Form No. 3326–671 Z149 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) Lower Left of Console (Part No. 98-4387) Below Center 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 Under Seat (Part No. 1–603845) 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.
4. Secure cables with (2) 1/4 x 3/4″ (19 mm) bolts 1/4″ washers and 1/4″ locknuts (Fig. 8). 4. If there is no fluid, add fluid to reservoir approximately a 1/4″ (6mm) below the top of baffle. 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.
Operation Grease with No. 2 general purpose lithium base or molybdenum base grease. 1. Grease the fittings on the three spindle bearings. Grease until it comes out lower seals (Fig. 10). Think Safety First 1 Please carefully read all the safety instructions on pages 3–NO TAG. Knowing this information could help you, your family, pets or bystanders avoid injury.
Parking Brake 5. Move the throttle control to the “FAST” position before starting a cold engine (Fig. 5). Always set the parking brake when you stop the machine or leave it unattended. 6. Turn ignition key to “START” to energize starter. When engine starts, release key (Fig. 6). Important Do not park on slopes unless wheels are chocked or blocked. Important Do not engage starter for more than 10 seconds at a time. If engine fails to start allow 30 second cool-down period between attempts.
The Safety Interlock System 3. Turn the ignition key to “OFF” (Fig. 6). Note: If the engine has been working hard or is hot, let it idle for a minute before turning the ignition key “OFF.” This helps cool the engine before it is stopped. In an emergency, the engine may be stopped by turning the ignition key to “OFF.” Caution If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. 4.
4. Sitting on the seat, “ENGAGE” parking brake, PTO “OFF” and lock the motion control levers in neutral. Now start the engine. While the engine is running, center the motion controls and move (forward or reverse); the engine should stop. 2 3 1 5. Sitting on the seat, “DISENGAGE” parking brake, move PTO switch “OFF” and move the motion control levers to neutral lock position. Try starting the engine; the engine should not crank. 4 m–2715 Figure 8 Driving Forward or Backward 1.
Instruments 1. Raise the height-of-cut lever to the transport position (also the 4-1/2″ (114 mm) cutting height position) (Fig. 11). Hour Meter 2. To adjust, remove hairpin cotter and clevis pin from height-of-cut bracket (Fig. 11). 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. 3. Select hole in height-of-cut bracket corresponding to the height-of-cut desired, and insert clevis pin (Fig.
4. Reinstall the stud nut and washer (Fig. 12). 5. Repeat adjustment on other gage wheels. 3 1 4 1 2 3 2 m–4124 Figure 13 5 1. Center rollers and spacer 2. Nut m–4167 3. Bolt Figure 12 1. Gage wheel 2. Stud 3. Washer 4. Nut 5. Wheel nut and washer. Do not remove. 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. Center Rollers 1. To adjust, move the lever sideways to unlock seat (Fig. 14).
To Push the Machine Danger 1. Disengage the power take off (PTO) and turn the ignition key to “OFF” to stop the engine. Without the grass deflector, discharge cover, or complete grass catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris. Contact with rotating mower blade(s) and thrown debris will cause injury or death. 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.
Cutting a Lawn for the First Time 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. If it is not possible to use one full width ramp, use enough individual ramps to simulate a full width continuous ramp. Cut grass slightly longer than normal to ensure the cutting height of the mower does not scalp any uneven ground.
Keep the Underside of the Mower Clean Clean clippings and dirt from the underside of the mower after each use. If grass and dirt build up inside the mower, cutting quality will eventually become unsatisfactory. Blade Maintenance Maintain a sharp blade throughout the cutting season because a sharp blade cuts cleanly without tearing or shredding the grass blades. Tearing and shredding turns grass brown at the edges, which slows growth and increases the chance of disease.
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 oil level Check safety system Clean cooling systems 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 cleaner1 Che
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 2. Inspect the blades, especially the curved area (Fig. 16). If you notice any damage, wear, or a slot forming in this area (item 3 in Fig.
Front Warning Contact with sharp blade can cause serious injury. Wear gloves or wrap sharp edges of the blade with a rag. Hold the blade end using a rag or thickly-padded glove. Remove the blade bolt, spring disk and blade from the spindle shaft (Fig. 19). m–1078 Figure 17 1 2 3 4 MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE m–4318 m–2539 Figure 19 Figure 18 1. Sail area of blade 2. Blade 3. Rotate the opposite ends of the blades forward.
blade is not balanced, file some metal off the end of the sail area only (Fig. 19). Repeat this procedure until the blade is balanced. 4 1 2 1 5 5 m–1855 2 Figure 21 1. Blade 2. Balancer 6 Installing the Blades 3 1. Install the blade onto the spindle shaft (Fig. 19). 5 Important The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting. m–4369 Figure 22 2. Install the flat washer, lock washer and blade bolt (Fig. 19).
A. Lightly tap the element on a flat surface to remove dust and dirt (Fig. 25). 1 6 B. Inspect the element for tears, an oily film, and damage to the rubber seal. Important Never clean the paper element with pressurized air or liquids, such as solvent, gas, or kerosene. Replace the paper element if it is damaged or cannot be cleaned thoroughly. ÓÓÓ ÓÓÓ ÓÓÓ 4 2 3 5 m–4366 Figure 23 1. Cover nuts 2. Foam element 3. Paper element 1 4. Wing nut 5. Air cleaner base 6. Cover m–4367 4.
