Form No. 3326–672 Z153 Z–Master with 52 SFS Side Discharge Mower Model No.
Warning Install Motion Control Levers . . . . . . . . . . . . . . . Activate the Battery . . . . . . . . . . . . . . . . . . . . . . . Install Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . Greasing the Bearings . . . . . . . . . . . . . . . . . . . . . Check the Leveling of Mower Deck . . . . . . . . . . Check Side Discharge Chute . . . . . . . . . . . . . . . . Check Engine Oil Level . . . . . . . . . . . . . . . . . . .
Adjusting Motion Controls . . . . . . . . . . . . . . . . . Adjusting Parking Brake . . . . . . . . . . . . . . . . . . . Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Waste Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . Mercury Tilt Switch . . . . . . . . . . . . . . . . . . . . . . . Mercury Tilt Switch Disposal . . . . . . . . . . . . . . . Replacing the Grass Deflector . . . . . . . . .
• Become familiar with the safe operation of the equipment, operator controls, and safety signs. • Never operate with the PTO shield, or other guards not securely in place. Be sure all interlocks are attached, adjusted properly, and functioning property. • All operators and mechanics should be trained. The owner is responsible for training the users. • Never operate with the discharge deflector raised, removed or altered, unless using a grass catcher.
• Keep hands, feet, hair and loose clothing away from attachment discharge area, underside of mower and any moving parts while engine is running. • Carefully release pressure from components with stored energy. • Disconnect battery or remove spark plug wire before making any repairs. Disconnect the negative terminal first and the positive last. Reconnect positive first and negative last. • Stop the engine before removing the grass catcher or unclogging the chute.
• Be certain that the seat belt can be released quickly if the machine is driven or rolls into ponds or water. • 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 mow slopes exceeding 15 degrees. • Avoid turning on slopes. If you must turn, turn slowly and gradually downhill, if possible. • Do not mow near drop-offs, ditches, or embankments.
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. Top of Console Under Seat (Part No. 103–0315) On Control Panel (Part No. 103–0167) On Right Side of Height-of-Cut Plate (Part No. 1–653140) On Left Side of Height-of-Cut Plate (Part No. 1–653147) Below Center Of Console (Part No. 103–0262) Lower Left of Console (Part No.
On Top Left Side of Frame (Part No. 1–633818) Under Footrest (Part No. 99-3924) On Tilt Switch (Part No. 1–643401) On Top of Hydraulic Reservoir (Part No. 1–523552) On Frame Near Muffler (Part No.
On Right Side of Mower (Part No. 66 1340) On Left Side of Mower (Part No. 43 8480) Under Belt Cover (3) Under Footrest (1) (Part No. 98-5954) On Deflector (Part No. 54 9220) On Top Center of Mower (Part No. 99 3943) On Top of Mower in Center (Part No. 98 3798) 99–3943 (2) On Belt Covers (Part No. 67 5360) On Left Front of Mower (Part No.
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.
Assembly Loose Parts Note: Use the chart below to verify all parts have been shipped. Description Qty.
2. Remove retaining rod from seat and insert the “L” shaped end of the rod into the hole directly above the left–side hydraulic pump (Fig. 3). 3. Place the seat retaining rod to the outside of the mounting tab of the seat frame and secure with 5/16-18 x 1″ (26 mm) bolt and 5/16″ (8mm) locknut (Fig. 3). 2 1 4. Tighten until snug, then loosen so the rod pivots freely. 1 3 2 m–3751 Figure 4 1. Mounting plate 2. Bolt 3/8-18 x 1″ (26 mm) 3. Spring washer 3/8″ 5.
Danger 4 Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns. 2 • Do not drink electrolyte and avoid contact with skin, eyes or clothing. Wear safety glasses to shield your eyes and robber gloves to protect your hands. • Fill the battery where clean water is always available for flushing the skin. • Follow all instructions and comply with all safety messages on the electrolyte container. 3 1 2. Place battery on a level surface. 3.
5. Slide the red terminal boot onto the positive (red) battery post. 5. Run the machine 15 minutes to allow any air to purge out of the system and warm fluid. 6. Secure battery with J-bolts, hold down clamp and (2) 1/4″ washers and (2) 1/4″ wing nuts (Fig. 8). 6. Recheck level while fluid is warm. Add fluid to raise level to top of the baffle, if required. 7. Position drain tube away from belts and other parts to prevent corrosion.
1. Grease the fittings on the three spindle bearings. Grease until it comes out lower seals (Fig. 10). Caution 1 This machine produces sound levels in excess of 85dBA at the operator’s ear and can cause hearing loss through extended periods of exposure. Wear hearing protection when operating this machine. 1 2 M-4159 Figure 11 Figure 10 1. Caution 1. Spindles 2. Wear hearing protection Controls Check the Leveling of Mower Deck Become familiar with all the controls (Fig.
Parking Brake 5. Move the throttle control to the “FAST” position before starting a cold engine. Always set the parking brake when you stop the machine or leave it unattended. 6. Turn ignition key to “START” to energize starter. When engine starts, release key. Important Do not park on slopes unless wheels are chocked or blocked. Important Do not engage starter for more than 10 seconds at a time. If engine fails to start allow 30 second cool-down period between attempts.
