Form No. 3327–659 Z149 and Z153 Z Master with 52 SFS Side Discharge Mower Model No. 74179—Serial No. 220000389 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 . . . . . .
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 48 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 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 2 Refer to Adjusting the Mower Level, page 38, in the Maintenance section. 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, one located 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. 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.
Important Make sure fuel shut off valve is closed before transporting or storing machine, as fuel leakage may occur. Set parking brake before transporting. 2 1 Operating the Power Take Off (PTO) 2 1 The power take off (PTO) switch engages and disengages power to the electric clutch. m–4201 m–2719 Figure 13 Engaging the PTO Figure 14 1. PTO—On 2. PTO—Off 1. Choke—On 2. Choke—Off 1. While seated in the seat, release the pressure on the traction control levers and place in neutral. 2.
The Safety Interlock System 3. Sitting on the seat, engage the parking brake, move the PTO to Off, and lock the motion control levers in neutral. Now start the engine. While the engine is running, release the parking brake, engage the PTO and rise slightly from the seat; the engine should stop. Caution If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. 4.
Adjusting the Height-of-Cut The farther you move the traction control levers in either direction, the faster the machine will move in that direction. The height-of-cut is adjusted from 1-1/2 to 4-1/2 in. (38 to 114 mm) in 1/4 in. (6 mm) increments by relocating the clevis pin in different hole locations. To stop, pull the motion control levers to neutral. 1. Raise the height-of-cut lever to the transport position (also the 4-1/2 in. [114 mm] cutting height position) (Fig. 19). 2 3 1 2.
Positioning the Seat 4. Reinstall the stud nut and washer (Fig. 20). 5. Repeat the adjustment on the other gage wheels. 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. 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 1 4. Nut 5. Wheel nut and washer.
Pushing the Machine by Hand Operating with Side Discharge Important Always push the machine by hand. Never tow the machine because hydraulic damage may occur. The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. Danger To Push the Machine 1. Disengage the power take off (PTO) and turn the ignition key to Off.
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.
Mow at Correct Intervals 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. If you cannot mow for an extended period, first mow at a high cutting height; then mow again two days later at a lower height setting. Cutting Speed To improve cut quality, use a slower ground speed.
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 26 Figure 27 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 in. (3 mm). If this dimension exceeds 1/8 in.
Installing the Blades Servicing the Air Cleaner 1. Install the blade onto the spindle shaft (Fig. 27). Foam Element: Clean and oil after every 25 operating hours. Important The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting. Paper Element: Clean after every 100 operating hours. Replace after every 300 operating hours or yearly, whichever comes first. 2. Install the flat washer, lock washer, and blade bolt (Fig. 27).
Cleaning the Foam Element Installing the Foam and Paper Elements 1. Wash the foam element in liquid soap and warm water. When the element is clean, rinse it thoroughly. Important To prevent engine damage, always operate the engine with the complete foam and paper air cleaner assembly installed. 2. Dry the element by squeezing it in a clean cloth (do not wring). 1. Carefully slide the foam element onto the paper air cleaner element (Fig. 31). 3. Soak the element in new engine oil (Fig. 32).
4. 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. m–5625 Figure 35 1. Oil drain valve 1 6. Slowly pour approximately 80% of the specified oil, on page 30, into the filler cap (Fig. 34).
Servicing the Spark Plug Checking the Spark Plug 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. Use a spark plug wrench for removing and installing the spark plug(s) and a gapping tool/feeler gauge to check and adjust the air gap. Install a new spark plug(s) if necessary. Clean or replace the spark plug and set the gap every 100 hours. Type: NGK BPR5ES (or equivalent) Air Gap: 0.
Replacing the Fuel Filter 2. Close the fuel shut-off valve (Fig. 40). 3. Loosen the hose clamp at the fuel filter and slide it up the fuel line away from the fuel filter (Fig. 40). Replace the fuel filter after every 200 operating hours or yearly, whichever occurs first. 4. Pull the fuel line off of the fuel filter (Fig. 40). Never install a dirty filter if it is removed from the fuel line. 5. Open the fuel shut-off valve for the left and right tanks.
