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Toro Z580 Z Master Operator'S Manual Download Page 28

Maintenance

Recommended Maintenance Schedule(s)

Maintenance Service

Interval

Maintenance Procedure

After the first 8 hours

• Change the engine oil.
• Check the engine cooling system level.
• Adjust the mower belt tension for 72 inch mower decks.
• Check the hydraulic fluid.

After the first 25 hours

• Change the hydraulic filter.

After the first 100 hours

• Change gear box oil.

Before each use or daily

• Check the safety system.
• Check the engine oil.
• Check the engine cooling system level.
• Clean the hyraulic oil cooler and radiator screen.
• Check the mower blades.
• Clean the mower deck.

Every 25 hours

• Grease the mower deck and spindles.
• Grease the mower belt idler arm.
• Grease the pump belt idler arm.
• Grease the drive belt idler arm.
• Grease the brake lever.
• Check the hydraulic fluid.

Every 50 hours

• Check the tire pressure.
• Check the PTO drive belt.
• Check the pump drive belt.

Every 100 hours

• Change the engine oil. (more often in dirty or dusty conditions)
• Check the spark plug.
• Check the wheel hub slotted nut.
• Check the gear box oil level.
• Check the engine cooling system hoses.
• Inspect the belts for cracks and wear.
• Check the hydraulic hoses.

Every 150 hours

• Lubricate the machine with light oil.

Every 200 hours

• Change the engine oil filter.
• Grease the brake pivot.

Every 250 hours

• Check or replace the air filter (more often in dirty or dusty conditions)

Every 400 hours

• Replace the fuel filters (more often in dirty or dusty conditions).

Every 500 hours

• Adjust the caster pivot bearing.
• Adjust the electric clutch.

Yearly

• Grease the front caster pivots (more often in dirty or dusty conditions).
• Change the gear box oil.
• Change the engine coolant.
• Change the hydraulic filter and oil.

Yearly or before storage

• Paint chipped surfaces.
• Perform all maintenance procedures listed above before storage.

Important:

Refer to your engine operator’s manual for additional maintenance procedures.

28

Summary of Contents for Z580 Z Master

Page 1: ...8 911 Rev A Z580 Z Master with a 60in or 72in TURBO FORCE Side Discharge Mower Model No 74253 Serial No 280000001 and Up Model No 74254 Serial No 280000001 and Up Register at www Toro com Original Instructions EN ...

Page 2: ...te and maintain your product properly and to avoid injury and product damage You are responsible for operating the product properly and safely You may contact Toro directly at www Toro com for product and accessory information help finding a dealer or to register your product Whenever you need service genuine Toro parts or additional information contact an Authorized Service Dealer or Toro Custome...

Page 3: ...e Fuel Tank 36 Electrical System Maintenance 36 Servicing the Battery 36 Servicing the Fuses 38 Drive System Maintenance 39 Adjusting the Tracking 39 Checking the Tire Pressure 39 Checking the Wheel Hub Slotted Nut 40 Adjusting the Caster Pivot Bearing 40 Servicing the Gear Box 40 Adjusting the Electric Clutch 41 Cooling System Maintenance 42 Servicing the Cooling System 42 Brake Maintenance 44 Ad...

Page 4: ...rea where the equipment is to be used and remove all objects such as rocks toys and wire which can be thrown by the machine Use extra care when handling gasoline 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 C...

Page 5: ...e event of an emergency Be aware there is no rollover protection when the roll bar is down Check the area to be mowed and never fold the ROPS in areas where there are slopes drop offs or water Lower the rollbar only when absolutely necessary Do not wear the seat belt with the roll bar folded down Check carefully for overhead clearances i e branches doorways electrical wires before driving under an...

Page 6: ...Slope Chart 6 ...

Page 7: ...ructions are easily visible to the operator and are located near any area of potential danger Replace any decal that is damaged or lost 1 403005 1 523552 1 643253 54 9220 58 6520 1 Grease 66 1340 65 2690 68 8340 98 4387 1 Warning wear hearing protection 7 ...

Page 8: ...98 5954 105 7798 107 1613 107 1857 107 1860 1 Height of cut 107 1861 107 1864 8 ...

Page 9: ...107 2102 107 2112 107 2114 107 2449 108 5981 110 2067 9 ...

