Form No. 3359-137 Rev A Z590-D Z Master® with 60in or 72in TURBO FORCE® Side Discharge Mower Model No. 74268—Serial No. 280000001 and Up Model No. 74268CP—Serial No. 280000001 and Up Model No. 74269—Serial No. 280000001 and Up Model No. 74269CP—Serial No. 280000001 and Up Register at www.Toro.com.
Warning CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and 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.
Using the Rollover Protection System (ROPS) .......................................................... 16 Think Safety First ............................................... 17 Understanding the Audible Alarms ..................... 17 Operating the Parking Brake ............................... 18 Starting and Stopping the Engine ........................ 18 Operating the Power Take Off (PTO) ................. 20 The Safety Interlock System................................ 20 Driving Forward or Backward........
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 gas 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 103-3276 107-1613 103-5881 107-1857 104-2449 104-7759 107-1860 1.
107-1861 107-2102 107-1864 107-2112 107-2114 9
Manufacturer’s Mark 1. Indicates the blade is identified as a part from the original machine manufacturer. 107-7673 1. Cutting blade 107-9863 107-7705 107-9864 1. Read the Operator’s Manual.
0-2068 1. Read the Operator’s Manual. 115-3562 114-9600 1. Read the Operator’s Manual.
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. 107-9866 1. Fast 3. Neutral 2. Slow 12 4.
Hour Meter Product Overview 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 (Figure 4). Glow Plug Light (Orange Light) The glow plug indicator light turns on when the ignition switch is turned to the on position. When the light turns off, the engine is ready to be started (Figure 4).
Operation Note: Determine the left and right sides of the machine from the normal operating position. 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. 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 octane rating of 40.
Filling the Fuel Tank 1. Shut the engine off and set the parking brake. 2. 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 the bottom of the filler neck. This space in the tank allows the fuel to expand. Do not fill the fuel tanks completely full. 3. Install fuel tank caps securely. Wipe up any fuel that may have spilled. 4. If possible, fill the fuel tank after each use.
Using the Rollover Protection System (ROPS) To avoid injury or death from rollover: keep the roll bar in the raised locked position and use the seat belt. Ensure that the rear part of the seat is secured with the seat latch. Figure 6 1. Full down position There is no rollover protection when the roll bar is in the down position. 2. Down position with bagger installed Important: Ensure that the rear part of the seat is secured with the seat latch. • Lower the roll bar only when absolutely necessary.
Think Safety First Please read all safety instructions and symbols in the safety section. Knowing this information could help you or bystanders avoid injury. Operating on wet grass or steep slopes can cause sliding and loss of control. Wheels dropping over edges can cause rollovers, which may result in serious injury, death or drowning. Figure 8 There is no rollover protection when the roll bar is down. 1. Safe Zone-use the Z Master here on slopes less than 15 degrees or flat areas. 2.
brake is disengaged and the lever will rest against the brake stop. Figure 10 Figure 11 Continuous Audible Alarm 1. Parking brake-ON 2. Parking brake-OFF The continuous audible alarm alerts the user that the engine is over heating. Refer to Servicing the Cooling System. 3. Brake Stop Starting and Stopping the Engine Pulsing Audible Alarm The pulsing audible alarm alerts the user to low oil pressure or the alternator is not charging. Refer to Checking the Engine Oil and check the alternator belt.
Figure 12 1. 2. 3. 4. Ignition switch Throttle control Glow plug light Power take off (PTO) Switch 5. 6. 7. 8. Hour meter Fuel cap Volt meter Engine Temperature gauge Figure 14 1. Throttle—fast 2. Throttle—slow Starting the Engine in Cold Weather (Below 14°F or -10°C) Important: Use starting cycles of no more than 30 seconds per minute to avoid overheating the starter motor. Use the correct engine oil for the starting temperature. Refer to Servicing the Engine Oil in Engine Maintenance , page 33. 1.
