Form No. 3327-657 Z150 and Z153 Z Master with 52 SFS Side Discharge Mower Model No. 74178—Serial No. 220000313 and Up Model No. 74197—Serial No.
Warning Checking the Engine Oil Level . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Think Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating the Parking Brake . . . . . . . . . . . . . . . . . Starting and Stopping the Engine . . . . . . . . . . . . . . Operating the Power Take Off (PTO) . . . . . . . . . . The Safety Interlock System . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Toro Total Coverage Guarantee . . . . . . . . . . . . . . This manual uses two other words to highlight information. Important calls attention to special mechanical information and Note: emphasizes general information worthy of special attention. Page 47 52 Introduction Safety Read this manual carefully to learn how to operate and maintain your product properly.
• Wear appropriate clothing including hard hat, safety glasses and ear protection. Long hair, loose clothing or jewelry may get tangled in moving parts. • Look behind and down before backing up to be sure of a clear path. • Never carry passengers and keep pets and bystanders away. • Inspect the area where the equipment is to be used and remove all objects such as rocks, toys and wire which can be thrown by the machine. • Slow down and use caution when making turns and crossing roads and sidewalks.
• Keep all parts in good working condition and all hardware tightened. Replace all worn or damaged decals. Slope Operation Slopes and ramps are a major factor related to loss-of-control and tip-over accidents, which can result in severe injury or death. All slopes and ramps require extra caution. If you cannot back up the slope or if you feel uneasy on it, do not mow it.
Service • Never store the machine or fuel container inside where there is an open flame, such as near a water heater or furnace. • Keep nuts and bolts tight, especially the blade attachment bolts. Keep equipment in good condition. • Never tamper with safety devices. Check safety systems for proper operation before each use. • Use only genuine replacement parts to ensure that original standards are maintained. • Check brake operation frequently. Adjust and service as required.
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.
98-4387 1. Warning—wear hearing protection. 66-1340 98-5954 67-5360 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.).
104-8172 99-3943 104-8569 1. Engine 65–2690 103–0262 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.
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 5. Sulfuric acid can cause blindness or severe burns. 6. Flush eyes immediately with water and get medical help fast. 7. Maximum fill line 12 8. Minimum fill line 9.
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.
Setup Note: Determine the left and right sides of the machine from the normal operating position. Loose Parts Note: Use the chart below to verify that all parts have been shipped. Description Qty. Rear wheels 2 Retaining rod 1 Bolt, 5/16 x 1 in. 1 Locknut, 5/16 in. 1 Control lever—right 1 Control lever—left 1 Bolt, 3/8 x 1 in. 4 Spring washer, 3/8 in.
Installing the Seat Retaining Rod 4. Align the front\rear position of the levers, with each other, in the neutral position. Loosen the hardware and adjust by sliding/tilting the lever(s) forward or backward until they are properly aligned (Fig. 4). 1. Tilt the seat up. Remove the locknut (5/16 in.) from the bolt attaching the seat retaining rod to the seat frame (Fig. 3). 2.
Activating the Battery Warning Bulk electrolyte with 1.265 specific gravity must be purchased from a local battery supply outlet. Charging battery produces gasses that can explode and cause serious injury. Danger • Keep cigarettes, sparks and flames away from battery. • Make sure the ignition switch is off. • Ventilate when charging or using battery in an enclosed space. Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns.
Checking the Leveling of the Mower Deck Controls Become familiar with all of the controls (Fig. 9) before you start the engine and operate the machine. Check the level of the deck before the machine is first put into use. 1 8 8 2 Refer to Adjusting the Mower Level, page 37, in the Maintenance section. 2 Checking the Side Discharge Chute Remove the plastic tie holding the side discharge chute up and lower it into place.
Switching the Fuel Tanks 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. 11). 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.
Operating the Power Take Off (PTO) 2 1 2 The power take off (PTO) switch engages and disengages power to the electric clutch. 1 Engaging the PTO 1. While seated in the seat, release the pressure on the traction control levers and place in neutral. m–4201 m–2719 Figure 13 2. Place the throttle in the fast position. Figure 14 1. PTO—On 2. PTO—Off 3. Pull out on the power take off (PTO) switch to engage (Fig. 17). 1. Choke—On 2. Choke—Off 1 1 2 2 1 3 2 m–4268 m–2720 m–4201 Figure 15 1.
