Form No. 3326–673 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 . . . . . . . . . . . . . . . . . . .
Replacing the Deck Belt . . . . . . . . . . . . . . . . . . . Replacing the Pump Drive Belt . . . . . . . . . . . . . . Adjusting Motion Controls . . . . . . . . . . . . . . . . . Adjusting Parking Brake . . . . . . . . . . . . . . . . . . . Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Waste Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . Mercury Tilt Switch . . . . . . . . . . . . . . . .
• Slow down and use extra care on hillsides. Be sure to travel in the recommended direction on hillsides. Turf conditions can affect the machine’s stability. Use caution while operating near drop–offs. Training • Read the Operator’s Manual and other training material. If the operator(s) or mechanic(s) can not read English it is the owner’s responsibility to explain this material to them. • Slow down and use caution when making turns and when changing directions on slopes.
• Be aware of the mower discharge direction and do not point it at anyone. Do not operate the mower without either the entire grass catcher or the guard in place. • Let engine cool before storing and do not store near flame. • Shut off fuel while storing or transporting. Do not store fuel near flames or drain indoors. • Slow down before turning. Sharp turns on any terrain may cause loss of control. • Park machine on level ground. Never allow untrained personnel to service machine.
• When operating machine on slopes, banks or near drop offs, always have ROPS (roll over protection) installed. • When operating a machine with ROPS (roll over protection) always use seat belt. • 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.
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.
1 8 8 2 Releasing the Parking Brake 2 1. Push forward and down on the parking brake lever to release the parking brake (Fig. 13). The parking brake is “DISENGAGED”. 1 2 7 m–4121 3 Figure 13 1. Parking brake—ON 4 5 10 6 9 2. Parking brake—OFF m–4200 Figure 12 1. 2. 3. 4. 5. Ignition switch Motion control lever Parking brake lever Throttle Choke 6. 7. 8. 9. 10. Starting and Stopping the Engine Power take off (PTO) Height-of-Cut lever Fuel cap Hourmeter Fuel shut-off valve Starting 1.
7. After the engine starts, move the choke to “OFF” (Fig. 15). If the engine stalls or hesitates, move the choke back to “ON” for a few seconds. Then move the throttle lever to desired setting. Repeat this as required. Important Make sure fuel shut off valve is closed before transporting or storing machine, as fuel leakage may occur. Operating the Power Take Off (PTO) 2 1 The power take off (PTO) switch engages and disengages power to the electric clutch. 2 Engaging the PTO 1 m–4201 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.
Fuel Tanks To go straight, apply equal pressure to both motion control levers (Fig. 19). 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. 21). To turn, release pressure on the motion control lever toward the direction you want to turn (Fig. 19). To stop push the motion control levers to neutral.
1 2 3 1 4 3 2 m-4122 5 Figure 22 1. Height-of-cut lever 2. Clevis pin m–4167 3. Hairpin cotter Figure 23 1. Gage wheel 2. Stud 3. Washer 5. Lower height–of–cut lever onto clevis pin. Adjusting Anti-Scalp Rollers 4. Nut 5. Wheel nut and washer. Do not remove. Center Rollers Whenever you change the height-of-cut it is recommended to adjust the height of the anti-scalp rollers. 1. Disengage the power take off (PTO) and turn the ignition key to “OFF”.
To Push the Machine 1. Disengage the power take off (PTO) and turn the ignition key to “OFF” to stop the engine. 3 2. Rotate the by-pass valves counterclockwise 1 turn to push. This allows hydraulic fluid to by-pass the pump enabling the wheels to turn (Fig. 26). Important Do not rotate by–pass valves more than 1 turn. This prevents valves from coming out of the body and causing fluid to run out. 1 2 m–4124 To Operate the Machine Figure 24 1. Center rollers and spacer 2. Nut 1.
Loading Machines Danger Use extreme caution when loading units on trailers or trucks. One full width ramp that is wide enough to extend beyond the rear tires is recommended instead of individual ramps for each side of the unit. The lower rear section of the tractor frame extends back between the rear wheels and serves as a stop for tipping backward. Having a full width ramp provides a surface for the frame members to contact if the unit starts to tip backward.
Tips for Mowing Grass Long Grass Fast Throttle Setting If the grass is ever allowed to grow slightly longer than normal, or if it contains a high degree of moisture, raise the cutting height higher than usual and cut the grass at this setting. Then cut the grass again using the lower, normal setting. For best mowing and maximum air circulation, operate the engine at “FAST.
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 • • • • Change engine oil1 Service paper air cl
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.
Cleaning the Cooling System Note: Service the air cleaner more frequently (every few hours) if operating conditions are extremely dusty or sandy. Clean the air intake screen from grass and debris before each use. Removing the Foam and Paper Elements Clean cooling fins and engine shrouds every 300 hours or yearly, which ever comes first. 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. 1.
Important worn. 2. Place the air cleaner assembly onto the air cleaner base and install wingnuts (Fig. 34). Replace the foam element if it is torn or 1 ÓÓÓÓ ÓÓÓ ÓÓÓÓ ÓÓÓ ÓÓÓÓ ÓÓÓ ÓÓÓÓ 3. Install the air cleaner cover and secure with cover nuts (Fig. 34). 2 Engine Oil Change oil: M-4370 • After the first 8 operating hours. Figure 35 1. Foam element • After every 100 operating hours. 2. Oil Note: Change oil more frequently when operating conditions are extremely dusty or sandy. 2.
