FORM NO. 3322–438 Rev B Z–Master Compact Series Z150 with 52” SFS Side Discharge Mower Model No. 74172–992000 & UP Operator’s Manual IMPORTANT: Read this manual carefully. It contains information about your safety and the safety of others. Also become familiar with the controls and their proper use before you operate the product.
Introduction Thank you for purchasing a Toro product. All of us at Toro want you to be completely satisfied with your new product, so feel free to contact your local Authorized Service Dealer for help with service, genuine replacement parts, or other information you may require. Whenever you contact your Authorized Service Dealer or the factory, always know the model and serial numbers of your product.
Contents Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safe Operating Practices . . . . . . . . . . . . . . Slope Chart . . . . . . . . . . . . . . . . . . . . . . . . . Safety and Instruction Decals . . . . . . . . . . Gasoline and Oil . . . . . . . . . . . . . . . . . . . . . . . . Recommended Gasoline . . . . . . . . . . . . . . Stabilizer/Conditioner . . . . . . . . . . . . . . . . Filling the Fuel Tank . . . . . . . . . . . . . . . . . Check Engine Oil Level . . . . . . . . .
Safety This machine meets or exceeds CPSC blade safety requirements for rotary mowers and the B71.4 1990 specifications of the American National Standards Institute, in effect at time of production. 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.
Safety General Operation 1. 2. Read, understand, and follow all instructions in the operator’s manual and on the machine before starting. Allow only responsible adults who are familiar with the instructions to operate the machine. 3. Clear the area of objects such as rocks, toys, wire, etc., which could be picked up and thrown by the blade. 4. Be sure the area is clear of other people before mowing. Stop the machine if anyone enters the area. 5. Never carry passengers. 6.
Safety Slope Operation Slopes are a major factor related to loss-of-control and tip-over accidents, which can result in severe injury or death. All slopes require extra caution. If you cannot back up the slope or if you feel uneasy on it, do not mow it. • Check carefully for overhead clearances (i.e. branches, doorways, electrical wires) before driving under any objects and do not contact them. DO NOT • Do not operate machine on hillsides or slopes exceeding 15°.
Safety Children Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the machine and the mowing activity. Never assume that children will remain where you last saw them. The following requirements must be followed to prevent injury to children. 1. Keep children out of the mowing area and under the watchful care of another responsible adult. 2. Be alert and turn the machine off if children enter the area. 3.
Safety Slope Chart Read all safety instructions on pages 3–5.
Safety 7
Safety 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. TOP OF CONSOLE UNDER SEAT (Part No. E513747) ON RIGHT SIDE OF HEIGHT OF CUT PLATE (Part No E653140) ON LEFT SIDE OF HEIGHT–OF–CUT PLATE (Part No E653147) BELOW CENTER OF CONSOLE (Part No. E633346) ON TOP OF CONSOLE LEFT AND RIGHT SIDES (Part No. E633354) ON TOP OF HYDRAULIC RESERVOIR (Part No.
Safety UNDER FOOTREST (Part No. 99–3924) ON FRAME NEAR MUFFLER (Part No. 65–2690) LOWER LEFT OF CONSOLE (Part No. 98–4387) ON TOP LEFT SIDE OF FRAME (Part No. E633818) YEA RLY ON CONTROL PANEL (Part No.
Safety ON RIGHT SIDE OF MOWER (Part No. 66-1340) UNDER DEFLECTOR (Part No. 66-6380) ON DEFLECTOR (Part No. 54-9220) ON LEFT SIDE OF MOWER (Part No. 43-8480) UNDER BELT COVER (3) UNDER FOOT REST (1) (Part No. 98Ć5954) (2) ON BELT COVERS (Part No. 67-5360) ON TOP OF MOWER IN CENTER (Part No. 98-3798) ON TOP CENTER OF MOWER (Part No. 99-3943) ON LEFT FRONT OF MOWER (Part No.
Gasoline and Oil 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. POTENTIAL HAZARD • In certain conditions gasoline is extremely flammable and highly explosive. WHAT CAN HAPPEN 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.
Gasoline and Oil Stabilizer/Conditioner Filling the Fuel Tank Add the correct amount of gas stabilizer/conditioner to the gas. Using a stabilizer/conditioner in the machine: 1. Shut the engine off and set the parking brake. 2. Clean around each fuel tank cap and remove the cap. Add unleaded regular gasoline to both fuel tanks, until the level is 1/4 to 1/2 inch (6 mm to 13 mm) below the bottom of the filler neck. This space in the tank allows gasoline to expand.
