Form No. 3351–906 Z153 Z Master with 132cm SFS Side Discharge Mower Model No. 74167TE—Serial No. 240000001 and Up Operator’s Manual Register your product at www.Toro.
This spark ignition system complies with Canadian ICES-002. Cleaning the Cooling System . . . . . . . . . . . . . . . . . Servicing the Air Cleaner . . . . . . . . . . . . . . . . . . . . Servicing the Engine Oil . . . . . . . . . . . . . . . . . . . . Servicing the Spark Plug . . . . . . . . . . . . . . . . . . . . Replacing the Fuel Filter . . . . . . . . . . . . . . . . . . . . Draining the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . Greasing and Lubrication . . . . . . . . . . . . . . . . . .
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; – use slow speeds on slopes and during tight turns; – stay alert for humps and hollows and other hidden hazards; • incorrect hitching and load distribution. • Use care when pulling loads or using heavy equipment. Preparation – Use only approved drawbar hitch points. • While mowing, always wear substantial footwear and long trousers. Do not operate the equipment when barefoot or wearing open sandals.
• 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. • Never store the equipment with fuel in the tank inside a building where fumes can reach an open flame or spark. • Do not mow slopes when grass is wet.
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 105 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. 99-8939 1. Read the Operator’s Manual. 2. Height of cut 99-3943 1. Engine 3. Remove the ignition key and read the instructions before servicing or performing maintenance. 105-6183 1. 2. 3. 4. 99-8936 1. Machine speed 2. Fast 3. Slow 4. Neutral 5. Reverse 99-8937 1. Right side fuel tank open 2.
93-7818 1. Warning—read the Operator’s Manual for instructions on torquing the blade bolt/nut to 115–149 N⋅m (85–110 ft.-lb.). 99-8941 1. Height of cut 98-1977 1. Entanglement hazard, belt—stay away from moving parts. 98-4387 1. Warning—wear hearing protection. 99-8942 1. Height of cut 99-8944 1. Explosion hazard—wear eye protection. 2. Caustic liquid/chemical burn hazard—to perform first aid, flush with water. 93-7010 3. Fire hazard—no fire, open flames, or smoking. 4.
Battery Symbols Some or all of these symbols are on your battery. 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. 93-7824 1. Thrown object hazard—stay a safe distance from the machine. 2. Thrown object hazard, mower—keep the deflector in place. 3. Cutting/dismemberment of hand or foot—stay away from moving parts. 7.
106-5517 1. Warning—do not touch the hot surface. 107-2131 1. Hydraulic oil level 2. Warning—do not touch the hot surface. 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. 12 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.
107-8443 1. Read the instructions before servicing or performing maintenance. 2. Hydraulic oil level 3. 4. 5. 6. Engine Tire pressure Hourly interval Grease 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.
Gasoline and Oil Recommended Gasoline Warning Use UNLEADED Regular Gasoline suitable for automotive use (85 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available. Gasoline is harmful or fatal if swallowed. Long-term exposure to vapors can cause serious injury and illness. Important Never use methanol, gasoline containing methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged. Do not mix oil with gasoline.
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. 2. Down position with bagger installed 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. 9). 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.
2 1 1 2 2 1 m–4201 Figure 11 m–4121 Figure 10 1. Parking brake—On m–2719 Figure 12 1. PTO—On 2. PTO—Off 2. Parking brake—Off Starting and Stopping the Engine 1. Choke—On 2. Choke—Off 1 1 Starting the Engine 2 1. Sit down on the seat and move the motion controls to the neutral locked position. 3 2 2. Set the parking brake; refer to Setting the Parking Brake, page 17. 3. Move the PTO (power take off) to Off (Fig. 11). M–4268 m–2720 4.
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.
5. Sitting on the seat, disengage the parking brake, move the PTO switch to Off, and move the motion control levers to the neutral lock position. Try starting the engine; the engine should not crank. 2 3 1 Driving Forward or Backward 4 The throttle control regulates the engine speed as measured in RPM (revolutions per minute). Place the throttle control in the Fast position for best performance. Always operate in the full throttle position. m–2715 Figure 16 1.
Adjusting the Height-of-Cut 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. The height-of-cut is adjusted from 1-1/2 to 4-1/2 inch (38 to 114 mm) in 1/4 inch (6 mm) increments by relocating the clevis pin in different hole locations. 3. After adjusting the height-of-cut, remove the nut and washer while holding the stud with a wrench (Fig. 18). 1.
