Form No. 3329–523 Rev A Z149 and Z153 Z Master with 52 SFS Side Discharge Mower Model No. 74179—Serial No. 230006001 and Up Model No. 74198—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 . . . . . . . . . . . .
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Storage . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Toro Total Coverage Guarantee . . . . . . . . . . . . . Page 47 48 49 52 Caution signals a hazard that may cause minor or moderate injury if you do not follow the recommended precautions. This manual uses two other words to highlight information.
• Keep hands and feet away from the cutting units. • The owner/user can prevent and is responsible for accidents or injuries occurring to himself or herself, other people or property. • Never carry passengers and keep pets and bystanders away. • Be alert, slow down and use caution when making turns. Look behind and to the side before changing directions. Preparation • Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job.
• Use only Toro-approved attachments. Warranty may be voided if used with unapproved attachments. • Use extreme care with grass catchers or other attachments. These can change the stability of the machine and cause loss of control. Using the Rollover Protection System (ROPS) • A rollbar is available and its use is recommended for areas where there are slopes, drop–offs or water. • When operating a machine with ROPS always use the seat belt.
Slope Chart 6
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.
67-5360 65–2690 98-4387 1. Warning—wear hearing protection. 93-1122 98-5954 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). 103–0262 104-4163 1. Explosion hazard 2. No fire, open flames, or smoking. 3. Caustic liquid/chemical burn hazard 98-3798 9 4. Wear eye protection 5. Read the Operator’s Manual. 6. Keep bystanders a safe distance from the battery.
4-8569 99-3943 1. Engine 103–2644 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 10 8. Minimum fill line 9.
106-6571 106-6586 103-1997 11
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.
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 inch) 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 Hydraulic Fluid Operation Check the hydraulic fluid level before the engine is first started; refer to Checking the Hydraulic Fluid, page 33. Note: Determine the left and right sides of the machine from the normal operating position. Greasing the Bearings Think Safety First Important Make sure that the cutting unit spindles are full of grease before the engine is first started. Please read all safety instructions and symbols in the safety section.
Using the Hour Meter Caution 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. This machine produces sound levels in excess of 85 dBA at the operators ear and can cause hearing loss through extended periods of exposure. 1 Wear hearing protection when operating this machine. m–4202 Figure 12 1. Hour meter Figure 10 Switching the Fuel Tanks 1. Warning—wear hearing protection.
Releasing the Parking Brake 2 Push forward and down on the parking brake lever to release the parking brake (Fig. 14). The parking brake is disengaged. 1 2 1 1 m–4201 m–2719 Figure 15 2 Figure 16 1. PTO—On 2. PTO—Off 1. Choke—On 2. Choke—Off m–4121 Figure 14 1. Parking brake—On 2. Parking brake—Off 1 1 2 Starting and Stopping the Engine 3 2 Starting the Engine 1. Sit down on the seat and move the motion controls to the neutral locked position. M–4268 m–2720 Figure 17 2.
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 20 1.
Adjusting the Height-of-Cut 4. Reinstall the stud nut and washer (Fig. 22). 5. Repeat the adjustment on the other gage wheels. 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. 1. Raise the height-of-cut lever to the transport position (also the 4-1/2 inch [114 mm] cutting height position) (Fig. 21). 2. To adjust, remove the hairpin cotter and clevis pin from the height-of-cut bracket (Fig. 21). 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. 24). 1 2. Slide the seat to the desired position and release the lever to lock the seat in position. m–6279 Figure 25 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.
Transporting the Machine Warning 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 the safety instructions. Knowing this information could help you, your family, pets, or bystanders avoid injury. Loading a unit onto a trailer or truck increases the possibility of backward tip–over and could cause serious injury or death. • Use extreme caution when operating a unit on a ramp.
Cutting a Lawn for the First Time Keep the Underside of the Mower Clean Cut grass slightly longer than normal to ensure that the cutting height of the mower does not scalp any uneven ground. However, the cutting height used in the past is generally the best one to use. When cutting grass longer than 6 inches (15 cm) tall, you may want to cut the lawn twice to ensure an acceptable quality of cut. Clean clippings and dirt from the underside of the mower after each use.