Where to Add Grease Lubricate the grease fittings as shown on the Check Service Reference Aid decal (Fig. 41). M–4159 Figure 42 Where to Add Light Oil or Spray Lubrication Figure 41 Lubricate the machine in the following areas with spray type lubricant or light oil. Lubricate every 160 hours. Greasing the Front Castor Pivots • Seat switch actuator Lubricate the front castor pivots once a year. • Brake handle pivot 1. Remove the hex plug and cap. Thread a grease zerk into the hole.
1 2 1 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 Check the hydraulic fluid level before engine is first started. Warning Check the hydraulic fluid level after first 8 operating hours. Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Check the hydraulic fluid level after every 25 operating hours.
3. Place a drain pan under the filter, remove the old filter, and wipe the filter adapter gasket surface clean (Fig. 45). 10. Start the engine and let it run for about two minutes to purge air from the system. Stop the engine and check for leaks. If one or both wheels will not drive, refer Bleeding the Hydraulic System, page 36. 11. Check the fluid level in the hydraulic tank while the fluid is warm. Add fluid to raise the level to the top of the baffle, if required. Do not overfill.
Adjusting the Motion Controls Adjusting the Hydraulic Pump Neutral Adjusting the Handle Neutral Note: Adjust the handle neutral first. That has to be correct before the following adjustment can be made. If the motion control levers do not align, or move easily into the console notch, an adjustment is required. Adjust each lever, spring, and rod separately. Danger Note: The motion control levers must be installed correctly; refer to Installing the Motion Control Levers, page 15.
Checking the Wheel Hub Slotted Nut Warning Electrical system will not perform proper safety shut off with jumper wire installed. Check after every 500 operating hours. • 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. The slotted nut needs to be torqued to 125 ft.-lb. (170 N⋅m). 1.
7 5. Place 2 thick blocks (1-1/4 in. [35 mm]) under the rear left and right lower edge of the mower. Place 1 block (1-3/8 in. [44 mm]) under the front center lower edge of the mower, not under the anti-scalp roller brackets. Lower the mower to the 1-1/2 in. (38 mm) height-of-cut position (Fig. 50). 9 8 5 3 1 6 4 2 1 m–4116 Figure 51 1. 2. 3. 4. 2 m–4122 Bottom chain bolt Top chain bolt Front swivel 10-1/4 in. (260 mm) spring compressed 5. 6. 7. 8. 9.
1. Stop the engine, set the parking brake, remove the key, and disconnect the spark plug wire(s) from the spark plug(s). Note: Increase the tension by lengthening the push arms and decrease the tension by shortening the push arms. 3 4 2. Remove the belt covers over the outside spindles. 1 3. Loosen the outer nut on the spring eye bolt (Fig. 53). 1 2 4 5 3 2 7 m–3740 Figure 52 1. Push arm 2. 15-5/1 in. (389 mm) nominal 3. Jam nut 4.
1 4 5 1 3 5 3 4 6 2 M–4159 m–4119 Figure 54 Figure 55 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 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. 3 2 Checking Electrolyte Level M–4120 Figure 56 1. 2. 3. 4. Brake lever Spring, 2-3/4 in. (74 mm) Adjusting nuts Collar on brake rod 1. With the engine off, open the hood to locate the battery. 5. 3/16–1/4 in. (5–7 mm) 6. Jam nut and yoke 7. Trunnion 2.
Installing the Battery Removing the Battery 1. Position battery in tray with terminal posts toward the engine (Fig. 59). 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.
Note: Never fill the battery with distilled water while the battery installed in the machine. Electrolyte could be spilled on other parts and cause corrosion. 4 2 3. Remove the vent caps from the battery (Fig. 58). 3 4. Slowly pour distilled water into each battery cell until the level is up to the upper line (Fig. 58) on the battery case. 1 Important Do not overfill the battery because electrolyte (sulfuric acid) can cause severe corrosion and damage to the chassis. m–4970 5.
Mercury Tilt Switch Disposal 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. 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.