Page 10: ...fore 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 2 Remove the ignition key and read the instructions before servicing or performing maintenance 110 5772 1 Engine stop 5 Continuous variable setting 2 Engine run 6 Slow 3 Engine start 7 Power take off PTO 4 Fast 110 5794 110 ...

Page 11: ...110 6220 110 6221 Manufacturer s Mark 1 Indicates the blade is identified as a part from the original machine manufacturer 106 7492 11 ...

Page 12: ...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 12 ...

Page 13: ...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 Fuel Selector Valve The fuel selector valve is located under the left side of the seat Figure 5 Close the fuel selector valve when transporting or storing mower Move the selector valve to the lefthand LH or righthand R...

Page 14: ...n conditions during fueling static electricity can be released causing a spark which can ignite the gasoline vapors A fire or explosion from gasoline can burn you and others and can damage property Always place gasoline containers on the ground away from your vehicle before filling Do not fill gasoline containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic tru...

Page 15: ... is located under the left side of the seat Unlatch the seat and raise it to access the valve The unit has two fuel tanks One tank is on the left side and one on the right side Each tank connects to the fuel selector valve From there a common fuel line leads to the engine Figure 5 To use the left side fuel tank rotate the fuel selector valve to the LH lefthand location To use the right side fuel t...

Page 16: ...re 6 1 Full down position 2 Down position with bagger installed Important Ensure that the rear part of the seat is secured with the seat latch 4 To raise the roll bar remove the hairpin cotter pins and remove the two pins Figure 7 5 Raise the roll bar to the upright position and install the two pins and secure them with the hairpin cotter pins Figure 7 Important Always use the seat belt with the r...

Page 17: ... and warnings To avoid loss of control and possibility of rollover Do not operate near drop offs or near water Do not operate on slopes greater than 15 degrees Reduce speed and use extreme caution on slopes Avoid sudden turns or rapid speed changes Figure 8 1 Safe Zone use the Z Master here on slopes less than 15 degrees or flat areas 3 Water 2 Use walk behind mower and or hand trimmer near drop o...

Page 18: ...igure 10 The parking brake is disengaged and the lever will rest against the brake stop Figure 10 1 Parking brake ON 3 Brake Stop 2 Parking brake OFF Starting and Stopping the Engine Starting the Engine Note This machine does not have a manual choke This machine is equipped with an direct fuel injection DFI system 1 Raise the ROPS up and lock into place sit on the seat and fasten the seat belt 2 M...

Page 19: ... charge 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 Operating the Power Take Off PTO The power take off PTO switch starts and stops the mower blades and any powered attachments Engaging the PTO 1 If the engine is...

Page 20: ...ng 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 While the engine is running center either motion control and move forward or reverse the engine should stop Repeat for other motion control 5 Sitting on the seat disengage the parking brake move the PTO switch to off and move the motion control levers ...

Page 21: ...nders 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 Height of Cut The height of cut is adjusted from 1 1 2 to 5 inch 38 to 127 mm in 1 4 inch 6 mm increments by relocating the clevis pin into different hole locations 1 Rais...

Page 22: ...ge Nut 2 Bushing 4 Bolt Figure 19 1 Anti scalp roller 4 Flange Nut 2 Spacer 5 Bolt 3 Bushing 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 ...

Page 23: ...tion The suggested use for this position is a follows Use for short light grass mowing conditions Use in dry conditions For smaller grass clippings Propels grass clippings farther away from the mower Figure 21 Position B Use this position when bagging Figure 22 Position C This is the full open position The suggested use for this position is as follows Use in tall dense grass mowing conditions Use ...

Page 24: ...chine because hydraulic damage may occur 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 2 Rotate the by pass valves counterclockwise 1 turn to push This allows hydraulic fluid to by pass the pump enabling the wheels to turn Figure 26 Important Do not rotate by pass valves more...

Page 25: ...he machine to the trailer or truck with straps chains cable or ropes Secure a trailer to the towing vehicle with safety chains Driving on the street or roadway without turn signals lights reflective markings or a slow moving vehicle emblem is dangerous and can lead to accidents causing personal injury Do not drive machine on a public street or roadway Loading Machines Use extreme caution when load...