Removing the Blades 1. Refer to removing the blades on page 29. 3 2. Remove the blades before removing or installing the baffles and kickers. This will help with the positioning of the baffles and kickers. Installing or Removing the Recycler Baffle 1 2 1. Place the left and right sides of the baffle together with the center pin inserted into the flange. m–4124 Figure 19 1. Center rollers and spacer 2. Nut 2. Secure the flanges with a bolt (5/16 x 5/8 inch) and locknut (5/16 inch) (Fig. 20). 3.
. Warning 4 Open holes in the mower expose you and others to thrown debris which could cause injury. • Never operate mower without hardware mounted in all holes in mower. • Install hardware in mounting holes when mulching baffle is removed. 2 1 3 m–2423 Installing the Blades Figure 21 1. Kicker 2. Spacer Refer to installing the blades on page 30. 3. Bolt, 5/16 x 1 inch 4. Locknut, 5/16 inch Removing the Recycler Baffle 3.
Positioning the Seat 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. 23). 1 2. Slide the seat to the desired position and release the lever to lock the seat in position. m–6279 Figure 24 1. By-pass valve Operating with Side Discharge The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf.
• Securely fasten the machine to the trailer or truck with straps, chains, cable, or ropes. Warning • Secure a trailer to the towing vehicle with safety chains. Loading a unit onto a trailer or truck increases the possibility of backward tip–over and could cause serious injury or death. 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 Note: Determine the left and right sides of the machine from the normal operating position.
Important Refer to your engine operator’s manual for additional maintenance procedures. 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 2. Inspect the blades, especially the curved area (Fig. 26).
Front Warning Contact with sharp blade can cause serious injury. Wear gloves or wrap sharp edges of the blade with a rag. 1 m–1078 2 Figure 27 3 4 m–4318 Figure 29 MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE 1. Sail area of blade 2. Blade 3. Spring disk 4. Blade bolt m–2539 Figure 28 Sharpening the Blades 2. Rotate the opposite ends of the blades forward. Warning 3. Measure from a level surface to the cutting edge of the blades at the same position as in step 1 above.
4 1 2 1 m–1855 Figure 31 1. Blade 5 5 2. Balancer 2 6 Installing the Blades 1. Install the blade onto the spindle shaft (Fig. 29). 3 Important The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting. 5 m–4369 2. Install the flat washer, lock washer, and blade bolt (Fig. 29). Torque the blade bolt to 85–110 ft-lb (115–150 N⋅m). Figure 32 1. Air intake screen 2. Fan housing 3.
6. Remove the safety filter only if you intend to replace it. 3. Carefully slide the primary filter over the safety filter (Fig. 33). Ensure that it is fully seated by pushing on the outer rim of the filter while installing it. Important Never attempt to clean the safety filter. If the safety filter is dirty, then the primary filter is damaged and you should replace both filters. Important filter. 4. Install the air cleaner cover with the side indicated as UP facing up and secure the latches (Fig. 33).
6. Slide the oil dipstick fully into the filler tube. Do not thread it onto the tube (Fig. 34). Pull the dipstick out and look at the end. If the oil level is low, slowly pour only enough oil into the filler tube to raise the level to the full mark. 1 Important Do not overfill the crankcase with oil because the engine may be damaged. Do not run engine with oil below the low mark because the engine may be damaged. m–5625 Figure 35 1. Oil drain valve 6.
5. Fill the crankcase with the proper type of new oil; refer to Servicing the Engine Oil, page 31. Important Always replace the spark plug(s) when it has a black coating, worn electrodes, an oily film, or cracks. Servicing the Spark Plug 2. Clean the electrode by scraping or with a wire brush to remove carbon deposits and wetness. Check the spark plug(s) after every 100 operating hours. Make sure that the air gap between the center and side electrodes is correct before installing the spark plug.
8. Install a new filter and move the hose clamps close to the filter (Fig. 40). Note: Now is the best time to install a new fuel filter because the fuel tank is empty. 9. Open the fuel shut-off valve on the console. 6. Install the fuel line onto the fuel filter. Slide the hose clamp close to the fuel filter to secure the fuel line (Fig. 40). 2 3 1 1 M–4294 Figure 39 1. Filter 4 2. Hose clamp 2 M–4294 Figure 40 1. Fuel shut-off valve 2. Fuel filter Draining the Fuel Tank 3. Hose clamp 4.
Where to Add Grease 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Lubricate the grease fittings as shown on the Check Service Reference Aid decal (Fig. 41). 3. Grease the fittings on the three spindle bearings (Fig. 42). 4. Grease the idler pulley pivot (Fig. 42). 5. Grease the fittings on the push arms (Fig. 42).
1 1 2 4 3 m–1872 Figure 43 1. Valve stem m–5615 Figure 44 1. Cap 2. Baffle Servicing the Hydraulic System 3. Cold fluid level—full 4. Hot fluid level—full Checking the Hydraulic Fluid Warning Check the hydraulic fluid level: • Before the engine is first started. Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • After the first 8 operating hours.