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. Disengaging the PTO Important: Make sure to remove the key as the fuel pump may run and cause the battery to lose charge. The Safety Interlock System To disengage, push the PTO switch to the off position (Figure 15).
To stop, pull the motion control levers to the neutral position. control levers to neutral lock position. Now start the engine. While the engine is running, release the parking brake, engage the PTO and rise slightly from the seat; the engine should stop. 4. Sitting on the seat, engage the parking brake, move the PTO switch to off and move the motion control levers to neutral lock position. Now start the engine.
Children or bystanders may be injured if they move or attempt to operate the tractor while it is unattended. Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes. Adjusting the Control Lever Resistance Figure 18 1. Height of cut lever The top damper mounting bolt can be adjusted to obtain a desired motion control lever resistance. Refer to Figure 17 for the mounting options. 2.
Note: The two middle rollers will not have a spacer (Figure 21). 4. Select a hole so the anti-scalp roller is positioned to the nearest corresponding height-of-cut desired. 5. Install the flange nut bushing, spacer, and bolt. Torque to 40-45 ft-lb (54-61 N-m) (Figure 20 , Figure 21 and Figure 22 ). 6. Repeat this adjustment on the other anti-scalp rollers. Figure 22 1. Anti-scalp roller 2. Spacer 3. Bushing 4. Flange Nut 5.
Figure 23 3. Rotate cam to increase or decrease locking pressure 4. Slot 1. Cam lock 2. Lever Figure 25 Positioning the Flow Baffle Position C The following figures are only recommendations for use. Adjustments will vary by grass type, moisture content, and height of grass. 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.
1. To adjust, move the lever sideways to unlock seat (Figure 27). Figure 28 1. Back rest knob Figure 27 1. Seat suspension knob 2. Right-side arm rest 2. Seat position adjustment lever Unlatching the Seat 2. Slide the seat to the desired position and release lever to lock in position. Push the seat latch rearward to unlatch the seat. This will allow access to the machine under the seat (Figure 29). Changing the Seat Suspension The seat can be adjusted to provide a smooth and comfortable ride.
Pushing the Machine by Hand Important: Always push the machine by hand. Never tow the machine because hydraulic damage may occur. 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. Pushing the Machine 1. Disengage the power take off (PTO) and turn the ignition key to off.
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 31). 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.
Driving off the Z Stand 1. Remove the chocks or blocks. 2. Raise the latch to the unlocked position (Figure 34). Figure 32 4. Bracket Pin 5. Bottom of slot 1. Z Stand 2. Latch 3. Bracket 3. Raise the latch. Swing the stand foot out front and slide stand toward machine, into the bottom of slot (Figure 32 and Figure 33). Figure 34 1. Z Stand 2. Latch 3. Locked position 4. Unlocked position 3. Start the engine and place it at half throttle. Disengage the parking brake. 4.
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 cooling system level. • 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. Before each use or daily • • • • • • Check the safety system. Check the engine oil. Check cooling system level. Clean the cooling system. Check the mower blades.
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. Lubrication Where to Add Grease Greasing and Lubrication Lubricate the grease fittings as shown on the Check Service Reference Aid decal (Figure 35).
Important: Make sure cutting unit spindles are full of grease weekly. Grease the Idler Arms 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2. Grease the drive belt idler arms (Figure 37). 1. Grease the cooling fan belt idler arm (Figure 37). 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the belt covers. 4.
Engine Maintenance Servicing the Air Cleaner Note: Service the air cleaner more frequently if operating conditions are extremely dusty or sandy. Removing the Filters 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 40 1. Latches 2. Air cleaner cover 3. Air filter body 3.
Important: Do not press on the soft inside area of the filter. 4. Install the air cleaner cover with the side indicated as UP facing up and secure the latches (Figure 40). 5. Install the front engine panel. Servicing the Engine Oil Oil Type: High-quality detergent oil classified “API Service CF or CF-4" or higher for diesel engines. Do not use special additives with recommended oils. Crankcase Capacity: 3.5 quarts (3.3 liters) Viscosity: See the table below. Figure 42 1. Oil dipstick 2.