Page 26: ...ght of the mower does not scalp any uneven ground However the cutting height used in the past is generally the best one to use When cutting grass longer than six inches tall you may want to cut the lawn twice to ensure an acceptable quality of cut Cut 1 3 of the Grass Blade It is best to cut only about 1 3 of the grass blade Cutting more than that is not recommended unless grass is sparse or it is...

Page 27: ...of the mower after each use If grass and dirt build up inside the mower cutting quality will eventually become unsatisfactory Blade Maintenance Maintain a sharp blade throughout the cutting season because a sharp blade cuts cleanly without tearing or shredding the grass blades Tearing and shredding turns grass brown at the edges which slows growth and increases the chance of disease Check the cutt...

Page 28: ...lt Check the pump drive belt Every 100 hours Change the engine oil more often in dirty or dusty conditions Check the spark plug Check the wheel hub slotted nut Check the gear box oil level Check the engine cooling system hoses Inspect the belts for cracks and wear Check the hydraulic hoses Every 150 hours Lubricate the machine with light oil Every 200 hours Change the engine oil filter Grease the ...

Page 29: ...any paint off the front of the fitting s 4 Connect a grease gun to the fitting Pump grease into the fittings until grease begins to ooze out of the bearings 5 Wipe up any excess grease Greasing the Front Caster Pivots Service Interval Yearly more often in dirty or dusty conditions 1 Remove the dust cap and adjust the caster pivots Keep the dust cap off until greasing is done Refer to Adjusting the...

Page 30: ...ndles 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 29 4 Grease the fittings on the 3 spindle bearings Figure 29 Figure 29 5 Grease the pump belt idler arm Figure 3...

Page 31: ... parking brake 2 Stop the engine remove the key and wait for all moving parts to stop before leaving the operating position 3 Release the seat and tip it forward 4 Raise the radiator cover 5 Release the latches on the air cleaner and pull the air cleaner cover off of the air cleaner body Figure 32 6 Clean the inside of the air cleaner cover with compressed air 7 Gently slide the filter out of the ...

Page 32: ...ange 61 ounces 1 8 L Viscosity See the table below Figure 33 Note Using multi grade oils 5W 20 10W 30 and 10W 40 will increase oil consumption Check the oil level more frequently when using them Checking the Engine Oil Level Service Interval Before each use or daily Note Check the oil when the engine is cold Contact with hot surfaces may cause personal injury Keep hands feet face clothing and othe...

Page 33: ...et the parking brake 4 Stop the engine remove the key and wait for all moving parts to stop before leaving the operating position 5 Slide the drain hose over the oil drain valve 6 Place a pan below the drain hose Rotate oil drain valve to allow oil to drain Figure 35 7 When oil has drained completely close the drain valve 8 Remove the drain hose Figure 35 Note Dispose of the used oil at a recyclin...

Page 34: ...Type NGK BPR4ES or equivalent Air Gap 0 030 inch 0 75 mm Removing the Spark Plug 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 Pull the wire s off the spark plug s Figure 39 Now clean around the spark plug s to prevent dirt fro...

Page 35: ... the electronic control unit ECU has detected a problem or fault in the direct fuel injection DFI system Once the MIL illuminates initial trouble shooting checks should be made Refer to Troubleshooting page 59 under the MIL section If these checks do not correct the problem further diagnosis and servicing by an Authorized Service Dealer is necessary Servicing the Fuel Filters Replacing the Fuel Fi...

Page 36: ...ash hands after handling Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns Do not drink electrolyte and avoid contact with skin eyes or clothing Wear safety glasses to shield your eyes and rubber gloves to protect your hands Removing the Battery Battery terminals or metal tools could short against metal machine components causing sparks Sparks can cause th...

Page 37: ...e the positive red battery cable Figure 42 Figure 42 1 Negative Battery Post 3 Red cable 2 Positive Battery Post 4 Black cable 6 Remove both wing nuts 1 4 inch securing the battery clamp Figure 43 7 Remove the two bolts holding the hydraulic tank in place Figure 43 8 Slide the hydraulic tank away from the battery 9 Remove the battery Figure 43 1 Battery 4 Wing nut 2 Hydraulic tank 5 Right side fue...

