Form No. 3361-740 Rev B Z580-D Z Master® with a 52in, 60in or 72in TURBO FORCE® Side Discharge Mower Model No. 74266—Serial No. 290000001 and Up Model No. 74267—Serial No. 290000001 and Up Model No. 74274—Serial No. 290000001 and Up To register your product or download an Operator's Manual or Parts Catalog at no charge, go to 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............................ 16 Switching the Fuel Tanks .................................... 16 Using the Rollover Protection System (ROPS) .......................................................... 16 Think Safety First ............................................... 17 Operating the Parking Brake ............................... 18 Starting and Stopping the Engine ........................ 19 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 65-2690 1-523552 66-1340 1-643253 68-8340 98-4387 1. Warning—wear hearing protection.
98-5954 107-1857 104-2449 107-1860 105-7798 107-1613 8
107-1861 107-2102 107-1864 107-2112 107-2114 9
110–0806 108-5955 110-2067 108-5957 110-2068 1. Read the Operator’s Manual.
2-2389 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. PTO (Power take off) 110-3851 1. Remove the ignition key and read the instructions before servicing or performing maintenance. 114-9600 1. Read the Operator’s Manual. 110-3852 1. Remove the ignition key and read the instructions before servicing or performing maintenance. 2.
106-7492 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.
110-0819 Product Overview Figure 4 1. 2. 3. 4. 5. Hour meter Ignition switch Fuel selector valve Audible alarm Glow plug switch 6. 7. 8. 9. Glow plug light Engine Temperature light Throttle control PTO Switch 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.
over heating. Refer to Servicing the Cooling System in , page . Fuel Selector Valve The fuel selector valve is located behind the seat. Close the fuel selector valve when transporting or storing mower. Move the selector valve to the lefthand (LH) or righthand (RH) position for operation. Figure 5 1. Safety interlock symbols 2. Hour meter 3.
Operation In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. Note: Determine the left and right sides of the machine from the normal operating position. Adding Fuel • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any fuel that spills. The engine runs on clean, fresh diesel fuel with a minimum cetane rating of 40.
• The biodiesel portion of the fuel meet specification ASTM D6751 or EN14214. Close the fuel selector valve before transporting or storing machine. • 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.
Important: Always use the seat belt with the roll bar in the raised position. There is no rollover protection when the roll bar is in the down position. 1 • Lower the roll bar only when absolutely necessary. 2 • 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.
Operating on wet grass or steep slopes can cause sliding and loss of control. This machine produces sound levels in excess of 85 dBA at the operators ear and can cause hearing loss through extended periods of exposure. Wheels dropping over edges can cause rollovers, which may result in serious injury, death or drowning. Wear hearing protection when operating this machine. There is no rollover protection when the roll bar is down.
Figure 11 1. Parking brake-ON 2. Parking brake-OFF 3. Brake Stop Starting and Stopping the Engine Figure 12 1. 2. 3. 4. Starting the Engine in Normal Weather 1. Raise the ROPS up and lock into place, sit on the seat and fasten the seat belt. Hour meter Ignition switch Glow plug switch Glow plug light 5. Engine Temperature light 6. Throttle control 7. PTO Switch 9. Turn the key to the start position and the glow plug indicator light will come back on.
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. Important: Make sure to remove the key as the fuel pump may run and cause the battery to lose charge. Figure 14 1. Throttle—fast 2.
Figure 16 1. Triangles light up when the interlock components are in the correct position Figure 15 1. PTO-On 2. PTO-Off Testing the Safety Interlock System Service Interval: Before each use or daily Disengaging the PTO 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.
Machine can spin very rapidly. Operator may lose control of machine and cause personal injury or damage to machine. • Use caution when making turns. • Slow the machine down before making sharp turns. Driving Forward 1. Release the parking brake; refer to Releasing the Parking Brake in , page . 2. Move the levers to the center, un-locked position. 3. To go forward, slowly push the motion control levers forward (Figure 17).
2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Children or bystanders may be injured if they move or attempt to operate the tractor while it is unattended. 3. After adjusting the height-of-cut, adjust the rollers by removing the flange nut, bushing, spacer, and bolt (Figure 19 , Figure 20 and Figure 21 ). Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes.
Figure 22 3. Rotate cam to increase or decrease locking pressure 4. Slot 1. Cam lock 2. Lever Figure 21 1. Anti-scalp roller 2. Spacer 3. Bushing 4. Flange Nut 5. Bolt Positioning the Flow Baffle The following figures are only recommendations for use. Adjustments will vary by grass type, moisture content, and height of grass. 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.
