vibration. Uneven cutting g height. g Blades do not rotate. Possible Causes Corrective Action 1. Engine mounting bolts are loose. 1. Tighten engine mounting bolts. 2. Loose engine pulley, idler pulley, or blade pulley. 2. Tighten the appropriate pulley. 3. Engine pulley is damaged. 3. Contact Authorized Service Dealer. 1. Traction belt is worn, loose or broken. 1. Contact Authorized Service Dealer. 2. Traction belt is off pulley.
