Form Count No. 3353-652 Rev D on it. Z593-D Z Master ®with 52in or 60in TURBO FORCE ® Side Discharge Mower m Model No. 74264--Serial No. 250000001 and Up Model No. 74265--Serial No. 250000001 and Up k_ 0 093 Register your product at www.Toro.
CALIFORNIA Proposition The engine exhaust contains chemicals California other to cause reproductive 65 Warning from this product known to the State cancer, birth of defects, or harm. \ Important: This engine is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code G000935 Section 4442 to use or operate the engine on any forest-covered, brush-covered, or grass-covered land. Other states or federal areas may have similar laws.
Switching the Fuel Tanks ................... Using the Rollover Protection System (ROPS) .................. 16 16 Inspecting Think Safety First .............................. Operating the Parking Brake .............. Starting and Stopping the Engine .............................. 18 18 Replacing Replacing Replacing the Power Take Off
Safety hair, loose clothing or jewelry may get tangled in moving parts. Improper use or maintenance by the operator or owner can result in injur 7 To reduce the potential for injur B comply with these safeDTinstructions and always pay attention to the safety alert symbol, which means CAUTION, WARNING, or DANGER-"personal safety instruction." Failure to comply with the instruction may result in personal injury or death.
Keep units. • • hands and feet away from the cutting Never carry passengers and keep pets and bystanders away. Be alert, slow down and use caution when maMng turns. Look behind and to the side before changing directions. • Always avoid sudden starting or stopping on a slope. If tires lose traction, disengage the blades and proceed slovdy off the slope.
Carefully release pressure with stored energ}_ from components Disconnect battery or remove spark plug wire before making any repairs. Disconnect the negative terminal first and the positive last. Reconnect positive first and negative last. Use care when checking blades. Wrap the blade(s) or wear gloves, and use caution when servicing them. Only replace blades. Never straighten or weld them. Keep hands and feet away from moving parts. If possible, do not make adjustments with the engine running.
Fold along appropriate line sLOPE TillS IS A 5+ SLOPE ,T edge.
Safety and Instructional 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. 1-523552 _i_ CAUTION ROTATING 54-9220 BLADES! STOP ENGINE BEFORE REACHING UNDERNEATH. 1-11143.-_3 1-643253 I!1 58-6520 KEEPHANDSandFEETAWAY 43-8480 1.
103-1636 68-8340 98-4387 1. Warning--wear hearing protection.
6-9989 107-1613 107-1857 107-1622 70
107-1864 107-1860 107-2102 107-1861 77
108-5957 107-2112 THIS COOLING SYSTEM PROTECTED BY: © Shell DEX-COOL ®_Extended Life Antifreeze/Coolant 108-5981 Top off with Shell DEX-COOL ®* Extended Life Antifreeze/Coolant. Suggested change interval is at 4 years or 4,000 hours of service. DEX-COOL is a registered trademark of General Motors Corp.
110-3852 Remove the ignition key and read the instructions 2. before servicing or performing maintenance. 110-3853 110-3851 1. Remove the ignition key and read the instructions servicing or performing maintenance. Continuous tone signals the user that engine is overheating. Cutting/dismemberment hazard, fan and entanglement hazard, belt. before 2. Manufacturer's Indicates machine 110-0819 13 the blade is identified manufacturer.
Product Overview Hour The hour meter engine 7 8 Meter records has operated. the number It operates of hours when the engine is running. Use these times for scheduling maintenance (Figure 4). 4 the regular 6 Glow Plug Light The glow plug indicator light turns on when the glow plug button is engaged (Figure 4). 3 Glow 5 Plug Switch This switch activates the glow plugs and is indicated by the glow plug light. Hold down the glow plug switch for 10 seconds prior to starting.
Operation In certain flammable Note: Determine the left and right sides of the machine from the normal operating position. Adding Fuel • • you and others Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any fuel Use summer grade diesel fuel (No. 2-D) at temperatures above 20 ° F (-7° C) and winter grade diesel fuel (No. I-D or No. I-D/2-D blend) below 20 ° F (-7 ° C).