Assembly Loose Parts Note: Use the chart below to verify all parts have been shipped. DESCRIPTION QTY.
Assembly Install Drive Wheels Install Seat Retaining Rod 1. Uncrate mower. 4. 1. Remove wheel bolts or nuts from rear wheel hubs. Tilt seat up. Remove 5/16” (8mm) locknut from bolt attaching seat retaining rod to seat frame (Fig. 2). 5. 2. Align holes. Mount drive wheels with the valve stem to the outside of the traction unit. 3. Secure using wheel bolts or nuts provided. Torque to 95ft–lbs (128 NSM).
Assembly Install Motion Control Levers 8. Remove the (4) 3/8–16 x 1” (26 mm) bolts and (4) 3/8” spring washers which attach the motion control levers to the control arm shafts for shipping (Fig. 3). 9. Place the levers (with the mounting plate towards the rear) on the outside of the control arm shaft and secure with (4) 3/8–16 x 1” (26 mm) bolts and (4) 3/8” spring washers (Fig. 3). 12.
Assembly Activate the Battery 2. Bulk electrolyte with 1.260 specific gravity must be purchased from a local battery supply outlet. Remove filler caps from the battery. Slowly pour electrolyte into each cell until the electrolyte level is up to the lower part of the tube (Fig. 5). 1 1. Remove the battery from the machine. IMPORTANT: Be careful not to damage the long vent tube when removing the battery box.
Assembly Install Battery 1. Position battery in tray with terminal posts toward the left hand side of mower (Fig. 7). WHAT CAN HAPPEN • Battery gasses can explode. 2. Slide the red terminal boot onto the positive (red) battery cable. HOW TO AVOID THE HAZARD 3. Install the positive (red) battery cable to positive (+) battery terminal then negative battery cable and ground wire to the negative (–) battery terminal. 4.
Assembly Hydraulic System Check the Leveling of Mower Deck Checking the Hydraulic Fluid Check the hydraulic fluid level before engine is first started. Check the level of the deck before the machine is first put into use. Fluid Type: Mobil 1 15W–50 synthetic motor oil. Refer to Mower Leveling and Compression Spring Adjustment sections in the Maintenance section on page 35. IMPORTANT: Use only oil specified. Other fluids could cause system damage. Hydraulic System Oil Capacity: 2.1 qt. (2.0 l) 1.
Operation Think Safety First Controls Please carefully read all the safety instructions on pages 2–10. Knowing this information could help you, your family, pets or bystanders avoid injury. Become familiar with all the controls (Fig. 1) before you start the engine and operate the machine. 1 8 8 2 2 POTENTIAL HAZARD • Loud sound can cause ear damage and loss of hearing. WHAT CAN HAPPEN • Ear damge or hearing loss may occur. HOW TO AVOID THE HAZARD • Wear ear protection when operating this machine.
Operation Parking Brake Always set the parking brake when you stop the machine or leave it unattended. Releasing the Parking Brake 1. Push forward and down on the parking brake lever to release the parking brake (Fig. 2). The parking brake is “DISENGAGED”. IMPORTANT: Do not park on slopes unless wheels are chocked or blocked. 1 Setting the Parking Brake 1. 2. Move the motion control levers (Fig. 1) out to the neutral lock position.
Operation Starting and Stopping the Engine 2 1 Starting 2 1. Sit down on the seat and move the motion controls to neutral locked position. 2. Set the parking brake; refer to Setting the Parking Brake, page 20. 3. Move the PTO (power take off) to “OFF” (Fig. 3). 4. Move the choke control to “ON” position before starting a cold engine. Note: 5. 6. m–4201 Figure 3 m–2719 Figure 4 1. PTO-On 2. PTO-Off A warm or hot engine may require choking.
Operation 1. Move the throttle lever to “SLOW” (Fig. 5). Operating the Power Take Off (PTO) 2. Move the PTO (power take off) to “OFF” (Fig. 3). The power take off (PTO) switch engages and disengages power to the electric clutch. 3. Turn the ignition key to “OFF” (Fig. 6). Stopping Note: If the engine has been working hard or is hot, let it idle for a minute before turning the ignition key “OFF.” This helps cool the engine before it is stopped.
