Toro Z590-D Z Master Operator'S Manual Download Page 63

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Problem

Possible Cause

Corrective Action

1. Blade(s) not sharp.

1. Sharpen the blade(s).

2. Cutting blade(s) is/are bent.

2. Install new cutting blade(s).

3. Mower is not level.

3. Level the mower from side-to-side and

front-to-rear.

4. Underside of mower is dirty.

4. Clean the underside of the mower.

5. Tire pressure is not correct.

5. Adjust the tire pressure.

Uneven cutting height.

6. Blade spindle bent.

6. Contact an Authorized Service Dealer.

1. Drive belt is worn, loose or broken.

1. Check the belt tension.

2. Drive belt is off pulley.

2. Install the drive belt and check

adjusting shafts and belt guides for
correct position.

3. Deck belt is worn, loose or broken.

3. Install a new deck belt.

4. Deck belt is off pulley.

4. Install the 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.

Summary of Contents for Z590-D Z Master

Page 1: ... 72in TURBO FORCE Side Discharge Mower Model No 74268 Serial No 310000001 and Up Model No 74269 Serial No 310000001 and Up To register your product or download an Operator s Manual or Parts Catalog at no charge go to www Toro com Original Instructions EN ...

Page 2: ... 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 Customer Service and have the model and serial numbers of...

Page 3: ...s 34 Engine Maintenance 36 Servicing the Air Cleaner 36 Servicing the Engine Oil 37 Fuel System Maintenance 39 Servicing the Fuel Filter and Water Separator 39 Servicing the Fuel Tank 40 Electrical System Maintenance 40 Servicing the Battery 40 Servicing the Fuses 41 Drive System Maintenance 42 Adjusting the Tracking 42 Checking the Tire Pressure 43 Checking the Wheel Hub Slotted Nut 43 Adjusting ...

Page 4: ... area 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 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 C...

Page 5: ...e machine Be certain that the seat belt can be released quickly in the 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 clea...

Page 6: ... degrees Use the slope chart to determine the degree of slope of hills before operating Do not operate this machine on a slope greater than 15 degrees Fold along the appropriate line to match the recommended slope 2 Align this edge with a vertical surface a tree building fence pole etc 3 Example of how to compare slope with folded edge 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 103 3276 103 5881 104 2449 104 7759 105 7798 107 1613 107 1857 107 1860 8 ...

Page 9: ...107 1861 107 1864 107 2102 107 2112 107 2114 9 ...

Page 10: ...nufacturer s Mark 1 Indicates the blade is identified as a part from the original machine manufacturer 107 7673 1 Cutting blade 107 7705 107 9863 107 9864 1 Read the Operator s Manual 109 7949 110 2067 10 ...

Page 11: ...rval 2 Power Take off PTO 3 Parking brake 4 Neutral 5 Operator presence switch 6 Battery 114 9600 1 Read the Operator s Manual 117 0916 1 Fast 3 Slow 2 Continuous variable setting 117 2718 117 7818 1 Read the Operator s Manual for information on fuses 11 ...

Page 12: ...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 12 ...

Page 13: ...107 9866 1 Fast 2 Slow 3 Neutral 4 Reverse 13 ...

Page 14: ...ur 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 5 Safety Interlock Indicators There are symbols on the hour meter and they indicate with a black triangle that the interlock component is in the correct position Figure 6 Battery Indicator Light When the ignition key is initially turned to th...

Page 15: ... when the ignition switch is turned to the on position When the light turns off the engine is ready to be started Figure 5 Temperature Light The temperature light comes on when the engine is over heating Figure 5 Audible Alarm 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 Maintenan...

Page 16: ...ls Never fill the fuel tank inside an enclosed trailer Do not fill the fuel tank completely full Fill the fuel tank to the bottom of the filler neck The empty space in the tank allows gasoline to expand Overfilling may result in fuel leakage or damage to the engine or emission system if equipped Never smoke when handling fuel and stay away from an open flame or where fuel fumes may be ignited by a...

Page 17: ...l 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 7 To use the left side fuel tank rotate the fuel selector valve to the LH position lefthand location To use the right side fuel tank rotate the fuel selector valve to the RH position righthand location Figure 7 Close the fuel selector...

Page 18: ...ould help you or bystanders avoid injury DANGER 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 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 protect...

Page 19: ...check the alternator belt Operating the Parking Brake Always set the parking brake when you stop the machine or leave it unattended Setting the Parking Brake 1 Move the motion control levers Figure 19 out to the neutral lock position 2 Pull up and back on the parking brake lever to set the parking brake Figure 13 The parking brake lever should stay firmly in the engaged position WARNING Parking br...