, Clean around each fuel tank cap and remove the cap. Add fuel to both fuel tanks, until the level is 1/4 to 1/2 inch (6 to 13 mm) below 2 the bottom of the filler neck. This space in the tank allows the fuel to expand. Do not fill the fuel tanks completely full. , , Install fuel tank caps securel> Wipe up any fuel that may have spilled. If possible, fill the fuel tank after each use. This will minimize possible buildup of condensation inside the fuel tank.
5. To raise the roll bar, remove the hairpin cotter pins and remove the two pins (Figure 7). There is no rollover protection bar is in the down position. when • Lower the roll bar only when necessary. • Do not wear the seat bar is in the down and belt the roll 6. Raise the roll bar to the upright position and install the two pins and secure them with the hairpin cotter pins (Figure 7). absolutely when Important: Always use the seat the roll bar in the raised position.
Think Safety First 1 2 Please read all safety instructions and symbols in the safety section. I_owing this information could help you or bystanders avoid injur> Operating on wet grass or steep slopes cause sliding and loss of control. \ can Wheels dropping over edges can cause rollovers, which may result in serious injury, death or drowning. There is no rollover bar is down.
Setting the Parking Brake Set the paring brake; refer to Setting the Paring Brake. , 1. Move the motion control levers (Figure 16) out to the neutral lock position. Move the PTO (power take oft) switch to the off position (Figure 12). , 2. Pull up and back on the paring brake lever to set the paring brake (Figure 11). The paring brake lever should stay firmly in the engaged )osition. Move the throttle lever to the middle position (Figure 14).
Note: Additional starting cycles may be required when starting the engine for the first time after the fuel system has been completely without fuel• , Release the svdtch after 10 to 15 seconds. The light will turn off. Turn the key to the start position and the glow plug indicator light will come back on. When the engine starts, release the ke): Important: more than overheating 4 1. 2. Ignition Off Stopping 13 3. 4. switch of no to avoid Note: Do not use fuel left over from the summer.
Operating Off (PTO) the Power The Safety Take The power take off (PTO) svdtch starts and stops the mower blades and any powered attachments. Engaging the Interlock System If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. PTO 1. If the engine is cold, allow the engine to warm up 5 to 10 minutes before engaging the PTO. 2. While seated in the seat, release the pressure on the traction control levers and place in neutral.
PTO and rise slightly from the seat; the engine should stop. 4. The farther you move the traction control levers in either direction, the faster the machine will move in that direction. Sitting on the seat, engage the paring brake, move the PTO switch to off and move the To stop, pull the motion control levers to the neutral position. motion control levers to neutral lock position. Now start the engine.
, Children or bystanders they move or attempt while it is unattended. may be injured if to operate the tractor , Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes.
Swing the lever back over to tighten the baffle and cam locks (Figure 21)• , If the cams do not lock the baffle into place or it is too fight, loosen the lever and then rotate the cam lock. Adjust the cam lock until the desired lock:ing pressure is achieved• 3 4 J 2 G000943 Figure 1. 2. Anti-scalp Bushing roller 1 19 3. 4. 2 Flange Nut Bolt 3 G000945 Figure 21 1. Cam lock 3. Rotate cam to increase or 2. Lever 4.
G000946 Figure 22 Position B G000948 Use this position when bagging. Figure 24 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. Important: To adjust, move the lever sideways to unlock seat (Figure 25). Slide the seat to the desired position and release lever to lock in position. G000947 Figure 23 Position C This is the full open position. for this position is as follows.
Unlatching the Seat The machine will not drive unless by-pass valves are turned in. Push the seat latch rearward to unlatch the seat. This vdll allow access to the machine under the seat (Figure 26). 2 3 2 3 2 G000950 G000966 Figure 26 1. 2. 3. Seat latch Fuel cap Seat Figure 27 1. 2. Pushing Hand the Machine pumps The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf.