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.
1 MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE 2 3 4 m–2539 m–4318 Figure 29 Figure 30 2. Rotate the opposite ends of the blades forward. 1. Sail area of blade 2. Blade 3. Spring disk 4. Blade bolt 3. Measure from a level surface to the cutting edge of the blades at the same position as in step 1 above. The difference between the dimensions obtained in steps 1 and 3 must not exceed 1/8 inch (3 mm).
Installing the Blades Safety Filter: Replace after every 600 operating hours. 1. Install the blade onto the spindle shaft (Fig. 30). Note: Check the filters more frequently if operating conditions are extremely dusty or sandy. Important The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting. Removing the Filters 2. Install the flat washer, lock washer, and blade bolt (Fig. 30). Torque the blade bolt to 85–110 ft-lb (115–150 N⋅m). 1.
Servicing the Primary Filter Viscosity: See the table below. USE THESE SAE VISCOSITY OILS Check and/or replace it after 200 operating hours. If the primary filter is dirty, bent, or damaged then replace the filter. Do not clean the primary filter. Servicing the Safety Filter Replace it after 600 operating hours. 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.
Changing the Oil 2. Remove the old filter (Fig. 37). 1. Start the engine and let it run for five minutes. This warms the oil so that it drains better. 3. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Fig. 37). 2. Park the machine so that the drain side is slightly lower than the opposite side to ensure that the oil drains completely. Disengage the power take off (PTO), set the parking brake, stop the engine, and remove the key. 1 3. Place a pan below the oil drain.
2. Tighten the spark plug(s) to 16 ft-lb (22 N⋅m). 3. Push the wire(s) onto the spark plug(s) (Fig. 38). 1 Replacing the Fuel Filter Replace the fuel filter after every 200 operating hours or yearly, whichever occurs first. 2 Never install a dirty filter if it is removed from the fuel line. 1. Disengage the power take off (PTO), set the parking brake, stop the engine, and remove the key. m–4294 2. Close the fuel shut-off valve on the console. Figure 38 1. Spark plug wire installed 2. Spark plug 3.
3. Connect a grease gun to the fitting. Pump grease into the fittings until grease begins to ooze out of the bearings. 1. Park the machine on a level surface to ensure that the fuel tanks drain completely. Then disengage the power take off (PTO), set the parking brake, stop the engine, and remove the key. 4. Wipe up any excess grease. 2. Close the fuel shut-off valve (Fig. 41). Where to Add Grease 3. Loosen the hose clamp at the fuel filter and slide it up the fuel line away from the fuel filter (Fig.
3. Grease the idler pulley pivot (Fig. 43). 4. Grease the fittings on the push arms (Fig. 43). 1 m–1872 Figure 44 1. Valve stem Servicing the Hydraulic System Checking the Hydraulic Fluid M–4159 Check the hydraulic fluid level before engine is first started. Figure 43 Check the hydraulic fluid level after first 8 operating hours. Check the hydraulic fluid level after every 25 operating hours.
Replacing the Hydraulic Filter 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. Change the hydraulic filter: • After the first 8 operating hours. Note: The fluid level should be to the top of the hot level of the baffle, when the fluid is warm (Fig. 45). • After every 200 operating hours. 7. Install the cap on the filler neck. 1. Position machine on a level surface, stop the engine, and remove the key.
Checking the Hydraulic Lines 8. If there is no fluid, add fluid to the reservoir to approximately 1/4 inch (6 mm) below the top of the baffle. 1 After every 100 operating hours, check the hydraulic lines and hoses for leaks, loose fittings, kinked lines, loose mounting supports, wear, weather and chemical deterioration. Make necessary repairs before operating. Note: Keep the areas around the hydraulic system clean from grass and debris buildup.