The Safety Interlock System 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. In an emergency, the engine may be stopped by turning the ignition key to “OFF.” Caution 4. Pull wire off spark plug(s) to prevent possibility of someone accidentally starting the machine before transporting or storing machine.
4. Sitting on the seat, “ENGAGE” parking brake, PTO “OFF” and lock the motion control levers in neutral. Now start the engine. While the engine is running, center the motion controls and move (forward or reverse); the engine should stop. 2 3 1 5. Sitting on the seat, “DISENGAGE” parking brake, move PTO switch “OFF” and move the motion control levers to neutral lock position. Try starting the engine; the engine should not crank. 4 m–2715 Figure 19 Driving Forward or Backward 1.
Instruments 1. Raise the height-of-cut lever to the transport position (also the 4-1/2″ (114 mm) cutting height position) (Fig. 22). Hour Meter 2. To adjust, remove hairpin cotter and clevis pin from height-of-cut bracket (Fig. 22). 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. 3. Select hole in height-of-cut bracket corresponding to the height-of-cut desired, and insert clevis pin (Fig.
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. 25). 2. Slide the seat to the desired position and release lever to lock in position. 1 4 3 2 5 m–4167 Figure 23 1. Gage wheel 2. Stud 3. Washer 4. Nut 5. Wheel nut and washer. Do not remove. 1 m–3655 Figure 25 Center Rollers 1. Adjustment lever 1.
the safety instructions on pages 3–13. Knowing this information could help you, your family, pets or bystanders avoid injury. To transport the machine: • Lock brake and block wheels. 1 • Securely fasten the machine to the trailer or truck with straps, chains, cable, or ropes. Figure 26 • Secure a trailer to towing vehicle with safety chains. 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 Recommended Maintenance Schedule Maintenance Service Interval After First Use Each Use Maintenance Procedure • Check hydraulic fluid level • Change engine oil • Change hydraulic filter • • • • Check engine oil level Check safety system Clean cooling systems1 Clean mower housing Every 5 Hours • Check cutting blades • Grease blade spindle bearings Every 25 Hours • • • • • • • • • Every 50 Hours • Service the spark arrester Every 100 Hours • • • • Every 200 Hours • Change oil filter1 •
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. Cutting Blades Inspecting the 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 30 m–1078 1. Sail area of blade 2. Blade Figure 28 3. Spring disk 4. Blade bolt Sharpening the Blades MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE 1. Use a file to sharpen the cutting edge at both ends of the blade (Fig. 31). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges. m–2539 Figure 29 1 3. Rotate the opposite ends of the blades forward.
Air Cleaner C. Put oil on the element (Fig. 34). Squeeze the element to distribute the oil. Foam Element: Clean and re-oil after every 25 operating hours. Important worn. Replace the foam element if it is torn or Paper Element: Replace after every 100 operating hours. 2 Note: Service the air cleaner more frequently (every few hours) if operating conditions are extremely dusty or sandy. 1 Removing the Foam and Paper Elements 1.
2. Place the air cleaner assembly onto the air cleaner base (Fig. 33). 1 3 3. Install the air cleaner cover and secure with cover nut (Fig. 33). Engine Oil 2 Change oil: • After the first 5 operating hours. m–4090 • After every 100 operating hours. m–3219 Figure 36 Note: Change oil more frequently when operating conditions are extremely dusty or sandy. 1. Oil dipstick 2. Filler tube Oil Type: Detergent oil (API service SG or SH) 3. Metal end Crankcase Capacity: w/filter, 2.1 qt.
Change Oil Filter Removing the Spark Plug(s) Replace the oil filter every 200 hours or every other oil change. 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key. Note: Change oil filter more frequently when operating conditions are extremely dusty or sandy. 2. Pull the wire(s) off the spark plug(s) (Fig. 39). Now clean around the spark plug(s) to prevent dirt from falling into the engine and potentially causing damage.
2 3 1 1 0.030 in. (0.76 mm) m–3215 2 Figure 40 1. Center electrode insulator 2. Side electrode m–4088 Figure 41 3. Air gap (not to scale) 1. Filter Installing the Spark Plug(s) 2. Hose clamp Fuel Tank 1. Install the spark plug(s). Make sure the air gap is set correctly. Draining The Fuel Tank 2. Tighten the spark plug(s) to 20 ft-lb (27 N.m). Danger 3. Push the wire(s) onto the spark plug(s) (Fig. 39). In certain conditions, gasoline is extremely flammable and highly explosive.
Where to Add Grease 6. Install the fuel line onto the fuel filter. Slide the hose clamp close to the fuel filter to secure the fuel line (Fig. 42). Lubricate the grease fittings as shown on the CHECK SERVICE REFERENCE AID decal (Fig. 43). 3 1 4 m–4088 2 Figure 42 1. Fuel shut-off valve 2. Fuel filter 3. Hose clamp 4. Fuel line Figure 43 Servicing the Spark Arrester Inspect the spark arrester every 50 hours for damage, such as holes in the screen, and for build-up on the screen.