Adding Engine Oil 1. Tilt the seat forward and remove the front engine panel (Figure 43). Figure 45 1. Note the clearance left in the filler opening. 5. Replace the dipstick and install the front engine panel. Figure 43 1. Front engine panel 6. Start the engine and run it at idle for 5 minutes. 2. Knob 7. Shut off the engine. 8. Wait 3 minutes and check the oil level. 2. Remove the oil filler cap and the dipstick (Figure 44). 9.
Fuel System Maintenance Servicing the Fuel Filter Draining the Water Separator Figure 46 1. Drain plug 2. Oil filter Service Interval: Every 40 hours 3. Dip stick 1. Position the machine on a level 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. Locate the water separator at the back left of the machine. 5.
Changing the Fuel Filter Electrical System Maintenance Service Interval: Every 400 hours/Yearly (whichever comes first) (more often in dirty or dusty conditions). Servicing the Battery Never install a dirty fuel filter if it is removed from the fuel line. Warning 1. Allow the machine to cool down. 2. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake.
2. First, install the positive (red) battery cable to positive (+) battery terminal. Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. 3. Then install the negative battery cable and ground wire to the negative (-) battery terminal. 4. Secure the cables with 2 bolts (1/4 x 3/4 inch), 2 washers (1/4 inch), and 2 locknuts (1/4 inch) (Figure 50).
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 47 and Adjusting the Hydraulic Pump Neutral in Hydraulic System Maintenance , page 48. Figure 51 1. Positive Battery Post 2. Negative Battery Post 3. Red (+) Charger Lead 4. Black (-) Charger Lead 1.
Checking the Tire Pressure 8. Tighten the nut until the next set of slots line up with the hole in the shaft (Figure 55). Service Interval: Every 50 hours or monthly, whichever occurs first. 9. Replace the cotter pin. Check the pressure at the valve stem (Figure 54). Maintain the air pressure in the rear tires at 13 psi (90 kPa). Uneven tire pressure can cause uneven cut. Check the tires when they are cold to get the most accurate pressure reading.
Cooling System Maintenance Servicing the Cooling System Discharge of hot pressurized coolant or touching hot radiator and surrounding parts can cause severe burns. • Do not remove the radiator cap when the engine is hot. Always allow the engine to cool at least 15 minutes or until the radiator cap is cool enough to touch without burning your hand before removing the radiator cap. Figure 56 1. Spring Washers 2. Lock Nut 3. Dust Cap • Do not touch radiator and surrounding parts that are hot.
Cooling System Capacity: 128 ounces (3.8 l) 4. Remove debris from the screen on the engine cover. Note: Do not open the radiator cap. Doing this may induce air into the cooling system. 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 57). 4.
Brake Maintenance Adjusting the Parking Brake Service Interval: Every 25 hours Every 200 hours 1. Disengage the brake lever (lever down). 2. Measure the length of the spring. The measurement should be 2-3/4 inch (70 mm) between the washers (Figure 58). 3. If an adjustment is necessary, loosen the jam nut below the spring and tighten the nut directly below the yoke (Figure 58). Turn the nut until the correct measurement is obtained. Tighten the two nuts together and repeat on the opposite side of the unit.
Belt Maintenance 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. Replacing the Mower Belt Figure 59 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.
Adjusting the Drive Belts 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. Note: Measure only the spring coils. 3. Measure the length of the spring. Check to make sure the coils of the spring on the spring-loaded idler pulley measures as listed below (Figure 63 and Figure 64). Figure 61 1. Rear engine panel 4.
Replacing and Tensioning the Alternator Belt Replacing the Alternator Belt Service Interval: Every 50 hours—Check the alternator 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. Tilt the seat forward and remove the front engine panel (Figure 66). Figure 64 1. Left adjustable pulley 2. Left spring loaded idler pulley 3.