5. Check where the control lever is relative to notch in console (Fig. 48). It should be centered allowing lever to pivot outward to the neutral lock position. 8 2 1 3 4 3 9 1 m–6282 2 Figure 48 1. Neutral locked position 2. Control lever 6 2 3. Neutral potion 7 9 6. If adjustment is needed, loosen the nut and jam nut against the yoke (Fig. 49). 8 1 7.
Setting the Hydraulic Pump Neutral 3. Move motion control lever forward and reverse, then back to neutral. Wheel must stop turning or slightly creep in reverse. Note: Adjust handle neutral first. That has to be correct before the following adjustment can be made. 4. Open throttle to fast. Make sure wheel remains stopped or slightly creeps in reverse, adjust if necessary. Danger Mechanical or hydraulic jacks may fail to support machine and cause a serious injury. • Use jack stand when supporting machine.
6. Tighten the nuts at the ball joints (Fig. 49). 2 Warning 3 Electrical system will not perform proper safety shut off with jumper wire installed. 4 • 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 m–6280 7. After both pump neutrals are set, shut off the machine. Figure 51 8. Remove jumper wire from wire harness connector and plug connector into seat switch.
Checking the Wheel Hub Slotted Nut 4. Raise the deck to the transport position (Fig. 54). Take force off of the two large deck lift springs by loosening the jam nut and front spring nut, in front of each spring, as far as possible (Fig. 55). Check after every 500 operating hours. 5. Place 2 thick blocks (1-1/4 inch [35 mm]) under the rear left and right lower edge of the mower. Place 1 block (1-3/8 inch [44 mm]) under the front center lower edge of the mower, not under the anti-scalp roller brackets.
2. Adjust each side the same amount. Each push arm should have a nominal length of 15-5/16 inch (389 mm) (Fig. 56). 10. Adjust the front swivel using the rear locking nut until the front chain is tight and the front of the deck is still touching the block. Tighten the front locking nut. Repeat for the opposite side. Note: Increase the tension by lengthening the push arms and decrease the tension by shortening the push arms. 7 9 8 1 5 3 4 3 1 6 4 2 2 m–6273 m–4116 Figure 56 Figure 55 1. 2. 3.
1. Stop the engine, set the parking brake, remove the key, and disconnect the spark plug wire(s) from the spark plug(s). 1 5 2. Remove the belt covers over the outside spindles. 3 3. Loosen the outer nut on the spring eye bolt (Fig. 57). 1 4 5 3 4 2 7 2 M–4159 Figure 58 Top View 6 1. Deck belt 2. Idler arm 3. Outside pulley M–4197 4. Spring 5. Idler pulley Figure 57 Top View 1. 2. 3. 4. Outer nut Idler pulley Idler arm Spring eye bolt Replacing the Pump Drive Belt 5. Spring 6.
4 5 1 3 4 5 7 6 1 6 2 m–4119 3 Figure 59 1. Clutch strap 2. Bolt 3. Clutch electrical wire 4. Belt 5. Idler 6. Clutch 2 M–4120 Figure 60 1. Brake lever 2. Spring, 2-3/4 inch (74 mm) 3. Adjusting nuts 4. 5. 6. 7. Collar on brake rod 3/16–1/4 inch (5–7 mm) Jam nut and yoke Trunnion Adjusting the Parking Brake Check the parking brake for proper adjustment. Servicing the Fuses 1. Disengage the brake lever (lever down). 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 Caution Engine oil, hydraulic oil, and engine coolant are pollutants to the environment. Dispose of these according to your state and local regulations. The mercury contained in the tilt switch is poisonous and exposure to mercury can cause severe illness. Mercury Tilt Switch • Never attempt to open or repair the tilt switch. • Avoid contact with the mercury. The tilt switch on this unit is located under the seat. Tilt the seat up to gain access.
BK BK GND PTO CLUTCH GY SW5 DK.GN SHOWN WITH LEVER IN NEUTRAL POSITION LT.GN (NEUTRAL) 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 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 the listed Toro Products if defective in materials or workmanship. The following time periods apply from the date of purchase: You must maintain your Toro Product by following the maintenance procedures described in the operator’s manual.
