Form No. 3327–249 Z149 and Z153 Z Master with 52 SFS Side Discharge Mower Model No. 74179—Serial No. 220000001 and Up Model No. 74198—Serial No.
Warning Activating the Battery . . . . . . . . . . . . . . . . . . . . . . Checking the Hydraulic Fluid . . . . . . . . . . . . . . . . Greasing the Bearings . . . . . . . . . . . . . . . . . . . . . . Checking the Leveling of the Mower Deck . . . . . . Checking the Side Discharge Chute . . . . . . . . . . . . Checking the Engine Oil Level . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Think Safety First . . . . . . . . . . . . . . . . . . . .
Replacing the Grass Deflector . . . . . . . . . . . . . . . . Waste Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mercury Tilt Switch . . . . . . . . . . . . . . . . . . . . . . . . Mercury Tilt Switch Disposal . . . . . . . . . . . . . . . . Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Storage . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Toro Total Coverage Guarantee . .
• Stop equipment and inspect blades after striking objects or if an abnormal vibration occurs. Make necessary repairs before resuming operations. Preparation • Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job. Only use accessories and attachments approved by the manufacturer. • Keep hands and feet away from the cutting units. • Look behind and down before backing up to be sure of a clear path.
• Before operating a machine with ROPS (roll over protection) be certain the seat belts are attached to prevent the seat from pivoting forward. • Charge batteries in an open well ventilated area, away from spark and flames. Unplug charger before connecting or disconnecting from battery. Wear protective clothing and use insulated tools. • Use only Toro-approved attachments. Warranty may be voided if used with unapproved attachments. • Keep all parts in good working condition and all hardware tightened.
• Do not mow on wet grass. Reduced traction could cause sliding. • Do not use a grass catcher on steep slopes. Heavy grass bags could cause loss of control or overturn the machine. 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.
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.
93-7818 104-8172 1. Warning—torque the blade bolt to 115–149 N⋅m (85–110 ft.-lb.). Read the operator’s manual for further instructions. 98-3798 104-4163 1. Explosion hazard 2. No sparks, flame, or smoking 3. Caustic liquid hazard—burns to hand and damage to items. 104-4164 1. Contains lead—do not throw the battery in the garbage. 10 4. Wear eye protection. 5. Read the operator’s manual. 6. Keep bystanders away.
65-2690 1-403005 1-653140 99-3924 1-653147 99–3943 99-3943 1. Engine pulley 103-0262 1. Right-hand fuel tank on 2. Left-hand fuel tank on 3.
99-3942 103-1997 12
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 39, 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.
Greasing and Lubrication Greasing the Bearings Lubricate the machine when shown on the Check Service Reference Aid decal (Fig. 41). Grease more frequently when operating conditions are extremely dusty or sandy. The cutting unit must be lubricated regularly; refer to the Recommended Maintenance Schedule, page 26. Grease with No. 2 general purpose lithium base or molybdenum base grease. Grease with No. 2 general purpose lithium base or molybdenum base grease. 1.
Checking the Tire Pressure 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. 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. 43). Check the tires when they are cold to get the most accurate pressure reading. 6.
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 the key. 2 Important Do not substitute with an automotive oil filter or severe hydraulic system damage may result. m–1256 2. Remove the hydro cap and temporarily cover the opening with a plastic bag and rubber band to prevent all hydro fluid from draining out. Figure 46 1. Hydraulic filter 2.
Checking the Hydraulic Lines 3. Check where the lever is relative to the notch in the console. It should be centered allowing the lever to pivot outward to the neutral lock position (Fig. 47). 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. 4. If an adjustment is needed, loosen the nut against the yoke. 5.
1. This adjustment must be made with the drive wheels turning. First raise the frame and block it up so that the drive wheels can rotate freely. 10. Shut off the unit. Remove the jumper wire from the wire harness connector and plug the connector into the seat switch. 11. Install the prop rod and lower the seat. Warning Adjusting the Castor Pivot Bearing Engine must be running so motion control adjustment can be performed. Contact with moving parts or hot surfaces may cause personal injury.
Checking the Wheel Hub Slotted Nut 4. Raise the deck to the transport position (Fig. 50). 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. 51). Check after every 500 operating hours. 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.
2. Adjust each side the same amount. Each push arm should have a nominal length of 15-5/16 in. (389 mm) (Fig. 52). 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 3 5 4 1 3 1 6 2 4 2 m–3740 m–4116 Figure 51 1. 2. 3. 4.
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. 53). 1 4 5 3 4 2 7 2 M–4159 Figure 54 Top View 1. Deck belt 2. Idler arm 3. Outside pulley 6 4. Spring 5. Idler pulley M–4197 Figure 53 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 55 1. Clutch strap 2. Bolt 3. Clutch electrical wire 4. Belt 5. Idler 6. Clutch 2 M–4120 Figure 56 1. 2. 3. 4. Brake lever Spring, 2-3/4 in. (74 mm) Adjusting nuts Collar on brake rod 5. 3/16–1/4 in. (5–7 mm) 6. Jam nut and yoke 7. 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 PTO CLUTCH GND 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 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.