Important Do not overfill the crankcase with oil because the engine may be damaged. 1 3 1 2 m–4674 Figure 38 M-4368 1. Oil drain valve Figure 37 1. Oil dipstick 2. Filler tube 3. Dipstick end 6. Slowly pour approximately 80% of the specified amount of oil, on page 30, into the filler tube (Fig. 37). Now check the oil level; refer to Checking Oil Level, page 30. Slowly add additional oil to bring to “FULL” mark on dipstick. Changing/Draining Oil 1. Start the engine and let it run five minutes.
4. Install the replacement oil filter to the adapter. Turn the oil filter clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 3/4 turn (Fig. 39). Important Always replace the spark plug(s) when it has a black coating, worn electrodes, an oily film, or cracks. 2. Clean the electrode by scraping or with a wire brussh to remove carbon deposits and wetness. 5. Fill the crankcase with the proper type of new oil; refer to Changing/Draining Oil, page 31. 3.
6. Open fuel shut-off valve on console. 3 2 1 4 1 2 Figure 43 M-4294 1. Fuel shut-off valve 2. Fuel filter Figure 42 1. Filter M-4294 2. Hose clamp 3. Hose clamp 4. Fuel line Servicing the Spark Arrester Fuel Tank Inspect the spark arrester every 50 hours for damage, such as holes in the screen, and for build-up on the screen. If it is damaged, replace it with a new spark arrester. If it is dirty, remove it and clean the screen with a wire brush and/or soak it in solvent.
m–4159 Figure 45 Figure 44 Where to Add Light Oil or Spray Lubrication Grease Front Castor Pivots Lubricate the front castor pivots once a year. Lubricate the machine in the following areas with spray type lubricant or light oil. Lubricate every 160 hours. 1. Remove hex plug and cap. Thread a grease zerk into hole. • Seat switch actuator. • Brake handle pivot. 2. Pump grease into zerk until it oozes out around top bearing. • Brake rod bushings. • Motion control bronze bushings. 3.
Replacing the Hydraulic Filter 5. Run the machine 15 minutes to allow any air to purge out of the system and warm fluid. Change the hydraulic filter: 6. Recheck level while fluid is warm. Add fluid to raise level to top of the baffle, if required. • After the first 8 operating hours. • After every 200 operating hours. Note: Fluid level should be to the top of the baffle when fluid is warm (Fig. 46). 1. Position machine on a level surface, stop the engine, and remove key from ignition switch. 7.
Warning 1 3 Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • 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. • Use cardboard or paper to find hydraulic leaks.
2. Remove dust cap from castor and tighten lock nut (Fig. 50). 1 4 3. Tighten until spring washers are flat and then back off a 1/4 turn to properly set the preload on the bearings (Fig. 50). 3 5 Important Make sure spring washers are installed correctly as shown in Figure 50. 2 3 m-4638 Figure 51 2 1. Slotted nut 2. Two threads or less showing 1 m–4640 Mower Leveling Figure 50 1. Spring washers 2. Lock nut 3. Hole in threaded shaft 4. Washer (if needed) 5. Slot 1.
13. Install anti-scalp rollers for proper height-of-cut and tighten securely. See Adjusting Anti-Scalp Rollers on page 22. Note: Do not loosen front chain hardware. 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. 53). 14. Raise deck lift lever to the transport position (Fig. 52). 15.
1. Stop the engine, set the parking brake, remove the key and disconnect the spark plug wire(s) from the spark plug(s). 2. Remove belt covers over outside spindles. 3. Loosen outer nut on spring eye bolt (Fig. 56). 1 3 4 2 5 6 7 1 m-4643 4 5 3 2 Figure 55 1. 2. 3. 4. Pivot bolt Throttle lever Belleville washers Tab washer 7 5. Washer 6. Bracket 7. Nut Clean Under Deck 6 m–4197 Figure 56 Remove grass build up under deck daily. Top View 1. Position mower on a flat surface.
1 4 5 1 3 5 3 4 6 2 m–4159 m–4119 Figure 57 Figure 58 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 Motion Controls Replacing the Pump Drive Belt Adjusting Handle Neutral Check pump drive belt for wear after every 50 hours of operation. If motion control levers do not align, or move easily into the console notch, adjustment is required.
1 1 4 3 2 M-4118 2 Figure 59 1. Right-hand motion control lever (shown) 6 2 2. Neutral lockout position 7 4. If adjustment is needed, loosen the nut against the yoke (Fig. 60). 8 1 5.
Adjusting Parking Brake Warning Check parking brake for proper adjustment. Engine must be running so motion control adjustment can be performed. Contact with moving parts or hot surfaces may cause personal injury. 1. Disengage brake lever (lever down). Keep hands, feet, face, clothing and other body parts away from rotating parts, muffler and other hot surfaces. 3. If adjustment is necessary, loosen the jam nut below the spring and tighten the nut directly below the yoke (Fig. 61).
2. To replace fuses pull out on the fuse to remove it (Fig. 62). 1 2 2 3 1262 Figure 63 1 1. Filler caps 2. Lower part of tube m–3653 Adding Water to the Battery Figure 62 1. Main—30 amp 3. Plates The best time to add distilled water to the battery is just before you operate the machine. This lets the water mix thoroughly with the electrolyte solution. 2. Alternator—25 amp 1. Clean the top of the battery with a paper towel. Battery 2. Lift off the filler caps (Fig. 63). 3.
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 seat up to gain access.
8 6 4 2 3 5 1 7 m-5037 Figure 64 1. 2. 3. 4. 5. Bolt Spacer Locknut Spring Spring installed 6. Grass Deflector 7. Place behind deck edge before installing bolt 8.
Wiring Diagram 46
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 33. 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.