Page 38: ...y in the machine and connect the battery cables refer to Installing the Battery Note Do not run the machine with the battery disconnected electrical damage may occur Figure 44 1 Positive Battery Post 3 Red Charger Lead 2 Negative Battery Post 4 Black Charger Lead Servicing the Fuses The electrical system is protected by fuses It requires no maintenance however if a fuse blows check component circu...

Page 39: ...left and right sides of the machine from the normal operating position 4 To make the machine go right turn the knob towards the rightside of the machine Refer to Figure 46 5 To make the machine go left turn the knob towards the leftside of the machine Refer to Figure 46 6 Repeat adjustment until the tracking is correct Figure 46 1 Tracking knob 4 Turn this way to track right 2 Hydraulic tank 5 Tur...

Page 40: ...hours Yearly whichever comes first 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 49 4 Tighten the locknut until the spring washers are flat and then back off a 1 4 tur...

Page 41: ...ng the operating position 3 Unlatch the seat and tip it forward 4 Loosen the front engine panel knobs and remove the panel 5 Push down on the spring loaded idler pulley for the PTO drive belt and remove the belt from the clutch pulley Figure 51 Figure 51 1 PTO drive belt 3 Spring loaded idler pulley 2 Gear box 6 Unplug the electric connection for the clutch Figure 52 7 Remove the two bolts holding...

Page 42: ...e 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 Do not touch radiator and surrounding parts that are hot Rota...

Page 43: ...rflow bottle and fill it to the indicator line on the bottle Figure 54 Figure 54 1 Antifreeze overflow bottle 2 Indicator line on side of overflow bottle Cleaning the Hydraulic Oil Cooler and Radiator Screen Service Interval Before each use or daily Before each use check and clean the radiator screen and oil cooler Remove any build up of grass dirt or other debris from the oil cooler and radiator ...

Page 44: ...ng 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 for 60in Mower Decks 1 Disengage the PTO move the motion control levers to the neutral locked position an...

Page 45: ...leaving the operating position 3 Remove the belt covers Figure 59 Figure 59 1 Belt cover 3 Insert slot into the tab 2 Latch 4 Loosen the idler plate bolts holding the idler plate Figure 62 5 Remove the idler spring 6 Remove the belt guide on the spring loaded idler pulley shown in Figure 60 and Figure 62 7 Remove the existing belt 8 Install the new belt around the mower pulleys and the gearbox pul...

Page 46: ...the bolts holding the idler plate Figure 62 6 Insert a ratchet or breaker bar into the square hole in the idler plate to adjust the tension Figure 62 7 Rotate the ratchet or breaker bar to move the idler plate until the idler spring is between 10 and 10 1 4 inches 25 4 and 26 0 cm from post to post as shown in Figure 62 8 While holding the belt tension and spring length tighten the idler plate bol...

Page 47: ...Spring loaded idler pulley 3 Spring Replacing the Pump Drive Belt Service Interval Every 50 hours Check the pump drive belt Note Remove the PTO drive belt first if the pump drive belt needs to be replaced 1 Tilt the seat forward and remove the front engine panel 2 Remove the PTO drive belt 3 Remove the spring from the idler arm Figure 65 4 Install the new belt around the engine and hydraulic pump ...

Page 48: ...below pivot shaft contacts the end of the slot just beginning to put pressure on the spring Figure 66 7 Check where the control lever is relative to notch in console Figure 66 It should be centered allowing lever to pivot outward to the neutral lock position Figure 66 1 Neutral locked position 3 Neutral position 2 Control lever 8 If adjustment is needed loosen the nut and jam nut against the yoke ...

Page 49: ... warm The fluid should be between cold and hot 7 If required add fluid to the hydraulic tank Note The fluid level should be to the top of the hot level of the baffle when the fluid is hot Figure 68 8 Install cap on filler neck Figure 68 1 Cap 3 Cold fluid level full 2 Baffle 4 Hot fluid level full Hydraulic fluid escaping under pressure can penetrate skin and cause injury If hydraulic fluid is inj...

Page 50: ... to purge air from the system Stop the engine and check for leaks If one or both wheels will not drive refer to Bleeding Hydraulic System 13 Recheck the fluid level while the fluid is warm The fluid should be between cold and hot 14 If required add fluid to the hydraulic tank Do not overfill Figure 71 1 Hydraulic filter 3 Adapter 2 Gasket Bleeding the Hydraulic System The traction system is self b...

