Form No. 3359-117 Rev A Z580-D Z Master® with a 52in, 60in or 72in TURBO FORCE® Side Discharge Mower Model No. 74266—Serial No. 280000001 and Up Model No. 74267—Serial No. 280000001 and Up Model No. 74274—Serial No. 280000001 and Up Register at www.Toro.com.
Warning CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Important: This engine is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code 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. Figure 1 1.
Checking the Engine Oil Level............................ 15 Switching the Fuel Tanks .................................... 15 Using the Rollover Protection System (ROPS) .......................................................... 16 Think Safety First ............................................... 17 Operating the Parking Brake ............................... 18 Starting and Stopping the Engine ........................ 18 Operating the Power Take Off (PTO) ................. 20 The Safety Interlock System...
Safety • Use extra care when handling diesel and other fuels. They are flammable and vapors are explosive. – Use only an approved container – Never refuel or drain the machine indoors. – Never remove fuel cap or add fuel with engine running. Allow engine to cool before refueling. Do not smoke. • Check that operator’s presence controls, safety switches and shields are attached and functioning properly. Do not operate unless they are functioning properly.
• Check the area to be mowed and never fold the ROPS in areas where there are slopes, drop offs or water. • Use extreme care when loading or unloading the machine into a trailer or truck. • Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision. • Lower the rollbar only when absolutely necessary. Do not wear the seat belt with the roll bar folded down. Slope Operation • Check carefully for overhead clearances (i.e.
Slope Chart 6
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. 58-6520 1. Grease 1-403005 66-1340 1-523552 65-2690 1-643253 68-8340 98-4387 1. Warning—wear hearing protection.
98-5954 105-7798 107-1860 107-1613 107-1857 107-1861 107-1864 8
104-2449 108-5955 107-2102 108-5957 107-2112 107-2114 108-5981 9
110-0305 110-2067 110-3851 1. Remove the ignition key and read the instructions before servicing or performing maintenance. 110-2068 1. Read the Operator’s Manual. 110-3852 1. Remove the ignition key and read the instructions before servicing or performing maintenance. 2. Continuous tone signals the user that engine is overheating. 110-3853 1. Cutting/dismemberment hazard, fan and entanglement hazard, belt. 10 2.
4-9600 110–3842 1. Read the Operator’s Manual. Manufacturer’s Mark 1. Indicates the blade is identified as a part from the original machine manufacturer.
106-9989 107-9309 1. Warning—read the Operator’s Manual for information on charging the battery; contains lead; do not discard. 2. Read the Operator’s Manual. 112-2389 1. Push to engage 2. Engine—preheat 3. Read the Operator’s Manual. 4. Engine—stop 5. Engine—run 6. Engine—start 7. Fast 8. Continuous variable setting 9. Slow 10.
110-0819 Product Overview Figure 4 1. 2. 3. 4. 5. Hour meter Ignition switch Glow plug switch Glow plug light Engine Temperature light 6. 7. 8. 9. Throttle control PTO Switch Audible alarm Fuel selector valve Figure 3 1. 2. 3. 4. Motion control lever Parking brake lever Height-of-cut lever Fuel cap (both sides) 5. 6. 7. 8. Controls Seat belt Roll bar Engine screen Hour Meter The hour meter records the number of hours the engine has operated. It operates when the engine is running.
Audible Alarm Operation This machine has an audible alarm that alerts the user to turn off the engine or engine damage can occur from over heating. Refer to Servicing the Cooling System in Cooling System Maintenance , page 42. Note: Determine the left and right sides of the machine from the normal operating position. Adding Fuel Fuel Selector Valve The engine runs on clean, fresh diesel fuel with a minimum octane rating of 40.
• The biodiesel portion of the fuel meet specification ASTM D6751 or EN14214. • The blended fuel composition should meet ASTM D975 or EN590. • Painted surfaces may be damaged by biodiesel blends. • Use B5 (biodiesel contend of 5%) or lesser blend in cold weather. • Monitor seals, hoses, gaskets in contact with fuel as they may be degrade over time. • Fuel filter plugging maybe expected for a time after converting to biodiesel blends. • Contact your distributor if you wish for more information on biodiesel.
