Toro Z Master 4000 Series Operator's Manual
60in or 72in e-z vac dfs collection system riding mower
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- Operator's manual (296 pages) ,
- Service manual (114 pages) ,
- Setup instructions (16 pages)
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Summary of Contents for Toro Z Master 4000 Series
- Page 1 Form No. 3450-666 Rev A 60in or 72in E-Z Vac ™ Collection System Z Master ® 4000 Series Riding Mower Model No. 78468—Serial No. 400000000 and Up Model No. 78474—Serial No. 400000000 and Up *3450-666* Register at www.Toro.com. Original Instructions (EN)
- Page 2 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 your product ready. Figure 1 Figure 2...
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Page 3: Table Of Contents
This manual uses 2 words to highlight information. Removing the Bagger ........33 Important calls attention to special mechanical Using the Grass Deflector......... 34 information and Note emphasizes general information Transporting Machines ........34 worthy of special attention. Maintenance ............35 Recommended Maintenance Schedule(s) ... -
Page 4: Safety
If you remove the grass catcher, be sure to install The following list contains safety information specific any discharge deflector or guard that might have to Toro products and other safety information you been removed to install the grass catcher. Do not must know. - Page 5 decal127-2857 127–2857 1. Warning—keep away from moving parts; keep all guards and safeties in place. decal126-4662 126-4662 1. Warning—read the Operator’s Manual for the correct quantity of counterbalance weight(s). 2. Loss of traction and steering or reduced stability hazard—Ez Vac counterbalance weight(s) installed without the Ez Vac may cause loss of traction and steering control.
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Page 6: Setup
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description Qty. – No parts required Prepare the machine. Shoulder bolt Wave washer Install the ROPS pivot shoulder bolt. Locknut (1/2 inch) 12.5 lb weight plate (60-inch machines only) Carriage bolt (3/8 x 2-1/2 inches)—60-inch machines only... - Page 7 Procedure Description Qty. Remove the existing belt cover, bracket, – No parts required and discharge chute. Blower pulley Pulley mount Locknut (3/8 inch) Belt-cover bracket Install the blower-pulley assembly. Speed nut Carriage bolt (1/4 x 3/4 inch) Locknut (1/4 inch) Baffle Carriage bolt (5/16 x 7/8 inch) Flange nut (5/16 inch)
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Page 8: Preparing The Machine
Important: If the reinforcement plates (Figure 4) are not installed on the machine, you cannot install the DFS Collection System onto the machine. g376188 Figure 4 Left side shown 1. Reinforcement plate Preparing the Machine No Parts Required Procedure Park the machine on a level surface. Move the motion-control levers to the N position. -
Page 9: Installing The Rops Pivot Shoulder Bolts
Installing the ROPS Pivot Installing the Weights Shoulder Bolts Parts needed for this procedure: 12.5 lb weight plate (60-inch machines only) Parts needed for this procedure: Carriage bolt (3/8 x 2-1/2 inches)—60-inch machines Shoulder bolt only Wave washer Hex-socket flange nut (3/8 inch)—60-inch machines only Locknut (1/2 inch) Caster weight... - Page 10 60-inch Machines Remove the existing 2 carriage bolts and 2 nuts from the top of the caster weight (Figure Discard the 2 carriage bolts and 2 nuts. Secure the 12.5 lb weight plate to the caster weight and bracket using the 2 carriage bolts (3/8 x 2-1/2 inches) and 2 hex-socket flange nuts (3/8 inch) as shown in Figure g375819...
- Page 11 Secure the assembled caster weight to the caster arm using 2 carriage bolts (3/8 x 1 inch) and 2 flange nuts (3/8 inch) as shown in Figure g375807 Figure 8 1. Carriage bolt (3/8 x 1 inch) 3. Flange nut (3/8 inch) 2.
- Page 12 g375806 Figure 9...
- Page 13 72-inch Machines Secure the weight to the caster arm using 2 carriage bolts (3/8 x 1 inch) and 2 flange nuts (3/8 inch) as shown in Figure Repeat this procedure on the other side. g341474 Figure 10 1. Carriage bolt (3/8 x 1 inch) 3. Flange nut (3/8 inch) 2.
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Page 14: Installing The Bagger Supports And Brackets
Remove the 2 torx-head bolts and 2 nuts from the left, rear guard (Figure 12). Note: Perform the step above on 1 side of the machine, then the other. Installing the Bagger Supports and Brackets Parts needed for this procedure: Upper bagger support Support plate Pivot mount... -
Page 15: Installing The Hopper Assembly
Secure the pivot mount and left upper bracket to the left, rear guard and bagger support using 2 hex-head bolts (5/16 x 3-1/4 inches), 2 washers, 2 locknuts (5/16 inch), 1 hex-head bolt (3/8 x 1-1/4 inches), and 1 locknut (3/8 inch) as shown Installing the Hopper Figure Assembly... - Page 16 g375897 Figure 14 Left side shown 1. Carriage bolt (5/16 x 2-1/4 4. Locknut (3/8 inch) inches) 2. Backer plate 5. Locknut (5/16 inch) 3. Carriage bolt (3/8 x 7/8 6. Left lower support inch) Position the hopper assembly on its back. Slide the hooks onto the lower mounting bracket (Figure 15).