Loading Without the grass cover, or complete 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 uuit (Figure 28). The lower rear section of the tractor frame extends back between the rear deflector, discharge grass catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris.
Operating Loading increases tip-over death. Fast a unit onto a trailer or truck the possibility of backward and could cause serious Use extreme caution unit on a ramp. Use only a single, Not use individual of the unit. If individual ramps when injury full width ramp; ramps for each a surround the mower by uncut grass. Always try to have one side of the mower free from uncut grass, which allows air to be drawn into the mower.
Long Grass 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. When Stopping If the machine's forward motion must be stopped while mowing, a clump of grass clippings may drop onto your lawn. To avoid this, move onto a previously cut area with the blades engaged.
Maintenance Recommended Maintenance Maintenance Service I nte rva I Maintenance Afterthefirst8 operating hours • Check cooling system level. • Check the hydraulic fluid. After the first operating 25 hours After the first 50 operating hours After the first operating 100 hours Procedure • Change the hydraulic filter and oil. • Change • Change the engine the engine • Change gear box oil. oil. oil filter.
If you leave the key in the ignition switch, seriously injure you or other bystanders. Remove the key from do any maintenance. someone the ignition and disconnect Set the wire aside so that could the wire it does Lubrication Where Lubricate and the machine Lubrication when from start the spark not accidentally to Add Lubricate Greasing accidently Check the grease Service the engine plug(s) contact and before the spark you plug.
Greasing and Belt the Mower Idlers 7. Grease the PTO drive belt idler arm (Figure 31). Deck 8. Grease the pump belt idler arm (Figure 31). The mower deck must be lubricated weeMy or every 25 hours• Grease with No. 2 general purpose lithium base or molybdenum base grease• Important: Make sure cutting are full of grease weekly. , , 3. , unit spindles \ \ \ \ \ Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake.
appear discard as bright it. spots. If the filter is damaged 1 2 3 4 G001048 Figure 33 G001049 1. 2. Figure 32 1. 2. 3. 4. Air filter body Air filter Air filter body Air filter the Air Filter Change engine the Engine If installing a new filter, check the filter for shipping damage. Do not use a damaged filter. • Change the engine 50 operating hours. , Carefully slide the filter into the filter body (Figure 33).
0 2 @20 0 20 -3o -2o Jo 5C 32 40 60 6 lo 7780 ao 100 ao 40 G001061 Figure Checking Note: the Check Engine the oil when 34 Oil Level the engine 3 is cold• G001057 , , , , Disengage the PTO, move the motion control levers to the neutral locked position and set the parMng brake. Figure 1. 2. Stop the engine, remove the ke), and wait for all moving parts to stop before leaving the operating position.
2 1 Figure 38 1. 2 Figure 36 1. Back of machine 2. , Drain plug , Adding Engine Engine 2. Oil fill cap G001058 Oil 1. Tilt the seat forward and remove the front engine panel (Figure 37). To add oil to the engine, locate and use a hose and funnel for adding oil (Figure 39). Add oil slow135chec_ng the level with the dipstick frequently until the level reaches the upper hole on the dipstick.
filter on by hand until the gasket contacts the oil filter adapter. Tighten 1/2 to 3/4 turn more. Important: Add the oil very slowly and do not block the opening of the filler hole (Figure 40). If you add oil too fast or block the hole, the oil could back up and foul the air intakes, causing engine 4. Add oil; refer to Adding Engine Oil. damage. 1 r ) 2 G000955 Figure40 1. Note the clearance left in the filler opening. 5. Replace panel. 6. Start the engine 7. Shut off the engine. 8.
them more frequently dirty conditions. Replacing the under Fuel extremely dusty or Battery electrolyte which is a deadly burns. Filter Ensure that an Authorized Service the fuel filter and any components Dealer replaces for the fuel • Ensure Dealer that can result and possible an Authorized replace components • components fuel leakage the in Removing fuel filter and any Battery against for the fuel system.
