Form No. 3329–863 Z149 and Z153 Z Master with 52in SFS Side Discharge Mower Model No. 74163—Serial No. 240000001 and Up Model No. 74167—Serial No. 240000001 and Up Operator’s Manual Register your product at www.Toro.
Warning Driving Forward or Backward . . . . . . . . . . . . . . . Stopping the Machine . . . . . . . . . . . . . . . . . . . . . . Adjusting the Height-of-Cut . . . . . . . . . . . . . . . . . Adjusting the Anti-Scalp Rollers . . . . . . . . . . . . . Positioning the Seat . . . . . . . . . . . . . . . . . . . . . . . Pushing the Machine by Hand . . . . . . . . . . . . . . . Operating with Side Discharge . . . . . . . . . . . . . . . Transporting the Machine . . . . . . . . . . . . . . . . . . .
Introduction Safety Read this manual carefully to learn how to operate and maintain your product properly. The information in this manual can help you and others avoid injury and product damage. Although Toro designs and produces safe products, you are responsible for operating the product properly and safely. Improper use or maintenance by the operator or owner can result in injury.
• Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision. • Use extra care when handling gasoline and other fuels. They are flammable and vapors are explosive. • Use only an approved container Slope Operation • Never remove gas cap or add fuel with engine running. Allow engine to cool before refueling. Do not smoke. • Do not mow slopes greater than 15 degrees. • Do not mow near drop–offs, ditches, steep banks or water.
• Lower the rollbar only when absolutely necessary. Do not wear the seat belt with the roll bar folded down. • Check carefully for overhead clearances (i.e. branches, doorways, electrical wires) before driving under any objects and do not contact them. Maintenance and storage • Disengage drives, lower implement, set parking brake, stop engine and remove key or disconnect spark plug wire. Wait for all movement to stop before adjusting, cleaning or repairing.
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.
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 10 4. Wear eye protection 5. Read the Operator’s Manual. 6. Keep bystanders a safe distance from the battery.
104-8569 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 11 8. Minimum fill line 9.
106-6586 103-1997 99-3924 107-2102 12
107-2112 13
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.
Operation 2 Note: Determine the left and right sides of the machine from the normal operating position. 1 Using the Rollover Protection System (ROPS) m–6836 Figure 2 Warning 1. Full down position To avoid injury or death from rollover: keep the roll bar in the raised locked position and use the seat belt. 2. Down position with bagger installed Important Always use the seat belt with the roll bar in the raised position. Ensure that the rear part of the seat is secured with the seat latch.
7. Tighten the front handles against the center roll bar ends (Fig. 3). 2 1 1 m–6897 Figure 4 1. Front handle 3 Think Safety First m–6478 Figure 5 Please read all safety instructions and symbols in the safety section. Knowing this information could help you or bystanders avoid injury. 1. Safe Zone—use the Z Master here on slopes less than 15 degrees or flat areas. 2. Use walk behind mower and/or hand trimmer near drop–offs and water. 3.
Controls The unit has two fuel tanks. One tank is 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. 9). Become familiar with all the controls (Fig. 7) before you start the engine and operate the machine. 1 8 8 To use the left side fuel tank rotate the fuel shut off valve to the LH, lefthand location.
2 1 1 2 2 1 m–4201 Figure 11 m–4121 Figure 12 1. PTO—On 2. PTO—Off Figure 10 1. Parking brake—On m–2719 2. Parking brake—Off Starting and Stopping the Engine 1. Choke—On 2. Choke—Off 1 1 2 Starting the Engine 1. Sit down on the seat and move the motion controls to the neutral locked position. 3 2 2. Set the parking brake; refer to Setting the Parking Brake, page 17. 3. Move the PTO (power take off) to Off (Fig. 11). M–4268 m–2720 4.
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 16 1.
Adjusting the Height-of-Cut 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 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. Disengage the power take off (PTO) and turn the ignition key to Off. Move the control levers to the neutral locked position and apply the parking brake. Remove the key. 1.
4. Reinstall the bolt, center rollers, and nut (Fig. 19). Important Do not rotate the by–pass valves more than 1 turn. This prevents the valves from coming out of the body and causing fluid to run out. 3 Changing to Machine Operation Turn the by-pass valves in to operate (Fig. 21). Note: Do not over tighten the by–pass valves. Note: The machine will not drive unless the by-pass valves are turned in. 1 2 m–4124 Figure 19 1. Center rollers and spacer 2. Nut 3.
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.
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 Note: Determine the left and right sides of the machine from the normal operating position.
Important Refer to your engine operator’s manual for additional maintenance procedures. 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 2. Inspect the blades, especially the curved area (Fig. 23).
Front Warning Contact with sharp blade can cause serious injury. Wear gloves or wrap sharp edges of the blade with a rag. 1 m–1078 2 Figure 24 3 4 m–4318 Figure 26 MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE 1. Sail area of blade 2. Blade 3. Spring disk 4. Blade bolt m–2539 Figure 25 Sharpening the Blades 2. Rotate the opposite ends of the blades forward. Warning 3. Measure from a level surface to the cutting edge of the blades at the same position as in step 1 above.