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Page 17: Installing The Handle Assembly
Installing the Handle Assembly Parts needed for this procedure: Handle assembly Clevis-pin spring Linkage Washer Cotter pin Carriage bolt (3/8 x 7/8 inch) Locknut (3/8 inch) Procedure Insert the linkage into the handle assembly and install the washer (Figure 16). Secure the linkage to the handle assembly using the cotter pin (Figure... -
Page 18: Removing The Existing Belt Cover, Bracket, And Discharge Chute
Remove the locknut, bolt, spring, and spacer holding the deflector to the pivot brackets (Figure 19). Removing the Existing Belt Cover, Bracket, and Discharge Chute No Parts Required Procedure Note: Clean the area around the belt cover before removing it. g015594 Lower the mower deck to the lowest height-of-cut Figure 19... -
Page 19: Installing The Blower-Pulley Assembly And Belt-Cover Bracket
Installing the Blower-Pulley Assembly and Belt-Cover Bracket Parts needed for this procedure: Blower pulley Pulley mount Locknut (3/8 inch) Belt-cover bracket Speed nut Carriage bolt (1/4 x 3/4 inch) Locknut (1/4 inch) Procedure g334846 Figure 20 Use a 3/8-inch ratchet in the square hole in the idler arm to remove tension on the idler spring 1. - Page 20 Use a wrench (1-1/2 inches) to hold the spindle shaft, as you remove the hex nut (3/4 inch) and washer from the spindle shaft (Figure 21). Note: Retain the hex nut (3/4 inch) and washer. g341576 Figure 21 1. Hex nut (3/4 inch) 3.
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Page 21: Installing The Baffle
Ensure that the blade bolt is torqued to 75 to 81 N∙m (55 to 60 ft-lb). Install the mower belt around the lower pulley of the double pulley (Figure 23). Installing the Baffle Parts needed for this procedure: Baffle Carriage bolt (5/16 x 7/8 inch) Flange nut (5/16 inch) Carriage bolt (3/8 x 7/8 inch) Flange nut (3/8 inch) - Page 22 Install the baffle using the carriage bolt (5/16 x 7/8 inch), flange nut (5/16 inch), 2 carriage bolts (3/8 x 7/8 inch), and 2 flange nuts (3/8 inch) as shown in Figure 26 Figure g376167 Figure 27 72-inch shown 1. Flange nut (3/8 inch) 4.
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Page 23: Installing The Blower Assembly
72-inch: Installing the Blower Assembly Parts needed for this procedure: Blower assembly Pivot pin Latch Hex-head bolt (3/8 x 1-1/2 inches) Spacer Locknut (3/8 inch) Procedure Ensure that the bolts and pivot pin are installed in the correct locations on the blower assembly as shown in g376190 Figure 28 Figure... - Page 24 Align the pivot pin on the blower with the pivot-pin hole in the mower deck (Figure 30). Lower the blower and slide the pivot pin into the pivot hole (Figure 30). Note: Ensure that the belt remains positioned in the blower pulley. g376058 Figure 30 1.
- Page 25 Close the blower assembly to see if the latches are adjusted correctly (Figure 33 Figure 34). Note: Loosen or tighten the bolt to ensure that the latches firmly hold the blower assembly against the mower deck but can be released by hand.
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Page 26: Installing The Blower Belt, Spring, And Blower-Belt Cover
Installing the Blower Belt, Spring, and Blower-Belt Cover Parts needed for this procedure: Blower-belt cover Cover knob Procedure Arrange the blower belt around the drive pulley as shown in Figure g376057 Figure 34 72-inch shown g376097 Figure 35 1. Blower pulley 4. -
Page 27: Installing The Discharge Tubes
Note: Ensure that the belt is correctly routed around the drive pulley. Installing the Discharge Tubes Parts needed for this procedure: Upper tube Lower tube Bolt (#10 x 3/4 inch) Locknut (#10) Washer (7/32 inch) Procedure g376091 Important: Make sure that the mower deck is in Figure 36 the lowest height-of-cut position while installing Installing the tension spring and aligning the belt... - Page 28 Note: This is marked to ensure the correct position for the upper tube when drilling the holes and connecting the upper and lower tubes. Note: The rubber seal must protrude out from the bagger hood. g376170 Figure 38 1. Upper tube 3.