Slide the red terminal boot off the positive (red) battery terminal. Then remove the positive (red) battery cable (Figure 43). 4 \ \, 3 4 3 5 2 2 G000959 G001050 Figure 43 1. 2. 6. Negative Battery Post Positive Battery Post Remove both the battery 3. 4. wing nuts (1/4 inch) clamp (Figure Figure 44 Red (+) cable Black (-) cable 1. 2. 3. Battery Hydraulic tank Bolts 4. 5. Wing nut Right side fuel tank securing 44). 7. Remove the two bolts holding tank in place (Figure 44). 8.
Charging the Battery Charging the battery can explode. Never sparks Fuse: produces damage when • Radiator fan, F2-30 amp, blade-type that and keep battery. 2. To replace the fuses, pull out on the fuse to remove it. Always keep the battery (1.265 specific gravity). This important to prevent battery fully charged is especially Ignition, FI-30 amp, blade-type 1. Unlatch the engine hood and raise the engine hood to gain access to fuse holder (Figure 46).
Drive System Maintenance Adjusting the Tracking The machine has a knob for adjusting the tracing located under the seat. Important: Adjust the handle neutral hydraulic pump neutral before adjusting and the tracking. Refer to Adjusting the Handle Neutral in Controls System Maintenance, page 48 and Adjusting the Hydraulic Pump Neutral in Hydraulic System Maintenance, page 49. 1. Push both control levers forward the same distance.
4 \ GO01055 Figure 48 Checking the Wheel Slotted Nut Hub Check after every 500 operating hours. The slotted nut needs to be torqued to 125 ft-lb (1r0 N.m). 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the paring brake. Figure 47 1. 2. 3. Tracking knob Hydraulic tank Hydraulic pumps 4. 5. Turn this way to track right Turn this way to track left 2.
7. Torque (Figure 8. Tighten the slotted 40). nut to 125 ft-lb. the nut until the next set of slots line up with the hole in the shaft (Figure 9. Servicing (170 N°m) Replace the cotter Checking the Gear the Gear Box Box Oil Level 49). Use SAE 75W-90 Synthetic Gear Lube. pin. 1. Park the machine on a level surface• Adjusting Bearing the Caster Pivot , Check after every 500 operating hours or at storage, which ever comes first• , 1.
Cooling System Note: Do not open the radiator cap. Doing may induce air into the cooling system. Maintenance 1. Position the machine the engine, Servicing the Cooling System Discharge of hot pressurized coolant touching hot radiator and surrounding can cause severe burns. Do not remove the radiator the radiator cap. Do not touch radiator parts that are hot. and brake. Unlatch 3. With the engine cool, check the overflow bottle level. The fluid needs to be up to the bump on 4.
, 3 If adjustment is necessar3, repeat the procedures above. 7. Repeat on the opposite side of machine. 1 \ 2 1 4 3 Figure 54 G001104 1. Figure 53 1. 2. 3. Hydraulic oil cooler Left rear tire Radiator 2. Brake lever in engaged position Spring 2-1/2 inch (64 mm) 3. Adjusting nut and jam nut screen Belt Maintenance Changing Change the the engine Engine coolant Contact an Authorized the coolant.
5. Remove 6. Install the existing the new belt around and the gearbox (Figure 56). pulley the mower under pulleys Install to the idler arm (Figure 8. Install the belt guide on the spring loaded idler at a 45 degree angle as shown in Figure 56. 56). 55). Stop the engine, remove the ke), and wait for all moving parts to stop before leaving the operating position. , 2 Belt Disengage the PTO, move the motion control levers to the neutral locked position and set the paring brake.