Page 51: ... Engine must be running so motion control adjustment can be performed Contact with moving parts or hot surfaces may cause personal injury Keep hands feet face clothing and other body parts away from rotating parts muffler and other hot surfaces 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 ...

Page 52: ...motion control lever forward and reverse then back to neutral The wheel must stop turning or slightly creep in reverse 5 Open the throttle to fast Make sure the wheel remains stopped or slightly creeps in reverse adjust if necessary 6 Tighten the locknuts at the ball joints Figure 73 Figure 73 1 Double nuts 4 Locknut 2 Pump rod 5 Ball joint 3 Adjustment bolt 6 Pumps Electrical system will not perf...

Page 53: ...e Front to Rear Mower Pitch If one front chain is loose raise tighten the front support arm for that chain Refer to Adjusting the Front to Rear Mower Pitch Leveling the Mower Side to Side 1 Position the right blade side to side Figure 74 Figure 74 1 Measure here from blade to hard surface 2 Measure at B and C 2 Measure the right blade at the B location from a level surface to the cutting edge of t...

Page 54: ...equal chain tension 7 Loosen the front swivel jam nuts at the front of the right and left swivels approximately a 1 2 inch 13 mm Figure 75 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 75 9 Tighten both swivel jam nuts against the front swivel to lock the height 10 Check to make sure ...

Page 55: ...se or daily 1 Inspect the cutting edges Figure 78 If the edges are not sharp or have nicks remove and sharpen the blades Refer to Sharpening the Blades 2 Inspect the blades especially the curved area Figure 78 If you notice any damage wear or a slot forming in this area Figure 78 immediately install a new blade Figure 78 1 Cutting Edge 3 Wear slot Forming 2 Curved Area 4 Crack Checking for Bent Bl...

Page 56: ...e serious injury Wear proper eye protection when sharpening blade 1 Use a file to sharpen the cutting edge at both ends of the blade Figure 80 Maintain the original angle The blade retains its balance if the same amount of material is removed from both cutting edges Figure 80 1 Sharpen at original angle 2 Check the balance of the blade by putting it on a blade balancer Figure 81 If the blade stays...

Page 57: ...igure 83 3 Install the bolt and nut Place the J hook end of the spring around the grass deflector Figure 83 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 Figure 83 1 Bolt 5 Spring installed 2 Spacer 6 Grass Deflector 3 Locknut 7 L end of spring place behind deck edge before installing bolt 4 Spring 8 ...

Page 58: ...ide of the mower then wash the mower with a garden hose Note Run the machine with the PTO engaged and the engine at high idle for 2 to 5 minutes after washing 11 Check the condition of the blades refer to Servicing the Cutting Blades in Mower Deck Maintenance page 53 12 Prepare the machine for storage when non use occurs over 30 days Prepare the machine for storage as follows A Add a petroleum bas...

Page 59: ...ugged 5 Clean or replace the fuel cap 6 Dirt in the fuel filter 6 Replace the fuel filter Engine loses power 7 Dirt water or stale fuel is in the fuel system 7 Contact an Authorized Service Dealer 1 Engine load is excessive 1 Reduce the ground speed 2 Oil level in the crankcase is low 2 Add oil to the crankcase Engine overheats 3 Cooling fins and air passages above the engine are plugged 3 Remove ...

Page 60: ...tall deck pulley and check the idler pulley idler arm and spring for correct position and function Blades do not rotate 5 Broken or missing idler spring 5 Replace the spring 1 Engine is too hot 1 Turn engine off and let it cool 2 Old gas in the gas tank 2 Use new gas 3 The fuel shut off valve is not open completely 3 Open the fuel shut off valve 4 Fuel tank vent cap is blocked 4 Make sure that the...

Page 61: ...Schematics Wire Diagram Rev A 61 ...

Page 62: ...Notes 62 ...

Page 63: ...Notes 63 ...

Page 64: ...is no other express warranty except for special emission system coverage on some products This express warranty does not cover the following Cost of regular maintenance service or parts such as lters fuel lubricants tune up parts blade sharpening brake and clutch adjustments Any product or part which has been altered or misused or required replacement or repair due to normal wear accidents or lack...

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