Oil Type: Detergent oil (API service SG or SH) Changing/Draining Oil Crankcase Capacity: 1.6 qt. (1.5 l) (When oil filter is not removed) 1. Start the engine and let it run five minutes. This warms the oil so it drains better. Viscosity: See table below 2. Park the machine so that the drain side is slightly lower than the opposite side to assure the oil drains completely. Then disengage the power take off (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine.
Change Oil Filter 2. Pull the wire(s) off the spark plug(s) (Fig. 29). Now clean around the spark plug(s) to prevent dirt from falling into the engine and potentially causing damage. Replace the oil filter every 200 hours or every other oil change. 3. Remove the spark plug(s). Note: Change oil filter more frequently when operating conditions are extremely dusty or sandy. 1. Drain the oil from the engine; refer to Changing/Draining Oil, page 31. 1 2. Remove the old filter (Fig. 28). 3.
2 3 1 2 0.030 in. (.75 mm) 1 m–3215 M-4294 Figure 30 1. Center electrode insulator 2. Side electrode Figure 31 3. Air gap (not to scale) 1. Filter 2. Hose clamp Installing the Spark Plug(s) Fuel Tank 1. Install the spark plug(s). Make sure the air gap is set correctly. Draining The Fuel Tank 2. Tighten the spark plug(s) to 16 ft-lb (22 N•m). Danger 3. Push the wire(s) onto the spark plug(s) (Fig. 29). In certain conditions, gasoline is extremely flammable and highly explosive.
Where to Add Grease 6. Install the fuel line onto the fuel filter. Slide the hose clamp close to the fuel filter to secure the fuel line (Fig. 32). Lubricate the grease fittings as shown on the CHECK SERVICE REFERENCE AID decal (Fig. 33). 3 1 4 2 M-4294 Figure 32 1. Fuel shut-off valve 2. Fuel filter 3. Hose clamp 4. Fuel line Figure 33 Servicing the Spark Arrester Inspect the spark arrester every 50 hours for damage, such as holes in the screen, and for build-up on the screen.
1. Stop the engine, set the parking brake, remove the key and disconnect the spark plug wire(s) from the spark plug(s). 5. Run the machine 15 minutes to allow any air to purge out of the system and warm fluid. 6. Recheck level while fluid is warm. Add fluid to raise level to top of the baffle, if required. 2. Grease the fittings on the three spindle bearings (Fig. 34). 3. Grease the idler pulley pivot (Fig. 34). Note: Fluid level should be to the top of the baffle when fluid is warm (Fig. 35). 4.
8. Clean up any spilled fluid. Important Do not substitute automotive oil filter or severe hydraulic system damage may result. 9. Start engine and let 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 Hydraulic System, page 36. 2. Remove hydro cap and temporarily cover opening with a plastic bag and rubber band to prevent all hydro fluid from draining out. 10. Recheck level while fluid is warm.
Tire Pressure Wheel Hub Slotted Nut 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. 38). Check the tires when they are cold to get the most accurate pressure reading. Check after every 500 operating hours. The slotted nut needs to be torqued to 125 ft-lbs (169.5 N m). 1.
7 5. Place two 1-1/4″ (35 mm) thick blocks under rear left and right lower edge of mower. Place one 1-3/8″ (44 mm) block under front center lower edge of mower. Not under anti-scalp roller brackets. Lower mower to the 1-1/2″ (38 mm) height-of-cut position (Fig. 41). 9 8 5 3 1 6 4 2 1 m–4116 Figure 42 1. 2. 3. 4. 2 m–4122 Bottom chain bolt Top chain bolt Front swivel 10-1/4″ (260 mm) spring compressed 5. 6. 7. 8. 9.
3. Lift the front of unit and support unit using jack stands. Note: Increase tension by lengthening the push arms and decrease tension by shortening push arms. 3 1 Danger 1 Mechanical or hydraulic jacks may fail to support machine and cause a serious injury. • Use jack stand when supporting machine. • Do not use hydraulic jacks. 2 m–3740 Figure 43 1. Push arm 2. 15-5/16″ (389 mm) nominal Belt Inspection 3. Jam nut 4. Ball joint Inspect all belts every 100 hours. 1.
2. Remove bolt from clutch strap and unplug clutch electrical wire (Fig. 47). Note: Dot not remove spring from eye bolt. 5. Verify length of push arms; refer to Adjusting Push Arms, page 38. 3. Pull spring loaded idler to side. Remove traction belt from the engine and hydro pump pulleys (Fig. 47). Caution 4. Install new belt around engine and hydro pump pulleys (Fig. 47). Spring is under tension when installed and can cause personal injury. 5. Pull spring loaded idler to side and align belt.
1 1 4 3 2 M-4118 Figure 48 1. Right-hand motion control lever (shown) 2 2. Neutral lockout position 6 2 7 4. If adjustment is needed, loosen the nut against the yoke (Fig. 49). 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. 50).
2. To replace fuses pull out on the fuse to remove it (Fig. 51). 1 2 2 3 1262 Figure 52 1 1. Filler caps 2. Lower part of tube m–3653 Adding Water to the Battery Figure 51 1. Main—20 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—20 amp 1. Clean the top of the battery with a paper towel. Battery 2. Lift off the filler caps (Fig. 52). 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 53 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 G. 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. H. Stop engine, allow to cool and drain the fuel tank; refer to Fuel Tank, page 33. I. 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 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.