There is no rollover protection when the roll bar is in the down position. • Lower the roll bar only when absolutely necessary. • Do not wear the seat belt when the roll bar is in the down position. • Drive slowly and carefully. • Raise the roll bar as soon as clearance permits. • Check carefully for overhead clearances (i.e. branches, doorways, electrical wires) before driving under any objects and do not contact them. Important: Lower the roll bar only when absolutely necessary. 1.
Important: Always use the seat belt with the roll bar in the raised position. Operating on wet grass or steep slopes can cause sliding and loss of control. 1 Wheels dropping over edges can cause rollovers, which may result in serious injury, death or drowning. 2 There is no rollover protection when the roll bar is down. Always keep the roll bar in the raised and locked position and use the seat belt. Read and follow the rollover protection instructions and warnings.
This machine produces sound levels in excess of 85 dBA at the operators ear and can cause hearing loss through extended periods of exposure. Wear hearing protection when operating this machine. The use of protective equipment for eyes, ears, feet and head is recommended. Figure 10 1. Parking brake-ON 2. Parking brake-OFF Figure 9 3. Brake Stop Starting and Stopping the Engine 1. Warning— wear hearing protection Starting the Engine in Normal Weather Operating the Parking Brake 1.
Figure 13 1. Throttle—fast Starting the Engine in Cold Weather (Below 23°F or -5°C) Figure 11 1. 2. 3. 4. Hour meter Ignition switch Glow plug switch Glow plug light 2. Throttle—slow 5. Engine Temperature light 6. Throttle control 7. PTO Switch Use the correct engine oil for the starting temperature. Refer to Servicing the Engine Oil in Engine Maintenance , page 30. 1. Start the engine with the throttle in the Fast position. 9.
4. Turn the ignition key to the off position (Figure 12). Wait for all moving parts to stop before leaving the operating position. 5. Remove the key to prevent possibility of someone accidentally starting the machine before transporting or storing machine. 6. Close the fuel selector valve before transporting or storing the machine. Important: Make sure that the fuel selector valve is closed before transporting or storing the machine, as fuel leakage may occur. Set the parking brake before transporting.
Testing the Safety Interlock System 2. Move the levers to the center, un-locked position. Service Interval: Before each use or daily 3. To go forward, slowly push the motion control levers forward (Figure 15). If the safety system does not operate as described below, have an Authorized Service Dealer repair the safety system immediately. 1. Sitting on the seat, engage the parking brake and move the PTO to on. Try starting the engine; the engine should not crank. 2.
To turn, release pressure on the motion control lever toward the direction you want to turn (Figure 15). To stop, push the motion control levers to the neutral position. Stopping the Machine To stop the machine, move the traction control levers to neutral and move to locked position, disengage the power take off (PTO), and turn the ignition key to off. Set the parking brake when you leave the machine; refer to Setting the Parking Brake in Operation , page 14.
Adjusting the Flow Baffle The mower discharge flow can be adjusted for different types of mowing conditions. Position the cam locks and baffle to give the best quality of cut. 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Figure 17 1. Anti-scalp roller 2. Spacer 3. Bushing 3.
• For smaller grass clippings. • Propels grass clippings farther away from the mower. Figure 21 Figure 23 Position B Positioning the Seat Use this position when bagging. 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 24). Slide the seat to the desired position and release lever to lock in position. Figure 22 Position C This is the full open position.
Figure 25 1. Seat latch 2. Fuel cap 3. Seat Figure 26 Pushing the Machine by Hand 1. Side console controls 2. By-pass valve Important: Always push the machine by hand. Never tow the machine because hydraulic damage may occur. 3. Hydraulic pumps Using the Side Discharge Pushing the Machine The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. 1. Disengage the power take off (PTO) and turn the ignition key to off.
Transporting Machines Avoid sudden acceleration when driving up a ramp and sudden deceleration when backing down a ramp. Both maneuvers can cause the unit to tip backward. 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.
Long Grass Operating Tips 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. Fast Throttle Setting For best mowing and maximum air circulation, operate the engine at the fast throttle position.
Maintenance Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 8 hours • Check the engine cooling system level. • Adjust the mower belt tension. • Check the hydraulic fluid. After the first 25 hours • Change the hydraulic filter. After the first 50 hours • Change the engine oil. • Change the engine oil filter. After the first 100 hours • Change the gear box oil. Before each use or daily • • • • • • Check the safety system. Check the engine oil.