Replacing the Hydraulic Filter Change the hydraulic filter: 1 3 • After the first 8 operating hours. • After every 200 operating hours. 2 Use summer filter above 32°F (0°C) Use winter filter below 32°F (0°C) 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. m–1256 Figure 46 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 1. Hydraulic filter 2.
Checking the Hydraulic Lines 2 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 Note: Keep areas around hydraulic system clean from grass and debris build up. 1 Waste Disposal m–6282 Figure 47 Engine oil, hydraulic oil, and engine coolant are pollutants to the environment. Dispose of these according to your state and local regulations.
Warning Engine must be running so motion control adjustment can be performed. Contact with moving parts or hot surfaces may cause personal injury. 8 1 4 3 9 Keep hands, feet, face, clothing and other body parts away from rotating parts, muffler and other hot surfaces. This adjustment must be made with drive wheels turning. 2 6 1. Raise the frame and block up the machine so drive wheels can rotate freely. 2 2. Disconnect electrical connector from the seat safety switch.
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 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. 3 2 9. Reinstall prop rod and lower the seat into position. 10.
Checking the Wheel Hub Slotted Nut 2 Check after every 500 operating hours. 3 The slotted nut needs to be torqued to 125 ft–lb (170 N⋅m). 4 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. 1 3. Remove the cotter pin. m–6280 4. Torque the slotted nut to 125 ft–lb (170 N⋅m) (Fig. 52). Figure 50 1. Pump rod 2.
Front Leveling the Mower at Three Positions Important There are only three measuring positions needed to level the mower. Setting Up the Machine B C 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. m–1078 Figure 53 3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 4. Check tire pressure of all four tires.
9. Tighten both swivel jam nuts against the front swivel to lock the height. 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. 10. Check to make sure there is equal tension on the chains and adjust again if needed. Adjusting the Front–to–Rear Mower Pitch Adjusting the Compression Spring 1. Position the right blade front-to-rear (Fig. 56). 1.
1 3 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 4 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the belt covers over the outside spindles. 2 4. Loosen the outer nut on the spring eye bolt (Fig. 60). m–6273 Figure 59 1. Push arm 2. 15-5/16 inch (389 mm) nominal 1 4 5 3 2 3. Jam nut 4.
1 4 5 1 3 5 3 4 6 2 M–4159 m–4119 Figure 61 Figure 62 Top View 1. Deck belt 2. Idler arm 3. Outside pulley 2 1. Clutch strap 2. Bolt 3. Clutch electrical wire 4. Spring 5. Idler pulley 4. Belt 5. Idler 6. Clutch Adjusting the Parking Brake Replacing the Pump Drive Belt Check the parking brake for proper adjustment. Check the pump drive belt for wear after every 50 hours of operation. 1. Disengage the brake lever (lever down). 1.
4 5 7 6 Servicing the Battery Warning 1 CALIFORNIA Proposition 65 Warning 3 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. 2 M–4120 Figure 63 1. Brake lever 2. Spring, 2-3/4 inch (74 mm) 3. Adjusting nuts 4. 5. 6. 7. Checking Electrolyte Level Collar on brake rod 3/16–1/4 inch (5–7 mm) Jam nut and yoke Trunnion 1.
Installing the Battery Removing the Battery 1. Position battery in tray with terminal posts toward the engine (Fig. 66). Warning 2. First, install the positive (red) battery cable to positive (+) battery terminal. Battery terminals or metal tools could short against metal machine components causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. 3. Then install negative battery cable and ground wire to the negative (–) battery terminal.
The best time to add distilled water to the battery is just before you operate the machine. This lets the water mix thoroughly with the electrolyte solution. 4 2 1. Remove the battery from the machine. 3 2. Clean the top of the battery with a paper towel. 1 3. Remove the vent caps from the battery (Fig. 65). 4. Slowly pour distilled water into each battery cell until the level is up to the upper line (Fig. 65) on the battery case.
Important The grass deflector must be able to lower down into position. Lift the deflector up to test that it lowers into the full down position. 8 6 4 2 3 5 1 7 m–5037 Figure 68 1. 2. 3. 4. 5. Bolt Spacer Locknut Spring Spring installed 6. Grass deflector 7. Place behind deck edge before installing bolt 8.
BK BK PTO CLUTCH GND GY DK.GN SHOWN WITH LEVER IN NEUTRAL POSITION LT.GN (NEUTRAL) SW5 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 g will not start, starts hard, or f il to fails t keep k running. i 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 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.