2 4 4 5 2 \ 6 G001158 3 1 Figure 59 G001157 1. 2. Pump drive belt Clutch 3. 4. Spring loaded idler pulley Spring Figure 58 1. 2. 3. PTO Drive belt Clutch Spring Replacing Belt 4. 5. 6. Spring loaded idler pulley Gear box Clutch stop bracket the Pump Replacing and Tensioning the Alternator Belt Drive Check the alternator belt for wear after every () hours of operation. Check pump drive belt for wear after every 50 hours of operation. Replacing the Alternator Belt 1.
10. Install the fan and fan plate to the machine with the 2 bolts previously removed (Figure 61)• 11. Install removed the oil cooler with the 4 bolts previously (Figure 61)• 12. Install the oil cooler shield and engine straps to the rear frame with the 4 bolts previously removed (Figure 60). 13. Install the engine straps machine (Figure 60). 14. Tighten 2 the bottom upper bolt holding (Figure 62). to the side of the bolt and install the the alternator and cover G001295 Figure 60 1. 2.
, 5 4 Begin with either control lever. the left or right motion Move the lever to the neutral position but not locked (Figure 63)• , , Pull the lever back until the clevis pin (on arm below pivot shaft) contacts the end of the slot (just beginuing to put pressure on the spring) (Figure 63). Check where the control lever is relative to notch in console (Figure 63)• It should be centered allowing lever to pivot outward to the neutral lock position. 3 2 3 G000968 Figure 62 I. 2. 3.
, 1 \ , Clean the area around filler neck of hydraulic tank (Figure 65). Remove the cap from the filler neck. Look inside to check if there is fluid in the reservoir (Figure 65). , 4 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 in Operation, page 15. 6 2 3 , 7 5 Note: The fluid level should be to the top of the hot level of the baffle, when the fluid is hot (Figure 65).
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 G001044 Figure 66 if this is not done. 1. Keep body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid. Use cardboard or paper hydraulic leaks. 4. Remove the righthand hydraulic line that comes into the adapter (Figure 67).
both wheels will not drive, refer to Bleeding Hydraulic System. Hydraulic penetrate 13. Recheck the fluid level while the fluid is warm. The fluid should be behveen cold and hot. fluid escaping under pressure 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. 14. If required, add fluid to the hydraulic tank. Do not overfill.
4 Engine must be running so motion control adjustment can be performed. Contact with moving personal parts or hot injury. surfaces may cause Keep hands, feet, face, clothing and body parts away from rotating parts, and other hot surfaces. , , other muffler Raise the frame and block up the machine drive wheels can rotate freely. Disconnect the electrical connector 1 2 so from the seat safety switch. Temporarily install a jumper wire across terminals in the wiring harness connector.
6. Tighten (Figure the locknuts 70). Mower Deck Maintenance at the ball joints Leveling Positions 1 2 \ the Mower at Three Important: There are only three measuring positions needed to level the mower. 3 Setting Up the Machine 1. Position mower on a flat surface. , 6 \ , , , G001066 Figure 70 , 1. 2. 3. Double nuts Pump rod Adjustment bolt 4. 5. 6. Locknut Ball joint Pumps jumper wire from • 7. 8. Remove the jumper connector switch. 9. Install Side-to-Side 3.
2 6 2 7 T- T- T G001042 Figure 1. , Measure here from blade to hard surface If the measurements 71 2. Figure Measure at B and C at positions Real chain Rear support arm Bolt Jam Nut 5. 6. 7. Adjustment bolt Front swivel Front support arm B or C are not correct, loosen the bolt attaching chain to the rear support arm (Figure , 1. 2. 3. 4. 72 the rear 72).
, Measure the right blade at the B location, from a level surface to the cutting edge of the blade tip (Figure 73). 1 9 \/ 8 5. Record this measurement. , The mower blade should be a 1/4 to 3/8 inch (6 to 10 mm) lower at position A than at position B (Figure 73). If it is not correct, proceed to the following steps. 4 5 Note: Both of the front swivels need to be adjusted the same amount to maintain equal chain tension.