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 before you do any maintenance. Lubrication Greasing and Lubrication Lubricate the machine when shown on the Check Service Reference Aid decal (Figure 28). Grease more frequently when operating conditions are extremely dusty or sandy. Grease Type: General-purpose grease. How to Grease 1.
Important: Make sure cutting unit spindles are full of grease weekly. Engine Maintenance 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. Servicing the Air Cleaner Note: Check the filters more frequently if operating conditions are extremely dusty or sandy. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Removing the Air Filter 3. Grease the idler pulley pivot (Figure 29).
Figure 31 1. Air filter body 2. Air filter Figure 32 3. Air cleaner cover 4. Latches 1. Air filter body 2. Air filter Installing the Air Filter 3. Air cleaner cover 4. Latches Servicing the Engine Oil 1. If installing a new filter, check the filter for shipping damage. Do not use a damaged filter. Oil Type: High-quality detergent oil classified API Service CD or higher for diesel engines. Do not use special additives with recommended oils. 2.
Checking the Engine Oil Level Changing the Engine Oil Service Interval: Before each use or daily Service Interval: After the first 50 hours Every 100 hours Note: Check the oil when the engine is cold. 1. Start the engine and let it run for five minutes. This warms the oil so it drains better. 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2. Park the machine on a level surface. 2.
Figure 38 1. Engine oil 2. Funnel and hose Figure 36 1. Knob 2. Front engine panel Important: Add the oil very slowly and do not block the opening of the filler hole (Figure 39). If you add oil too fast or block the hole, the oil could back up and foul the air intakes, causing engine damage. 2. Remove the oil filler cap and the dipstick (Figure 37). Figure 39 1. Note the clearance left in the filler opening. Figure 37 1. Engine 5. Replace the dipstick and install the front engine panel. 2.
Changing the Engine Oil Filter Service Interval: After the first 50 hours Every 200 hours 1. Place a drip pan beneath the oil drip tray to receive oil from the oil filter and oil passages in the engine. 2. Drain the oil from the engine; refer to Changing the Engine Oil. 3. Turn the filter counterclockwise to remove it (Figure 40 and Figure 41). Figure 41 1. Oil filter 2. Gasket Note: Dispose of the oil filter properly. Recycle in accordance with local codes. 4.
Fuel System Maintenance Use of improper components can result in system failure, fuel leakage and possible explosion. Servicing the Fuel Filters • Ensure that an Authorized Service Dealer replace the fuel filter and any components for the fuel system. Draining the Water Separator Service Interval: Every 40 hours • Use only approved fuel lines, hose clamps and fuel filters for high pressure systems. 1. Position the machine on a level surface. 2.
Electrical System Maintenance Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. Servicing the Battery • Always Disconnect the negative (black) battery cable before disconnecting the positive (red) cable.
Important: Always keep the battery fully charged (1.265 specific gravity). This is especially important to prevent battery damage when the temperature is below 32°F (0°C). 1. Make sure the filler caps are installed in battery. Charge battery for 10 to 15 minutes at 25 to 30 amps or 30 minutes at 10 amps. 2. When the battery is fully charged, unplug the charger from the electrical outlet, then disconnect the charger leads from the battery posts (Figure 45). 3.
Drive System Maintenance Adjusting the Tracking The machine has a knob for adjusting the tracking located under the seat. Important: Adjust the handle neutral and hydraulic pump neutral before adjusting 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. 2. Check if the machine pulls to one side.
Checking the Wheel Hub Slotted Nut Service Interval: Every 100 hours 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. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the cotter pin. 4. Check the distance from bottom of slot in nut to inside edge of hole. Two threads or less should be showing (Figure 49).
3. Remove the dust cap from caster and tighten lock nut (Figure 50). 4. Tighten the locknut until the spring washers are flat and then back off a 1/4 turn to properly set the pre-load on the bearings (Figure 50). Important: Make sure spring washers are installed correctly as shown in Figure 50. 5. Install the dust cap (Figure 50). Figure 51 3. Pulley 4. Rear plug 1. Gear box 2. Side plug Changing the Gear Box Oil Figure 50 1. Spring Washers 2. Lock Nut 3.