4 1 2 1 m–1855 Figure 28 1. Blade 5 5 2. Balancer 2 6 Installing the Blades 1. Install the blade onto the spindle shaft (Fig. 26). 3 Important The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting. 5 m–4369 2. Install the flat washer, lock washer, and blade bolt (Fig. 26). Torque the blade bolt to 85–110 ft-lb (115–150 N⋅m). Figure 29 1. Air intake screen 2. Fan housing 3.
3. Carefully slide the primary filter over the safety filter (Fig. 30). Ensure that it is fully seated by pushing on the outer rim of the filter while installing it. 6. Remove the safety filter only if you intend to replace it. 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. Important filter. 7.
6. Slide the oil dipstick fully into the filler tube. Do not thread it onto the tube (Fig. 31). 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. Do not run engine with oil below the low mark because the engine may be damaged. m–5625 Figure 32 1. Oil drain valve 6.
5. Fill the crankcase with the proper type of new oil; refer to Servicing the Engine Oil, page 29. Important Always replace the spark plug(s) when it has a black coating, worn electrodes, an oily film, or cracks. Servicing the Spark Plug 2. Clean the electrode by scraping or with a wire brush to remove carbon deposits and wetness. 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.
8. Install a new filter and move the hose clamps close to the filter (Fig. 37). Note: Now is the best time to install a new fuel filter because the fuel tank is empty. 9. Open the fuel shut-off valve on the console. 6. Install the fuel line onto the fuel filter. Slide the hose clamp close to the fuel filter to secure the fuel line (Fig. 37). 2 3 1 1 M–4294 Figure 36 1. Filter 4 2. Hose clamp 2 M–4294 Figure 37 1. Fuel shut-off valve 2. Fuel filter Draining the Fuel Tank 3. Hose clamp 4.
Where to Add Grease 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. Lubricate the grease fittings as shown on the Check Service Reference Aid decal (Fig. 38). 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Grease the fittings on the three spindle bearings (Fig. 39). 4. Grease the idler pulley pivot (Fig. 39). 5. Grease the fittings on the push arms (Fig. 39).
50 operating hours or monthly, whichever occurs first (Fig. 40). Check the tires when they are cold to get the most accurate pressure reading. 7. If required, add fluid to the hydraulic tank. Note: The fluid level should be to the top of the hot level of the baffle, when the fluid is hot (Fig. 41). Pressure: 13 psi (90 kPa) drive wheels and caster wheels 8. Install cap on filler neck. 1 1 2 4 3 m–1872 Figure 40 1. Valve stem m–5615 Figure 41 Servicing the Hydraulic System 1. Cap 2. Baffle 3.
Replacing the Hydraulic Filter Change the hydraulic filter: 1 3 • After the first 8 operating hours. • After every 200 operating hours. 2 Use summer filter above 32°F (0°C) Use winter filter below 32°F (0°C) 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. m–1256 Figure 43 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 1. Hydraulic filter 2.
Checking the Hydraulic Lines 9. Apply slight rearward pressure on the motion control lever, turn the head of the adjustment bolt in the appropriate direction until the control lever is centered in neutral lock position (Fig. 44). 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.
Setting the Hydraulic Pump Neutral Position 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.
6. Tighten the nuts at the ball joints (Fig. 45). 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 47 8. Remove jumper wire from wire harness connector and plug connector into seat switch.
Checking the Wheel Hub Slotted Nut Leveling the Mower at Three Positions Check after every 500 operating hours. Important There are only three measuring positions needed to level the mower. The slotted nut needs to be torqued to 125 ft–lb (170 N⋅m). 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. Setting Up the Machine 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 1.
Front 9. Tighten the jam nut under the rear support arm and tighten the bolt securing the chain to the rear support arm. 10. Adjust the opposite side if needed. Adjusting the Front–to–Rear Mower Pitch 1. Position the right blade front-to-rear (Fig. 53). B C m–1078 2. Measure the right blade at the A location (Fig. 53), from a level surface to the cutting edge of the blade tip (Fig. 54). Figure 50 3. Record this measurement. 4. Measure the right blade at the B location (Fig.
9. Tighten both swivel jam nuts against the front swivel to lock the height. 1 3 4 10. Check to make sure there is equal tension on the chains and adjust again if needed. Adjusting the Compression Spring 2 1. Raise the mower lift lever to the transport position (Fig. 55). m–6273 Figure 56 2. Check the distance between the two large washers, it needs to be 10–1/4 inches (260 mm) (Fig. 55). 1. Push arm 2. 15-5/16 inch (389 mm) nominal 3.
2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 1 5 3. Remove the belt covers over the outside spindles. 3 4. 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. CALIFORNIA • 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.
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.
Replacing the Grass Deflector 5. Wait five to ten minutes after filling the battery cells. Add distilled water, if necessary, until the electrolyte level is up to the upper line (Fig. 62) on the battery case. Warning 6. Reinstall battery vent caps. 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.
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 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 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.