- Page 29 Install the lower tube into the upper tube (Figure 41). g003424 Figure 41 1. Lower tube 2. Upper tube Slide the lower tube onto the boot and latch g030596 Figure 42 them together (Figure 42 Figure 43). 1. Blower assembly 3.
- Page 30 Using the 3 holes or indentations in the upper tube as a template, drill 3 holes (7/32-inch diameter) where the upper and lower tubes join together (Figure 44). g003423 Figure 43 g003390 1. Blower assembly 3. Latch Figure 44 2. Lower tube 1.
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Page 31: Checking The Tire Pressure
Join the upper and lower tubes with 3 bolts (#10 x 3/4 inch), 3 flat washers (7/32 inch), and 3 locknuts (#10) as shown in Figure Checking the Tire Pressure No Parts Required Procedure Note: Increase the tire pressure due to the additional weight. -
Page 32: Operation
Operation CAUTION Children or bystanders may be injured if they Note: Determine the left and right sides of the move or attempt to operate the tractor while machine from the normal operating position. it is unattended. Always remove the ignition key and engage WARNING the parking brake when leaving the machine To avoid personal injury, follow these... -
Page 33: Emptying The Bagger
Emptying the Bagger Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the Park the machine on a level surface, disengage operating position. the blade-control switch, and engage the parking Empty the bagger. brake. -
Page 34: Using The Grass Deflector
Open the blower assembly. Remove the blower assembly from the pivot hole. If you are changing to side-discharge mode, ensure that the grass deflector is installed and can be lowered into working position. Remove the collection system assembly. Using the Grass Deflector DANGER Without the grass deflector, discharge cover, or complete grass catcher assembly mounted... -
Page 35: Maintenance
Maintenance Recommended Maintenance Schedule(s) Maintenance Service Maintenance Procedure Interval • Inspect the blower belt. After the first 8 hours • Inspect the collection system. • Clean the hood screen. Before each use or daily • Clean the collection system. • Inspect the blower belt. Every 25 hours •... -
Page 36: Inspecting The Blower Belt
Inspecting the Blower Belt Service Interval: After the first 8 hours Every 25 hours Check the belts for cracks, frayed edges, burn marks, or any other damage. Replace damaged belts. Replacing the Blower Belt Disengage the PTO, move the motion-control levers to the N position, and EUTRAL... -
Page 37: Greasing The Idler Arm And Handle Pivot
Greasing the Idler Arm and Grease the handle pivot (Figure 51). Handle Pivot Service Interval: Every 50 hours—Grease the idler arm. Every 100 hours—Grease the handle pivot. Grease the blower belt idler arm (Figure 50). g375865 Figure 51 g375864 Figure 50 Inspecting the Collection System Service Interval: After the first 8 hours... -
Page 38: Adjusting The Closed Door
Adjusting the Closed Door Adjusting the Open Door Park the machine on a level surface, disengage Note: Perform this procedure after adjusting the door the blade-control switch, and engage the parking to completely close. brake. Adjust the handle link to so that the door opens as Shut off the engine, remove the key, and wait much as possible (Figure 53... -
Page 39: Adjusting The Latches
In most mowing conditions, the standard high-lift blades will provide the best bagging performance. The Toro Atomic blade is recommended for bagging leaves in dry conditions. In dry dusty conditions, the medium-lift or low-lift blades reduces dust and dirt blowout while providing effective bagging air flow. -
Page 40: Replacing The Grass Deflector
Replacing the Grass Install the bolt and the nut. Place 1 J-hook end of the spring around the Deflector grass deflector (Figure 56). Important: The grass deflector must be able WARNING to rotate. Lift the deflector up to the full open An uncovered discharge opening could allow position and ensure that it rotates into the the machine to throw objects toward you or... -
Page 41: Storage
Storage Clean the bagger; refer to Cleaning the Bagger Screen (page 35) Cleaning the Collection System (page 35). Inspect the bagger for damage; refer to Inspecting the Collection System (page 37). Make sure that the bagger is empty and thoroughly dry. Check the belt for wear or cracks. -
Page 42: Troubleshooting
Troubleshooting Problem Possible Cause Corrective Action There is abnormal vibration. 1. Cutting blade(s) is/are bent or 1. Install new cutting blade(s). unbalanced. 2. A blade-mounting bolt is loose. 2. Tighten the blade-mounting bolt. 3. A blower pulley or pulley assembly is 3. - Page 43 Notes:...
- Page 44 While the exposure from Toro products may be negligible or well within the “no significant risk” range, out of an abundance of caution, Toro has elected to provide the Prop 65 warnings. Moreover, if Toro does not provide these warnings, it could be sued by the State of California or by private parties seeking to enforce Prop 65 and subject to substantial penalties.