10. Tighten the lock nuts until there is slight binding on the feeler gauge but it can be moved easily within the air gap (Figure 54). 11. Repeat this for the remaining slots. 12. Check each slot again and make slight adjustments until the feeler gauge between the rotor and armature with very slight contact between them. Figure 52 1. Spring loaded idler pulley 2. Clutch Figure 54 3. PTO drive belt 4. Gear box 1. Slot 2. Adjusting nut 3. Feeler gauge 6.
Cooling System Maintenance 1. Position the machine on a level surface, stop the engine, and set the parking brake. 2. Unlatch the seat and tilt the seat up. 3. With the engine cool, check the overflow bottle level. The fluid needs to be up to the bump on the outside of the overflow bottle (Figure 55). Servicing the Cooling System 4. If the coolant level is low, add a 50/50 mix of extended life antifreeze/Dex-Cool® and water to the overflow bottle (Figure 55).
Brake Maintenance Adjusting the Parking Brake Service Interval: Every 25 hours Every 200 hours 1. Engage the parking brake, lever up. 2. Measure the length of the spring. Measurement should be 2-1/2 inch (64 mm) between the washers (Figure 57). 3. If adjustment is necessary, release the parking brake, loosen the jam nut below the spring and adjust the nut directly below the spring (Figure 57). Turn the nut until the correct measurement is obtained.
Belt Maintenance 8. Install the new belt around the mower pulleys and the gearbox pulley under the engine (Figure 59). Inspecting the Belts Service Interval: Every 100 hours Check the belts for squealing when the belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks and cracks are signs of a worn mower belt. Replace the mower belt if any of these conditions are evident.
Figure 61 1. Belt guide install at a 45 4. Ratchet or breaker bar degree angle 2. Idler spring length 5. Idler plate bolt (between 10 and 10-1/4 inches (25.4 and 26.0 cm)) 3. Idler plate Figure 60 1. Belt cover 2. Latch 3. Insert slot into the tab Adjusting the Mower Belt Tension for 72in Mowers Only Replacing the PTO Drive Belt Service Interval: Every 50 hours 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2.
4. Remove the spring from the idler arm (Figure 63). 5. Remove the clutch stop bracket. 6. Remove the old PTO drive belt. 7. Install the PTO drive belt around the clutch pulley and the gearbox pulley (Figure 63). 8. Intall the rubber clutch stop. 9. Install the spring to the idler arm (Figure 63). Figure 64 1. Clutch 2. Pump drive belt 3. Spring 4. Spring loaded idler pulley Replacing and Tensioning the Alternator Belt Replacing the Alternator Belt Service Interval: Every 50 hours Figure 63 1.
12. Install the oil cooler shield and engine straps to the rear frame with the 4 bolts previously removed (Figure 65). 13. Install the engine straps to the side of the machine (Figure 65). 14. Tighten the bottom bolt and install the upper bolt holding the alternator and cover (Figure 67). Tensioning the Alternator Belt 1. Place a handle between the alternator and cylinder block. 2.
Controls System Maintenance 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 the neutral lock position (Figure 69). Adjusting the Control Handle Neutral Position Note: Keeping rearward pressure on the lever will keep the pin at the end of the slot and allow the adjustment bolt to move the lever to the appropriate position.
Hydraulic System Maintenance Servicing the Hydraulic System Checking the Hydraulic Fluid Figure 70 Service Interval: After the first 8 hours 1. Cap 2. Baffle Every 25 hours 3. Cold fluid level-full 4. Hot fluid level-full Fluid Type: Mobil 1 15W-50 synthetic motor oil or equivalent synthetic oil. Hydraulic System Oil Capacity: 132 ounces (3.9 l) Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Important: Use oil specified or equivalent.
2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 10. Start the engine and let it 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. Important: Do not substitute automotive oil filter or severe hydraulic system damage may result. 3. Apply a thin coat hydro fluid to the rubber gasket on the replacement filter (Figure 71). 11.
1. Raise the frame and block up the machine so drive wheels can rotate freely. Hydraulic fluid escaping under pressure can penetrate skin and cause injury. 2. Disconnect the electrical connector from the seat safety switch. Temporarily install a jumper wire across terminals in the wiring harness connector. • 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. 3.