Page 20: ...the engine does not start immediately move the throttle control to fast and turn the key to the start position Note Additional starting cycles may be required when starting the engine for the first time after the fuel system has been completely without fuel Figure 15 1 Ignition switch 3 Run 2 Off 4 Start Figure 16 1 Throttle fast 2 Throttle slow Starting the Engine in Cold Weather Below 14 F or 10...

Page 21: ...gine to warm up 5 to 10 minutes before engaging the PTO 2 While seated in the seat release the pressure on the traction control levers and place in neutral 3 Place the throttle in the fast position Note Engaging the PTO with the throttle at the half or less position will cause excessive wear to the drive belts 4 Pull out on the power take off PTO switch to engage it Figure 17 Figure 17 1 PTO On 2 ...

Page 22: ... 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 to neutral lock position Try starting the engine the engine should not crank Driving Forward or Backward The throttle control regulates the engine speed as measured in rpm revolutions per minute Place the throttle control...

Page 23: ...rake in Operation Remember to remove the key from the ignition switch CAUTION 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 The top damper mounting bolt can be adjusted to obt...

Page 24: ... adjust the height of the anti scalp rollers 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 After adjusting the height of cut adjust the rollers by removing the flange nut bushing spacer and bolt Figure 23 Figure 24 and Figure 2...

Page 25: ...hten the baffle and cam locks Figure 26 6 If the cams do not lock the baffle into place or it is too tight loosen the lever and then rotate the cam lock Adjust the cam lock until the desired locking pressure is achieved Figure 26 1 Cam lock 3 Rotate cam to increase or decrease locking pressure 2 Lever 4 Slot Positioning the Flow Baffle The following figures are only recommendations for use Adjustm...

Page 26: ...ust move the lever sideways to unlock seat Figure 30 g012486 Figure 30 1 Seat suspension knob 2 Seat position adjustment lever 2 Slide the seat to the desired position and release lever to lock in position Changing the Seat Suspension The seat can be adjusted to provide a smooth and comfortable ride Position the seat where you are most comfortable To adjust it turn the knob in front either directi...

Page 27: ... 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 33 Important Do not rotate by pass valves more than 1 turn This prevents valves from coming out of the body and causing fluid to run out 3 Disengage parking brake before pushing Changing to Machine Operation Rotate the by pass valves clockwise 1 turn to op...

Page 28: ...recommended instead of individual ramps for each side of the unit Figure 34 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 If it is not possible to use one full width ramp use enough individual ramps to simulate ...

Page 29: ...acket pin Figure 35 Figure 35 1 Z Stand 4 Bracket Pin 2 Latch 5 Bottom of slot 3 Bracket 3 Raise the latch Swing the stand foot out front and slide stand toward machine into the bottom of slot Figure 35 and Figure 36 4 Lengthen the Z Stand by removing the clevis pin and hairpin cotter pin from the outer tube and sliding the foot out 5 Align the holes and install the clevis pin and hairpin cotter p...

Page 30: ...se 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 late fall when grass grows more slowly Mowing Direction Alternate mowing direction to keep the grass standing straight This...

Page 31: ...y 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 cutter blades daily for sharpness and for any wear or damage File down any nicks and sharpen the blades as necessary If a blade ...

Page 32: ...k the pump drive belt Check the alternator belt Every 100 hours Change the engine oil Check the 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 Replace the primary air filter Change the engine oil filter Grease the brake pivot Every 250 hours Change the hydraulic filter and hydraulic oil when ...

Page 33: ... all moving parts to stop before leaving the operating position 3 Clean the grease fittings with a rag Make sure to scrape 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 Where to Add Grease Lubricate the grease fittings as shown on the Check Service Reference Ai...

Page 34: ...ase the Idler Arms 1 Grease the cooling fan belt idler arm Figure 40 2 Grease the drive belt idler arms Figure 40 Figure 40 3 Grease the pump belt idler arm Figure 41 Greasing the Front Caster Pivots Service Interval Yearly Lubricate the front caster pivots once a year 1 Remove the dust cap and adjust the caster pivots Keep the dust cap off until greasing is done Refer to Adjusting the Caster Pivo...

Page 35: ...tely 1 8 inch 3 mm from the outer surface of the spacer nut to the end of the axle inside the nut 9 Insert the assembled nut and axle into the wheel on the side of the wheel with the new seal and bearing 10 With the open end of the wheel facing up fill the area inside the wheel around the axle full of general purpose grease 11 Insert the second bearing and new seal into the wheel 12 Apply a thread...