Controls System Maintenance 5. If the deflection is correct, torque the upper bolt to 170 in-lb (19 N-m) and the bottom bolt to 45 ft-lb (61 N-m) (Figure 67). 6. Install the pump drive belt; refer to Replacing the Pump Drive Belt. Adjusting the Control Handle Neutral Position 7. Install the front engine panel (Figure 66). If motion control levers do not align, or move easily into the console notch, adjustment is required. Adjust each lever, spring and rod separately.
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 69). 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 69). 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. Place drain pan under filter, remove the old filter and wipe the filter adapter gasket surface clean (Figure 71). Figure 70 1. Hot fluid level-full 2. Cold fluid level-full Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Figure 71 1.
Bleeding the Hydraulic System The traction system is self bleeding, however, it may be necessary to bleed the system if fluid is changed or after work is performed on the system. 1. Raise rear of the machine so wheels are off the ground and support with jack stands. 2. Start the engine and run at low idle speed. Engage the lever and traction on one side and spin the wheel by hand. 3. When the wheel begins to spin on its own, keep it engaged until wheel drives smoothly. (minimum 2 minutes) Figure 72 3.
Setting the Hydraulic Pump Neutral Position Note: Adjust the handle neutral first. That needs to be correct before the following adjustment can be made. This adjustment must be made with drive wheels turning. Mechanical or hydraulic jacks may fail to support machine and cause a serious injury. Figure 74 • Use jack stand when supporting machine. 1. Tracking knob 2. Hydraulic tank 3. Hydraulic pumps • Do not use hydraulic jacks. 4. Turn this way to track right 5. Turn this way to track left 3.
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 the 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. If needed, adjust to 13 psi (90 kPa) 5.
2. Measure the right blade at the B location, from a level surface to the cutting edge of the blade tip (Figure 76). 3. Record this measurement. This measurement needs to be 3-1/8 to 3-1/4 inches. 4. Position the left blade side-to-side (Figure 76). 5. Measure the left blade at the C location (Figure 76), from a level surface to the cutting edge of the blade tip. 6. Record this measurement. This measurement needs to be 3-1/8 to 3-1/4 inches (80 to 83 mm). 7.
Before Inspecting or Servicing the Blades the spring; counter-clockwise will lengthen the spring. 4. Lock the nut into position by tightening the spring jam nut (Figure 79). Park the machine on a level surface, disengage the blade control (PTO), and set the parking brake. Turn the ignition key to Off. Remove the key. Inspecting the Blades Service Interval: Before each use or daily 1. Inspect the cutting edges (Figure 80). If the edges are not sharp or have nicks, remove and sharpen the blades.
Contact with a sharp blade can cause serious injury. Wear gloves or wrap sharp edges of the blade with a rag. 1. Hold the blade end using a rag or thickly-padded glove. 2. Remove the blade bolt, spring disk and blade from the spindle shaft (Figure 84). Sharpening the Blades Figure 81 1. Measure here from blade to hard surface 2. Position A When sharpening blade, pieces of blade could be thrown and cause serious injury. 4. Rotate the opposite ends of the blades forward. 5.
Installing the Blades Important: The grass deflector must be able to lower down into position. Lift the deflector up to test that it lowers into the full down position. 1. Install the blade onto the spindle shaft (Figure 84). Important: The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting. 2. Install the spring disk and blade bolt. The spring disk cone must be installed toward the bolt head (Figure 84).
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. Service Interval: Before each use or daily Remove the grass buildup under the mower daily. 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. 1.
Note: A fuel stabilizer/conditioner is most effective when mixed with fresh fuel and used at all times. B. Run the engine to distribute conditioned fuel through the fuel system (5 minutes). C. Stop the engine, allow it to cool, and drain the fuel tank; refer to Servicing the Fuel Tank in Fuel System Maintenance , page 36. D. Restart the engine and run it until it stops. E. Dispose of fuel properly. Recycle as per local codes. Important: Do not store stabilizer/conditioned fuel over 90 days. 13.
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 the 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 the 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 the 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.