3. Remove cap from filler neck. Look inside to check if there is fluid in the reservoir (Fig. 45). 4. If there is no fluid, add fluid to reservoir approximately a 1/4″ (6mm) below the top of baffle. 5. Run the machine 15 minutes to allow any air to purge out of the system and warm fluid. 6. Recheck level while fluid is warm. Add fluid to raise level to top of the baffle, if required. Note: Fluid level should be to the top of the baffle when fluid is warm (Fig. 45). 7. Install cap on filler neck.
Replacing the Hydraulic Filter Change the hydraulic filter: 1 • After the first 8 operating hours. 3 • 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. m–1256 2. Remove hydro cap and temporarily cover opening with a plastic bag and rubber band to prevent all hydro fluid from draining out. Figure 47 1. Hydraulic filter 2.
Check Hydraulic Lines Castor Pivot Bearing Adjustment 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. Check after every 500 operating hours or at storage which ever comes first. 1. Stop the engine, set the parking brake, remove the key and disconnect the spark plug wire(s) from the spark plug(s).
8. Replace cotter pin. 6. Loosen bottom chain bolt in slot at rear of deck. Repeat for opposite side (Fig. 52). 1 Note: Do not loosen front chain hardware. 4 7. Loosen front and rear locking nut on either side of front swivel. Loosen until front chains are loose and deck is supported by blocks. Repeat for opposite side. (Fig. 52). 3 5 Note: When hardware is loose, deck will rotate the lift handle up out of position. 2 m-4638 8.
13. Install anti-scalp rollers for proper height-of-cut and tighten securely. See Adjusting Anti-Scalp Rollers on page 21. 14. Raise deck lift lever to the transport position (Fig. 51). 15. Adjust compression springs by turning the front spring nuts so the distance between the two large washers is 10-1/4″ (260 mm). Then tighten jam nut (Fig. 52). 1 3 4 2 5 6 7 m-4643 Note: Make sure all hardware is tight. Figure 54 Adjusting Push Arms 1. 2. 3. 4. 1.
2. Remove belt covers over outside spindles. 1 3. Loosen outer nut on spring eye bolt (Fig. 55). 1 4 5 5 3 3 2 7 4 2 m–4159 Figure 56 6 Top View m–4197 1. Deck belt 2. Idler arm 3. Outside pulley Figure 55 Top View 1. 2. 3. 4. Outer nut Idler pulley Idler arm Spring eye bolt 5. Spring 6. 9.375±.125 (238 mm±.3 mm) 7. Deck belt 4. Spring 5. Idler pulley Replacing the Pump Drive Belt Check pump drive belt for wear after every 50 hours of operation. 4. Remove belt.
4 5 1 3 1 6 2 2 m–4119 Figure 57 1. Clutch strap 2. Bolt 3. Clutch electrical wire M-4118 4. Belt 5. Idler 6. Clutch Figure 58 1. Right-hand motion control lever (shown) 2. Neutral lockout position 4. If adjustment is needed, loosen the nut against the yoke (Fig. 59). Adjusting Motion Controls 5.
Warning Engine must be running so motion control adjustment can be performed. Contact with moving parts or hot surfaces may cause personal injury. 1 4 3 Keep hands, feet, face, clothing and other body parts away from rotating parts, muffler and other hot surfaces. 2 2. Slide seat forward, disconnect prop rod and tilt seat fully forward. 6 2 3. Disconnect electrical connector from the seat safety switch. Temporarily install a jumper wire across terminals in the wiring harness connector. 7 4.
Adjusting Parking Brake Fuse: Main F1—20 amp, blade-type Alternator F2—20 amp, blade-type Check parking brake for proper adjustment. 1. Raise the seat to gain access to fuse holder (Fig. 61). 1. Disengage brake lever (lever down). 2. To replace fuses pull out on the fuse to remove it (Fig. 61). 2. Measure the length of the spring. Measurement should be 2.75″ (70 mm) between washers (Fig. 60). 2 3.
1 2 Warning Charging battery produces gasses that can explode and cause serious injury. 3 • 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. 1262 Figure 62 1. Filler caps 2. Lower part of tube 3. Plates Waste Disposal Adding Water to the Battery Engine oil, hydraulic oil and engine coolant are pollutants to the environment. Dispose of these according to your state and local regulations.
does not become part of solid waste or waters. Management and disposal practices must be within relevant federal, state or local laws. 8 6 4 2 Return the switch to your Toro dealer if it is faulty and is being replaced or if the unit containing the switch is no longer operating and is being scrapped. If the switch is damaged or broken open use extreme caution in handling. Call your local waste management authority or Toro Customer Service for instructions.
Wiring Diagram 44
Cleaning and Storage F. 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” to stop the engine. Remove the key. G. Stop engine, allow to cool and drain the fuel tank; refer to Fuel Tank, page 31. H. Restart engine and run until it stops. Repeat, on “CHOKE” until engine will not restart. 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.