Page 36: ...t on the outside of the filter Holes in the filter will appear as bright spots If the filter is damaged discard it Figure 44 1 Latches 4 Primary filter 2 Air cleaner cover 5 Safety filter 3 Air filter body Servicing the Primary Filter Service Interval Every 200 hours Replace the primary air filter 1 Do not clean the paper filter replace it Figure 44 2 Inspect the element for tears an oily film or ...

Page 37: ...ull the dipstick out and look at the metal end Figure 46 If the oil level is low slowly pour only enough oil into the fill hole to raise the level to the full mark Important Do not overfill the crankcase with oil because this may cause engine damage Do not run the engine with oil below the low mark because the engine may be damaged as a result Figure 46 1 Oil dipstick 3 Right side of machine 2 Met...

Page 38: ...stall the front engine panel 6 Start the engine and run it at idle for 5 minutes 7 Shut off the engine 8 Wait 3 minutes and check the oil level 9 Add oil if required to bring the level to the upper hole on the dipstick 10 Replace the dipstick and filler cap and the front engine panel 11 Check for leaks Important Do not overfill the crankcase with oil because this may cause engine damage Changing t...

Page 39: ...utral 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 Place a drain pan below the water separator 6 Open the drain valve on the water separator approximately one turn to allow water and other contaminates to drain Figure 52 7 Close th...

Page 40: ...y 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 DANGER 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 ...

Page 41: ...tive red battery post 6 Secure the battery with J bolts hold down clamp 2 washers 1 4 inch and 2 wing nuts 1 4 inch Figure 54 Charging the Battery WARNING Charging the battery produces gasses that can explode Never smoke near the battery and keep sparks and flames away from battery Important Always keep the battery fully charged 1 265 specific gravity This is especially important to prevent batter...

Page 42: ...Hydraulic System 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 Unlatch the seat and tilt the seat forward to access the tracking knob Note Determine the left and right sides of the machine from the normal operating position 4 To make the machine go right turn the knob towards the rig...

Page 43: ...ue the slotted nut to 125 ft lb 170 N m Figure 60 5 Check the distance from bottom of slot in nut to inside edge of hole Two threads or less should be showing Figure 60 6 If more than two threads are showing remove nut and install washer between hub and nut 7 Torque the slotted nut to 125 ft lb 170 N m Figure 60 8 Tighten the nut until the next set of slots line up with the hole in the shaft Figur...

Page 44: ...t operate the machine without the covers in place Keep fingers hands and clothing clear of rotating fan and drive shaft Shut off the engine and remove the ignition key before performing maintenance CAUTION Swallowing engine coolant can cause poisoning Do not swallow engine coolant Keep out of reach from children and pets Checking the Radiator Coolant Service Interval Before each use or daily After...

Page 45: ... on a level surface stop the engine and set the parking brake Important Before starting the engine clean grass from the pump drive belt compartment Check more often in dry conditions 2 Unlatch the seat tilt the seat up and raise the rubber flap above the drive belt compartment 3 Remove debris from the drive belt compartment and hydraulic pumps 4 Remove debris from the screen on the engine cover 5 ...

Page 46: ...lever up 6 Measure the distance between the spring bracket and the adjusting nut under spring bracket The measurement should be 1 4 5 16 inch 5 8 mm Figure 63 7 If an adjustment is necessary loosen the jam nut directly above the trunion roller Turn the lock nut below the trunion roller until the correct measurement is obtained Figure 63 8 Tighten the jam nut directly above the trunion roller Figur...

Page 47: ...er pulleys and the top pulley of the three stacked pulleys Figure 64 and Figure 65 6 Install the new belt around the mower pulleys and the top pulley of the three stacked pulleys Figure 64 and Figure 65 7 Pull on the spring loaded idler arm to loosen the belt tension and align the mower belt onto the idler pulley Figure 65 8 Install the belt covers and close the latches Figure 64 Figure 64 1 Belt ...

Page 48: ...p 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 68 and Figure 69 Left spring measurement 5 3 4 1 8 inch 14 6 0 3 cm Figure 68 Right spring measurement 5 1 2 1 8 inch...

Page 49: ...ervice 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 71 Figure 71 1 Front engine panel 2 Knob 4 Check the alternat...

Page 50: ... set up instructions 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 Unlatch the seat and tilt the seat forward 4 Begin with either the left or right motion control lever 5 Move the lever to the neutral position but not locked Fi...