Slide the seat to the desired position and release lever to lock in position. Figure 24 Figure 26 Position C 1. Adjustment lever This is the full open position. The suggested use for this position is as follows. • Use in tall, dense grass mowing conditions. • Use in wet conditions. • Lowers the engine power consumption. • Allows increased ground speed in heavy conditions. • This position is similar to the benefits of the Toro SFS mower. Unlatching the Seat 1.
Pushing the Machine 1. Disengage the power take off (PTO) and turn the ignition key to off. Move the levers to neutral locked position and apply parking brake. Remove the key. 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.
Loading Machines Use extreme caution when loading units on trailers or trucks. One full width ramp that is wide enough to extend beyond the rear tires is recommended instead of individual ramps for each side of the unit (Figure 29). The lower rear section of the tractor frame extends back between the rear wheels and serves as a stop for tipping backward. Having a full width ramp provides a surface for the frame members to contact if the unit starts to tip backward.
Mowing Direction shredding the grass blades. Tearing and shredding turns grass brown at the edges, which slows growth and increases the chance of disease. 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. Alternate mowing direction to keep the grass standing straight.
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 (72in mowers only). • 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 • Check the wheel hub slotted nut. • Check the wheel lug nuts. • Change the gear box oil.
Important: Refer to your engine operator’s manual for additional maintenance procedures. 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 30). Grease more frequently when operating conditions are extremely dusty or sandy.
Grease with No. 2 general purpose lithium base or molybdenum base grease. Important: Make sure cutting unit spindles are full of grease weekly. 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. Grease the idler pulley pivot (Figure 31). 4. Grease the fittings on the 3 spindle bearings (Figure 31).
Engine Maintenance 8. If the axle assembly has had both spacer nuts removed (or broken loose), apply a thread locking adhesive to one spacer nut and thread onto the axle with the wrench flats facing outward. Do Not thread spacer nut all of the way onto the end of the axle. Leave approximately 1/8 inch (3 mm) from the outer surface of the spacer nut to the end of the axle inside the nut. Servicing the Air Cleaner Note: Check the filters more frequently if operating conditions are extremely dusty or sandy.
Figure 34 1. Air filter body 2. Air filter Figure 35 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 41 1. Engine oil 2. Funnel and hose Figure 39 1. Knob 2. Front engine panel Important: Add the oil very slowly and do not block the opening of the filler hole (Figure 42). 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 40). Figure 42 1. Note the clearance left in the filler opening. Figure 40 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 43 and Figure 44). Figure 44 1. Oil filter 2. Gasket Note: Dispose of the oil filter properly. Recycle in accordance with local codes. 4.
Changing the Fuel Filter Fuel System Maintenance Never install a dirty fuel filter if it is removed from the fuel line. 1. Allow the machine to cool down. Servicing the Fuel Filter and Water Seperator 2. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. Service Interval: Every 40 hours—Drain the water separator. 3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
Servicing the Fuel Tank Electrical System Maintenance Do not attempt to drain the fuel tank. Ensure that an Authorized Service Dealer drains the fuel tank and services any components of the fuel system. Servicing the Battery Warning CALIFORNIA Proposition 65 Warning Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.
Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. • 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. 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2.
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 49). 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 Maintenance and Adjusting the Hydraulic Pump Neutral in Maintenance. 1. Push both control levers forward the same distance. 2. Check if the machine pulls to one side. If it does, stop the machine and set the parking brake. 3.
Checking the Wheel Hub Slotted Nut 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 dust cap from caster and tighten lock nut (Figure 54). 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 54).
Figure 56 1. Spring loaded idler pulley 2. Clutch Figure 55 6. Unplug the electric connection for the clutch (Figure 57). 3. Pulley 4. Rear plug 1. Gear box 2. Side plug 3. PTO drive belt 4. Gear box 7. Remove the two bolts holding the rubber clutch strap to the mower frame (Figure 57). 8. Remove the center bolt holding the clutch to the engine shaft and remove the clutch and key (Figure 57).
Cooling System Maintenance 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 58). 11. Repeat this for the remaining slots. Servicing the Cooling System 12. Check each slot again and make slight adjustments until the feeler gauge between the rotor and armature with very slight contact between them. Discharge of hot pressurized coolant or touching hot radiator and surrounding parts can cause severe burns.
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 59). 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 59). 5.
Brake Maintenance Belt Maintenance Adjusting the Parking Brake Inspecting the Belts Service Interval: Every 25 hours 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. Every 200 hours 1. Engage the parking brake, lever up. 2. Measure the length of the spring.