Operation The Safety Interlock System Understanding the Safety Interlock System The safety interlock system is designed to prevent the engine from starting unless: • You are sitting on the seat • The parking brake is on “ENGAGED” • The power take off (PTO) is disengaged “OFF” • The motion control levers are in neutral locked position The safety interlock system also is designed to stop the engine when the traction controls are moved with the parking brake on “ENGAGED” or if you rise from the seat w
Operation Driving Forward or Backward 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 Forward 1. Release the parking brake; refer to Setting the Parking Brake, page 20. 2. Move levers to the center, un-locked position. 3. To go forward, slowly push the motion control levers forward (Fig. 8).
Operation Instruments Fuel Tanks Hour Meter The hour meter records the number of hours the engine has operated. It operates when the engine is running. Use these times for scheduling regular maintenance. 1 The unit has two fuel tanks, located on the left and right sides. Each tank connects to the fuel shut off valve in the control panel. From there a common fuel line leads to the engine (Fig. 10). To use the right side fuel tank rotate the fuel shut off valve 1/4 turn to the right from the off location.
Operation Adjusting Height-of-Cut Adjusting Anti-Scalp Rollers The height-of-cut is adjusted from 1-1/2” to 5” (38 to 127 mm) in 1/4” (6 mm) increments by relocating clevis pin in different hole locations. Whenever you change the height-of-cut it is recommended to adjust the height of the anti-scalp rollers. 1. Raise the height-of-cut lever to the transport position (also the 5” (127 mm) cutting height position) (Fig. 11). 2.
Operation Stud Method Center Rollers 1. 1. Disengage the power take off (PTO) and turn the ignition key to “OFF”. Move controllers to neutral locked position and apply parking brake. 1. After adjusting height-of-cut, remove bolt and nut (Fig. 14). 2. Select hole so gage wheel is positioned to the nearest corresponding height-of-cut desired (Fig. 14). Disengage the power take off (PTO) and turn the ignition key to “OFF” to stop the engine.
Operation 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. 1. To adjust, move the lever sideways to unlock seat (Fig. 15). 2. Slide the seat to the desired position and release lever to lock in position. IMPORTANT: Always push the machine by hand. Never tow the machine because hydraulic damage may occur. To Push the Machine 1.
Operation Side Discharge The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. POTENTIAL HAZARD • Without the grass deflector or complete grass catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris. WHAT CAN HAPPEN • Contact with rotating mower blade(s) and thrown debris will cause injury or death.
Operation Tips for Mowing Grass Fast Throttle Setting Cutting Speed To improve cut quality, use a slower ground speed. 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.
Maintenance Service Interval Chart Service Operation Each Use 8 Hours 25 Hours Hydraulic fluid–check level Initial Initial X Oil—check level 50 Hours 100 Hours X Initial X Oil Filter–change (200 hours or every other oil change) Hydraulic filter–change Storage Service X X Oil—change* Safety System—check 200 Hours Initial X X X X X X X Chassis—grease* X X Linkage bushings—oil* X X Foam Air Cleaner—service* X X Paper Air Cleaner—service* X X Paper Air Cleaner—replace* X
Maintenance POTENTIAL HAZARD • If you leave the key in the ignition switch, someone could start the engine. WHAT CAN HAPPEN • Accidental starting of the engine could seriously injure you or other bystanders. HOW TO AVOID THE HAZARD • Remove the key from the ignition switch and pull the wire(s) off the spark plug(s) before you do any maintenance. Also push the wire(s) aside so it does not accidentally contact the spark plug(s).
Maintenance Inspecting the Blades Checking for Bent Blades 1. 1. Stop the engine, set the parking brake, remove the key and disconnect the spark plug wire(s) from the spark plug(s). 2. Rotate the blades until the ends face forward and backward (Fig. 18). Measure from a level surface to the cutting edge of the blades (Fig. 19). Note this dimension. 2. Inspect the cutting edges (Fig 17). If the edges are not sharp or have nicks, remove and sharpen the blades.
Maintenance Sharpening the Blades 1. POTENTIAL HAZARD • A blade that is bent or damaged could break apart and pieces could be thrown at bystanders or at you as you use the mower. Use a file to sharpen the cutting edge at both ends of the blade (Fig. 21). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges. WHAT CAN HAPPEN • Pieces of blade that may be thrown could seriously injure or kill you or bystanders.
Maintenance Mower Leveling Note: 1. Position mower on a flat surface. Stop the engine, set the parking brake, remove the key and disconnect the spark plug wire(s) from the spark plug(s). 2. Check tire pressure of all four (4) tires. If needed, adjust to 13 psi (90 kPa) 3. Set anti–scalp rollers to top holes or remove them completely for this adjustment. 8. When hardware is loose, deck will rotate the lift handle up out of position.