Page 51: ...king the Hydraulic Fluid Service Interval After the first 8 hours Every 25 hours Note There are two ways of checking the hydraulic oil One is when the oil is warm and one is when the oil is cold The baffle inside the tank has two levels depending if the oil is warm or cold 1 Position the machine on a level surface and set the parking brake 2 Clean the area around filler neck of hydraulic tank Figu...

Page 52: ...O 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 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 Figu...

Page 53: ...ck hydraulic fluid level and add as required to maintain proper level 5 Repeat this procedure on the opposite wheel Checking the Hydraulic Hoses Service Interval Every 100 hours Check the hydraulic hoses for leaks loose fittings kinked lines loose mounting supports wear weather and chemical deterioration Make necessary repairs before operating Note Keep areas around the hydraulic system clean from...

Page 54: ...nob in the appropriate direction until the wheel is still or slightly creeping in reverse Figure 79 Figure 79 1 Tracking knob 4 Turn this way to track right 2 Hydraulic tank 5 Turn this way to track left 3 Hydraulic pumps 3 Move the motion control lever forward and reverse then back to neutral The wheel must stop turning or slightly creep in reverse 4 Open the throttle to fast Make sure wheel rema...

Page 55: ... 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 Lower the mower to...

Page 56: ...t the A location from a level surface to the cutting edge of the blade tip Figure 83 Figure 83 1 Measure here from blade to hard surface 2 Measure at A and B 3 Record this measurement 4 Measure the right blade at the B location from a level surface to the cutting edge of the blade tip Figure 83 5 Record this measurement 6 The mower blade should be a 1 4 to 3 8 inch 6 to 10 mm lower at position A t...

Page 57: ...reak and a piece of the blade could be thrown into the operator s or bystander s area resulting in serious personal injury or death Inspect the blade periodically for wear or damage Replace a worn or damaged blade Before Inspecting or Servicing the Blades 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 Inspec...

Page 58: ...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 89 Sharpening the Blades WARNING When sharpening blade pieces of blade could be thrown and cause serious injury Wear proper eye protection when sharpening blade 1 Use a file to sharpen t...

Page 59: ...ring and spacer holding the deflector to the pivot brackets Figure 90 Remove the damaged or worn grass deflector 2 Place the spacer and spring onto grass deflector Place the L end of spring behind deck edge Note Make sure the L end of the spring is installed behind the deck edge before installing the bolt as shown in Figure 90 3 Install the bolt and nut Place the J hook end of the spring around th...

Page 60: ... cylinder head fins and blower housing Important You can wash the machine with mild detergent and water Do not pressure wash the machine Avoid excessive use of water especially near the control panel engine hydraulic pumps and motors 3 Check the brake refer to Servicing the Brake in Brake Maintenance page 46 4 Service the air cleaner refer to Servicing the Air Cleaner in Engine Maintenance page 36...

Page 61: ...t until it stops E 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 ...

Page 62: ...s plugged 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 Rem...

Page 63: ...sure Uneven cutting height 6 Blade spindle bent 6 Contact an Authorized Service Dealer 1 Drive belt is worn loose or broken 1 Check the belt tension 2 Drive belt is off pulley 2 Install the drive belt and check adjusting shafts and belt guides for correct position 3 Deck belt is worn loose or broken 3 Install a new deck belt 4 Deck belt is off pulley 4 Install the deck pulley and check the idler p...

Page 64: ...TOR B L I F3 8 7 R I 5 A 4 3 A S 1 2 5 3 B 2 2 A 2 R 20A S B 30A KEY SWITCH B S DIESEL 50A B KEY SW RED WHITE ORANGE GREY BLACK YELLOW WHITE 6 10A F4 START RELAY SW1 6 GLOW TIMER 4 F1 F2 2A I 2B GREEN BROWN BLUE 1A TEMP SWITCH DIODE TEMPERATURE IND VIOLET RED TAN PINK SW2 PTO SHOWN IN THE OFF POSITION ETR SOLENOID SW6 SEAT SWITCH ON SEAT A B IGNITION SW 4 RH NEUT SWITCH IN NEUT ACCESSOR Y CONNECT ...

Page 65: ...Notes 65 ...

Page 66: ...Notes 66 ...

Page 67: ...Notes 67 ...

Page 68: ...are Department Toro Warranty Company 8111 Lyndale Avenue South Bloomington MN 55420 1196 888 865 5676 U S Customers 888 865 5691 Canada customers Owner Responsibilities You must maintain your Toro Product by following the maintenance procedures described in the Operator s Manual Such routine maintenance whether performed by a dealer or by you is at your expense Items and Conditions Not Covered The...

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