Adjusting the Mower Belt Tension for 72in Mowers Only Service Interval: After the first 8 hours Important: To ensure proper mower belt tension, which will result in a longer belt life, check the mower belt tension after the first 8 hours of use and 8 hours after each belt change. 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.
Replacing the PTO Drive Belt Service Interval: Every 50 hours—Check the PTO drive belt. 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. Loosen the front engine panel knobs and remove the panel (Figure 66). Figure 67 1. Gear box 2. Spring 3. Spring loaded idler pulley 4. Clutch 5. Rubber clutch stop 6.
Figure 68 1. Clutch 2. Pump drive belt 3. Spring 4. Spring loaded idler pulley Figure 69 1. Oil cooler shield 2. Bolts Replacing and Tensioning the Alternator Belt 3. Engine straps 5. Remove the 4 bolts holding the oil cooler and position the oil cooler to the side (Figure 70). 6. Remove the 2 bolts holding the fan and fan plate to the machine (Figure 70). Replacing the Alternator Belt Service Interval: Every 50 hours—Check the alternator belt. 1.
Controls System Maintenance 12. Install the oil cooler shield and engine straps to the rear frame with the 4 bolts previously removed (Figure 69). 13. Install the engine straps to the side of the machine (Figure 69). Adjusting the Control Handle Neutral Position 14. Tighten the bottom bolt and install the upper bolt holding the alternator and cover (Figure 71). If motion control levers do not align, or move easily into the console notch, adjustment is required.
Hydraulic 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 73). 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. Servicing the Hydraulic System 10. Tighten the nut and jam nut (Figure 73). Checking the Hydraulic Fluid 11.
2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 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 75). Figure 74 1. Cap 2. Baffle 3. Cold fluid level-full 4. Hot fluid level-full Hydraulic fluid escaping under pressure can penetrate skin and cause injury.
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. Hydraulic fluid escaping under pressure can penetrate skin and cause injury. 11. Recheck the fluid level while the fluid is warm. The fluid should be between cold and hot.
1. Raise the frame and block up the machine so drive wheels can rotate freely. 2. Disconnect the electrical connector from the seat safety switch. Temporarily install a jumper wire across terminals in the wiring harness connector. 3. Unlatch the seat and slide seat forward. 4. Disconnect the seat rod and tilt the seat fully forward. Setting the Right-hand Hydraulic Pump Neutral Position 1. Start the engine, open the throttle 1/2 way and release parking brake.
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. 2. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 4. Check tire pressure of all four tires.
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 80). Note: It is recommended that both sides of the mower are adjusted the same distance. 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 Figure 79 1. Measure here from blade to hard surface 1.
Servicing the Cutting Blades 8. Adjust the lift nuts on both the left and the right side of the machine to achieve 1/4 to 3/8 inch (6 to 10 mm) lower in front at A than in the rear at B (Figure 80). Maintain sharp blades throughout the cutting season because sharp blades cut 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. 9.
A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders. • Always replace bent or damaged blade with a new blade. • Never file or create sharp notches in the edges or surfaces of blade. Figure 83 1. Cutting Edge 2. Curved Area 3. Wear/slot Forming 4. Crack Removing the Blades 2. Inspect the blades, especially the curved area (Figure 83). Blades must be replaced if a solid object is hit, if the blade is out of balance or is bent.
Replacing the Grass Deflector 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. Figure 85 1. Sharpen at original angle • Never operate the lawn mower unless you install a cover plate, a mulch plate, or a grass chute and catcher. 2. Check the balance of the blade by putting it on a blade balancer (Figure 86).
Cleaning Storage Cleaning Under the Mower Cleaning and Storage 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. Clean dirt and chaff from the outside of the engine cylinder head fins and blower housing. Service Interval: Before each use or daily Remove the grass buildup under the mower daily. 1.
D. Dispose of fuel properly. Recycle as per local codes. Important: Do not store stabilizer/conditioned fuel over 90 days. 13. Check and tighten all bolts, nuts, and screws. Repair or replace any part that is damaged. 14. Paint all scratched or bare metal surfaces. Paint is available from your Authorized Service Dealer. 15. Store the machine in a clean, dry garage or storage area. Remove the key from the ignition switch and keep it out of reach of children or other unauthorized users.
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: 65
Notes: 66
Notes: 67
The Toro Total Coverage Guarantee A Limited Warranty (see warranty periods below) Conditions and Products 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.