Maintenance 12. Raise deck to 3 inch height of cut and measure actual height from blade tips to ground. Height of cut for the front blade tips should be 3.00 ±.125 (76mm ± 3mm). Height of cut for rear blade tips should be 3.25±.125 (83mm± 3mm).Readjust if needed. Note: Greasing the Bearings The cutting unit must be lubricated regularly. Refer to the Service Interval Chart on page 31. Grease with No. 2 general purpose lithium base or molybdenum base grease.
Maintenance Replacing the Grass Deflector 1. Stop the engine, set the parking brake, remove the key and disconnect the spark plug wire(s) from the spark plug(s). 2. Remove the locknuts, bolts and springs holding the deflector mounts to the pivot brackets (Fig. 26). 3. If the pivot brackets need to be replaced, remove the carriage bolts and cone locknuts holding the old brackets to the top of the discharge opening, then install the replacement pivot brackets.
Maintenance Replacing the Deck Belt Squealing when the belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks and cracks are signs of a worn deck belt. Replace the deck belt if any of these conditions are evident. 1. POTENTIAL HAZARD • Spring is under tension when installed. WHAT CAN HAPPEN • Stored spring energy can cause personal Stop the engine, set the parking brake, remove the key and disconnect the spark plug wire(s) from the spark plug(s). 2.
Maintenance Air Cleaner 3. Carefully slide the foam element off the paper element (Fig. 29). Foam Element: Clean and re-oil after every 25 operating hours. 4. Unscrew the cover nut and remove the cover and paper element (Fig. 29). Paper Element: Replace after every 100 operating hours. Note: Cleaning the Foam and Paper Elements Service the air cleaner more frequently (every few hours) if operating conditions are extremely dusty or sandy. Removing the Foam and Paper Elements 1. 2. 1.
Maintenance 2. Paper Element Engine Oil A. Lightly tap the element on a flat surface to remove dust and dirt (Fig. 31). Change oil: B. Inspect the element for tears, an oily film, and damage to the rubber seal. 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. • After the first 5 operating hours. • After every 100 operating hours.
Maintenance Checking Oil Level Changing/Draining Oil 1. 1. Start the engine and let it run five minutes. This warms the oil so it drains better. 2. Park the machine so that the drain side is slightly lower than the opposite side to assure the oil drains completely. Then disengage the power take off (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key. 3. Place a pan below the oil drain. Remove the oil drain cap (Fig. 33). 4.
Maintenance Spark Plug Change Oil Filter Replace the oil filter every 200 hours or every other oil change. Note: 1. Change oil filter more frequently when operating conditions are extremely dusty or sandy. Drain the oil from the engine; refer to Changing/Draining Oil, page 41. Check the spark plug(s) after every 200 operating hours. Make sure the air gap between the center and side electrodes is correct before installing the spark plug.
Maintenance Greasing and Lubrication Checking the Spark Plug 1. Look at the center of the spark plug(s) (Fig. 36). If you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means the air cleaner is dirty. IMPORTANT: Never clean the spark plug(s). Always replace the spark plug(s) when it has a black coating, worn electrodes, an oily film, or cracks. 2. Lubricate the machine when shown on the CHECK SERVICE REFERENCE AID decal (Fig. 37).
Maintenance Fuel Filter Grease Front Castor Pivots Lubricate the front castor pivots once a year. 1. Remove hex plug and cap. Thread a grease zerk into hole. 2. Pump grease into zerk until it oozes out around top beraring. 3. Remove grease zerk in hole. Reinstall hex plug and cap. Replace the fuel filter after every 200 operating hours or yearly, whichever occurs first. Replacing the Fuel Filter Never install a dirty filter if it is removed from the fuel line. 1.
Maintenance Fuel Tank Draining The Fuel Tank 4. Pull the fuel line off fuel filter (Fig. 40). 5. Open fuel shut-off valve for left and right tanks. Allow gasoline to drain into a gas can or drain pan. (Fig. 40). Note: POTENTIAL HAZARD • In certain conditions gasoline is extremely flammable and highly explosive. 6. Now is the best time to install a new fuel filter because the fuel tank is empty. Install the fuel line onto the fuel filter.
Maintenance Hydraulic System 1 Checking the Hydraulic Fluid Check the hydraulic fluid level: • Before engine is first started. • After first 8 operating hours. • After 25 operating hours. 2 3 Fluid Type: Mobil 1 15W–50 synthetic motor oil. IMPORTANT: Use only oil specified. Other fluids could cause system damage. Figure 41 1. Cap 2. Baffle 3. Fluid level-Full System Capacity: 2.1 qt. (2.0 l) 1. Position machine on a level surface and stop the engine and set the parking brake. 2.