Understanding the Safety Interlock System Caution The safety interlock system is designed to prevent the engine from starting unless: Machine can spin very rapidly. Operator may lose control of machine and cause personal injury or damage to machine. • You are sitting on the seat. • Use caution when making turns. • Slow the machine down before making sharp turns. • The parking brake is engaged. • The power take off (PTO) is disengaged.
To turn, release pressure on the motion control lever toward the direction you want to turn (Fig. 18). 1 To stop, push the motion control levers to neutral. 2 Stopping the Machine To stop the machine, move the traction control levers to neutral and separate to lock, disengage the power take off (PTO), and turn the ignition key to Off to stop the engine. Also set the parking brake when you leave the machine; refer to Setting the Parking Brake, page 18. Remember to remove the key from the ignition switch.
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 the seat (Fig. 22). 2. Slide the seat to the desired position and release the lever to lock the seat in position. 1 4 3 2 5 m–4167 Figure 20 1. Gage wheel 2. Stud 3. Washer 4. Nut 5. Wheel nut and washer. Do not remove. 1 m–3655 Figure 22 Adjusting the Center Rollers 1. Adjustment lever 1.
Transporting the Machine 1 Use a heavy-duty trailer or truck to transport the machine. Ensure that the trailer or truck has all necessary lighting and marking as required by law. Please carefully read all of the safety instructions. Knowing this information could help you, your family, pets, or bystanders avoid injury. m–5642 To transport the machine: Figure 23 • Lock the brake and block the wheels. 1.
Mow at Correct Intervals Avoid sudden acceleration when driving up a ramp and sudden deceleration when backing down a ramp. Both maneuvers can cause the unit to tip backward. Normally, mow every four days. But remember, grass grows at different rates at different times. So to maintain the same cutting height, which is a good practice, mow more often in early spring. As the grass growth rate slows in mid summer, mow less frequently.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position.
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.
Front 1 2 3 4 M–4226 Figure 27 m–1078 1. Sail area of blade 2. Blade Figure 25 3. Spring disk 4. Blade bolt Sharpening the Blades Warning MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE When sharpening blade, pieces of blade could be thrown and cause serious injury. m–2539 Figure 26 Wear proper eye protection when sharpening blade. Warning 1. Use a file to sharpen the cutting edge at both ends of the blade (Fig. 28). Maintain the original angle.
Installing the Blades 3 1. Install the blade onto the spindle shaft (Fig. 27). 4 1 Important The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting. 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). 5 2 1 Servicing the Air Cleaner m–4815 Figure 30 Primary Filter: Clean or replace every 200 operating hours. 1. Latches 2. Air cleaner cover 3.
Servicing the Engine Oil 1 3 Change the oil: • After the first 5 operating hours. • After every 100 operating hours. 2 Note: Change the oil more frequently when operating conditions are extremely dusty or sandy. Oil Type: Detergent oil (API service SG or SH) m–3219 Crankcase Capacity: w/filter, 67 oz. (2 l) m–5626 Figure 31 Viscosity: See the table below. 1. Oil dipstick 2. Filler tube USE THESE SAE VISCOSITY OILS 10W–30, 10W–40 Changing the Engine Oil 1.
Changing the Oil Filter 2. Pull the wire(s) off of the spark plug(s) (Fig. 34). Clean around the spark plug(s) to prevent dirt from falling into the engine and potentially causing damage. Replace the oil filter every 200 hours or every other oil change. 3. Remove the spark plug(s) and metal washer. Note: Change the oil filter more frequently when operating conditions are extremely dusty or sandy. 1. Drain the oil from the engine; refer to Changing the Oil, page 29. 2.
Draining the Fuel Tank 2. Tighten the spark plug(s) to 20 ft.-lb. (27 N⋅m). 3. Push the wire(s) onto the spark plug(s) (Fig. 34). Danger Replacing the Fuel Filter In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property. Replace the fuel filter after every 200 operating hours or yearly, whichever occurs first. Never install a dirty filter if it is removed from the fuel line.