Figure 74 Figure 73 1. Tracking knob 2. Hydraulic tank 3. Hydraulic pumps 1. Double nuts 2. Pump rod 3. Adjustment bolt 4. Turn this way to track right 5. Turn this way to track left Setting the Left-hand Hydraulic Pump Neutral Position 4. Locknut 5. Ball joint 6. Pumps Electrical system will not perform proper safety shut off with jumper wire installed. 1. Loosen the locknuts at the ball joints on the pump control rod (Figure 74).
Mower Deck Maintenance Leveling the Mower at Three Positions Important: There are only three measuring positions needed to level the mower. Setting Up the Machine 1. Position mower on a flat surface. Figure 75 2. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 1. Measure here from blade to hard surface 3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 2. Measure at B and C 2.
8. Loosen the jam nut under the rear support arm and adjust the adjustment bolt to get a measurement of 3-1/8 to 3-1/4 inches (80 to 83 mm) (Figure 76). (6 to 10 mm) lower in front at A than in the rear at B (Figure 76). 9. Tighten both swivel jam nuts against the front swivel to lock the height. 10. Check to make sure there is equal tension on the chains and adjust again if needed. Note: It is recommended that both sides of the mower are adjusted the same distance. 9.
shredding the grass blades. Tearing and shredding turns grass brown at the edges, which slows growth and increases the chance of disease. If you notice any damage, wear, or a slot forming in this area (Figure 79), immediately install a new blade. Checking for Bent Blades Check the cutter blades daily for sharpness, and for any wear or damage. File down any nicks and sharpen the blades as necessary. If a blade is damaged or worn, replace it immediately with a genuine Toro replacement blade.
the machine, use genuine Toro replacement blades. Replacement blades made by other manufacturers may result in non-conformance with safety standards. Figure 82 1. Blade Contact with a sharp blade can cause serious injury. 2. Balancer Installing the Blades Wear gloves or wrap sharp edges of the blade with a rag. 1. Install the blade onto the spindle shaft (Figure 83). Important: The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting. 2.
Cleaning 2. Remove the damaged or worn grass deflector. 3. Place the spacer and spring onto the grass deflector. Place the L end of the spring behind the deck edge. Cleaning Under the Mower Note: Make sure the L end of the spring is installed behind the deck edge before installing the bolt as shown in Figure 84 Service Interval: Before each use or daily Remove the grass buildup under the mower daily. 4. Install the bolt and nut. 1.
Storage C. Restart the engine and run it until it stops. D. Dispose of fuel properly. Recycle as per local codes. Cleaning and Storage Important: Do not store stabilizer/conditioned fuel over 90 days. 1. Disengage the power take off (PTO), set the parking 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, especially the engine and hydraulic system.
Troubleshooting Problem Starter does not crank Engine will not start, starts hard, or fails to keep running. Possible Cause 1. Blade control (PTO) is engaged. 1. Move blade contro (PTO) to disengaged. 2. 3. 4. 5. Parking brake is not on. Operator is not seated. Battery is dead. Electrical connections are corroded or loose. 6. Fuse is blown. 7. Relay or switch is defective. 2. 3. 4. 5. 1. Fuel tank is empty. 1. Fill fuel tank with fuel. 2. Air cleaner is dirty. 2.
Problem Uneven cutting height. Blades do not rotate. Possible Cause Corrective Action 1. Blade(s) not sharp. 1. Sharpen the blade(s). 2. Cutting blade(s) is/are bent. 3. Mower is not level. 4. Underside of mower is dirty. 5. Tire pressure is not correct. 6. Blade spindle bent. 2. Install new cutting blade(s). 3. Level mower from side-to-side and front-to-rear. 4. Clean the underside of the mower. 5. Adjust the tire pressure. 6. Contact an Authorized Service Dealer. 1.
Schematics Wire Diagram (Rev.
Notes: 62
Notes: 63
The Toro Total Coverage Guarantee Landscape Contractor Equipment (LCE) A Limited Warranty Conditions and Products Covered Owner Responsibilities The Toro® Company and its afliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair the listed Toro Products if defective in materials or workmanship.