Maintenance Replacing the Hydraulic Filter Change the hydraulic filter: 1 • After the first 8 operating hours. • After every 200 operating hours. 1. Position machine on a level surface, stop the engine, and remove key from ignition switch. 2 IMPORTANT: Do not substitute automotive oil filter or severe hydraulic system damage may result. 2. 3 Remove hydro cap and temporarily cover opening with a plastic bag and rubber band to prevent all hydro fluid from draining out. A.
Maintenance Check Hydraulic Lines 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. Adjusting Motion Controls Adjusting Handle Neutral If motion control levers do not align, or move easily into the console notch, adjustment is required. Adjust each lever, spring and rod separately.
Maintenance 5. Apply slight rearward pressure on the motion control lever, turn the head of the adjustment bolt in the appropriate direction until lever is centered in neutral lock position (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 (Fig. 45). 6. Tighten nut and jam nut. 7. Repeat on opposite side of unit. Adjusting Hydraulic Pump Neutral Note: 8. Adjust handle neutral first.
Maintenance Note: Motion control lever must be in neutral while making any adjustments. 15. Open throttle to fast. Make sure wheel remains stopped or slightly creeps in reverse, re-adjust if necessary. 16. Repeat on opposite side of unit. Tighten locknuts against ball joints. POTENTIAL HAZARD • Electrical system will not perform proper safety shut off with jumper wire installed. WHAT CAN HAPPEN • Contact with moving parts may cause personal injury.
Maintenance Adjustment Parking Brake Fuse Check parking brake for proper adjustment. Service Interval/Specification 1. Disengage brake lever (lever down). 2. Measure the length of the spring. Measurement should be 2.75” (70 mm) between washers (Fig. 47). The electrical system is protected by fuses. It requires no maintenance: however, if a fuse blows check component/circuit for malfunction or short. 3.
Maintenance Battery Adding Water to the Battery Check the electrolyte level in the battery every 25 hours. Always keep the battery clean and fully charged. Use a paper towel to clean the battery case. If the battery terminals are corroded, clean them with a solution of four parts water and one part baking soda. Apply a light coating of grease to the battery terminals to prevent corrosion. The best time to add distilled water to the battery is just before you operate the machine.
Maintenance Wiring Diagram 53
Maintenance Cleaning and Storage 1. 2. Disengage the power take off (PTO), set the parking brake and turn the ignition key to “OFF” to stop the engine. Remove the key. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine. Clean dirt and chaff from the outside of the engine’s cylinder head fins and blower housing. IMPORTANT: You can wash the machine with mild detergent and water. Do not pressure wash the machine.
Troubleshooting PROBLEM Starter does not crank Engine will not start, starts hard, or fails to keep running. Engine g loses power. p 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. Check electrical connections for good contact. 6.
Troubleshooting PROBLEM Engine g overheats. Abnormal vibration. Machine does not drive. Abnormal vibration. 56 POSSIBLE CAUSES CORRECTIVE ACTION 1. Engine load is excessive. 1. Reduce ground speed. 2. Oil level in crankcase is low. 2. Add oil to crankcase. 3. Cooling fins and air passages under engine blower housing are plugged. 3. Remove obstruction from cooling fins and air passages. 1. Engine mounting bolts are loose. 1. Tighten engine mounting bolts. 2.
Troubleshooting PROBLEM Uneven cutting g height. g Blades do not rotate. POSSIBLE CAUSES CORRECTIVE ACTION 1. Blade(s) not sharp. 1. Sharpen blade(s). 2. Cutting blade(s) is/are bent. 2. Install new cutting blade(s). 3. Mower is not level. 3. Level mower from side-to-side and front-to-rear. 4. Gage wheel not set correctly. 4. Adjust gage wheel height. 5. Underside of mower is dirty. 5. Clean the underside of the mower. 6. Tire pressure is incorrect. 6. Adjust tire pressure. 7.
A OneĆYear Limited Warranty (A TwoĆYear Full Warranty for Residential Use) LCE What Is Covered By This Express Warranty? The Toro Company promises to repair any TORO Product used for commercial, institutional, or rental purposes if defective in materials or workmanship. The following time frames apply from the date of purchase: Product Warranty Period All Products . . . . . . . . . . . . . . . . . . 1 year All Spindles . . . . . . . . . . . . . . . . . . .