Before Blades Inspecting or Servicing the 2 Park the machine on a level surface, disengage the blade control (PTO), and set the paring brake. Turn the ignition key to Off. Remove the ke}: Inspecting the Blades , Inspect the cutting edges (Figure 75)• If the edges are not sharp or have nicks, remove and sharpen the blades. Refer to Sharpening the Blades• , Inspect the blades, especially the curved area (Figure 75).
A Contact injury. with a sharp Wear gloves blade with , Hold or wrap sharp edges serious 1 end using sharpening could be thrown Wear proper blade. Blade Installing Remove the blade bolt, spring disk and blade from the spindle shaft (Figure 79). When 1. and 2. the Install the blade (Figure 79). Blades blade, G000277 Balancer a rag or glove. the 2 Figure 78 of the 1. the blade Sharpening , can cause a rag.
Replacing Deflector the Grass An uncovered discharge opening could allow the lawn mower to throw objects in the operator's or bystander's direction and result in serious the blade could injury. occur. Also, Make down , , chute and \ with 1 Never operate the lawn you install a cover plate, a grass contact mower unless a mulch plate, or 5 G000977 catcher. sure the grass position.
Storage Cleaning A, and Storage 1. Disengage the power take off (PTO), set the paring brake, and turn the ignition key to Off. Remove the key. 2. Remove grass clippings, dirt, and grime from the external parts of the entire machine, an alcohol based stabilizer (ethanol or methanol). Note: A fuel stabilizer/conditioner is most effective when mixed with fresh fuel and used at all times. especially the engine and hydraulic system.
Troubleshooting Problem Starter does not crank Possible Cause 1. Blade control (PTO) Corrective is 1. Move blade contro engaged. 2. Parking 3. Operator 4. 5. Battery is dead. Electrical connections brake is not on. is not seated. Fuse is blown. Set the parking Sit on the seat. 4. 5. Charge the battery. Check the electrical 7. Relay or switch defective. connections contact. brake. for good is 6. 7. Replace fuse. Contact an Authorized Service Dealer. 1. Fuel tank is empty. 1.
Problem Machine does Possible not drive. 1. By pass valve closed 2. Cause Corrective is not vibration. the 2. Change the belt. 3. Change the belt. 4. Replace the spring. 5. Add hydraulic fluid to reservoir or let it cool down. tight. 3. Drive or pump belt is off a pulley. 4. Broken or missing idler spring. 5. Hydraulic fluid level is low or too hot. Abnormal Tighten valve. . Drive or pump belt is worn, loose or broken. 1. Install new cutting blade(s). 2. Blade mounting loose.
Problem Blades do not rotate. Possible 1. . Cause Corrective Drive belt or broken. is worn, Drive is off pulley. belt 3. Deck belt is worn, or broken. 4. Deck loose loose 1. Check the 2. Install drive 3. check adjusting shafts and belt guides for correct position. Install new deck belt. belt is off pulley. . Broken or missing spring. 62 idler 5. belt tension. belt and Install deck pulley and check the idler pulley, idler arm and spring for correct function. 5.
F3 "V 2CA Opt. o o Ol KEY ON OFF START SWITCH BIA AND XY NO BIS CONNECTI SW2 I° B ACCESORY CONNECTOR _GND R [ 3 A I N TERMINAL VIEW FROI_ BACK OF SWITCH (PTO) SW1 (IGNITION) S Y X V;G ALTERNATOR ml /REGULATOR n (B) M6 stud mVl_ VlO IK F1 30A B_pK SHOWN IN OFF POSITION R (SEAT SW6sw) SW3 F I OR (BRAKE) | SHOWN WITH PARK BRAKF DISENGAG I I D[__._ / VIO 4 91-A _ IN SEAT / DELAY MODOLI T-c CLUTCH PTO SHOWN WI" OPERATOR rHL y_ J SW -(R i SW7 P.
The Toro LCE Conditions and Products Total Coverage Guarantee A Limited Warranty Covered 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: Owner Responsibilities You must maintain your Toro Product by following the maintenance procedures described in the operator's manual.