Cleaning the Cooling Systems How to Grease Cleaning the Engine Screen 1. Disengage the power take off (PTO), stop the engine, and remove the key. Before each use, check and clean the engine screen. Remove any buildup of grass, dirt, or other debris from the engine air intake (Fig. 38). 2. Clean the grease fittings with a rag. Make sure to scrape any paint off of the front of the fitting(s). ÓÓ ÓÓ ÓÓ ÓÓ 3. Connect a grease gun to the fitting.
Greasing the Bearings Checking the Tire Pressure The cutting unit must be lubricated regularly; refer to the Recommended Maintenance Schedule, page 25. Grease with No. 2 general purpose lithium base or molybdenum base grease. 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. 42).
Replacing the Hydraulic Filter 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, page 18. Change the hydraulic filter: • After the first 8 operating hours. 6. Recheck the fluid level while the fluid is warm. If required, add fluid to the reservoir until it reaches the hot level of the baffle. • After every 200 operating hours. 1.
Note: Keep the areas around the hydraulic system clean from grass and debris buildup. 1 3 Warning Hydraulic fluid escaping under pressure can penetrate skin and cause injury. 2 • 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. Gangrene may result if this is not done. • Keep body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid.
7. Repeat on the opposite side of the unit. Warning 4 1 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. 6 2 2. Slide the seat forward, disconnect the prop rod, and tilt the seat fully forward. 5 7 3 3 m–3800 3. Disconnect the electrical connector from the seat safety switch.
Adjusting the Castor Pivot Bearing 8. Install the cotter pin. 1 4 Check after every 500 operating hours or at storage, whichever occurs first. 3 1. Stop the engine, set the parking brake, remove the key, and disconnect the spark plug wire(s) from the spark plug(s). 5 2. Remove the dust cap from the castor and tighten the locknut (Fig. 47). 2 m–4638 Figure 48 3. Tighten until the spring washers are flat and then back off 1/4 turn to properly set the preload on the bearings (Fig. 47). 1.
6. Loosen the bottom chain bolt in the slot at the rear of the deck. Repeat for the opposite side (Fig. 50). Note: When checking the blade tip heights, make sure that the blades are not bent and check the blade pointing front to rear. Note: Do not loosen front chain hardware. 13. Install the anti-scalp rollers for proper height-of-cut and tighten them securely; refer to Adjusting the Anti-Scalp Rollers, page 21. 7. Loosen the front and rear locking nut on either side of the front swivel.
Danger Caution Mechanical or hydraulic jacks may fail to support machine and cause a serious injury. Spring is under tension when installed and can cause personal injury. • Use jack stand when supporting machine. • Do not use hydraulic jacks. Do not remove spring from spring eye bolt. 5. Remove the spring loaded idler pulley (Fig. 52). 6. Route the new belt through the idler arm (Fig. 52). Inspecting the Belts Inspect all belts every 100 hours. 7.
5. Pull the spring loaded idler to the side and align the belt. Release pressure on the spring loaded idler (Fig. 54). 4 5 7 6 6. Install the deck belt. 1 4 5 1 3 3 6 2 m–4120 Figure 55 1. 2. 3. 4. m–4119 Figure 54 1. Clutch strap 2. Bolt 3. Clutch electrical wire 2 4. Belt 5. Idler 6. Clutch Brake lever Spring, 2-3/4 in. (70 mm) Adjusting nuts Collar on brake rod 5. 3/16–1/4 in. (5–7 mm) 6. Jam nut and yoke 7. Trunnion Servicing the Fuses The electrical system is protected by fuses.
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. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to off.
Charging the Battery Replacing the Grass Deflector Warning Warning Charging the battery produces gasses that can explode. 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. Never smoke near the battery and keep sparks and flames away from battery. Never operate the lawn mower unless you install a cover plate, a mulch plate, or a grass chute and catcher.
Waste Disposal Mercury Tilt Switch Disposal Engine oil, hydraulic oil, and engine coolant are pollutants to the environment. Dispose of these according to your state and local regulations. Several states have passed laws concerning the disposal of devices containing mercury. In all the remaining states it is advisable to follow similar procedures.
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.
The Toro Total Coverage Guarantee LCE A One-Year 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 any Toro Product used for commercial, institutional, or rental purposes if defective in materials or workmanship.
