Toro Z Master 4000 Series User manual

FormNo.3450-666RevA
60inor72inE-ZVac™DFS
CollectionSystem
ZMaster®4000SeriesRidingMower
ModelNo.78468—SerialNo.400000000andUp
ModelNo.78474—SerialNo.400000000andUp
Registeratwww.Toro.com.
OriginalInstructions(EN)*3450-666*

WARNING
CALIFORNIA
Proposition65Warning
UseofthisproductmaycauseexposuretochemicalsknowntotheStateofCalifornia
tocausecancer,birthdefects,orotherreproductiveharm.
Introduction
Readthisinformationcarefullytolearnhowtooperate
andmaintainyourproductproperlyandtoavoid
injuryandproductdamage.Youareresponsiblefor
operatingtheproductproperlyandsafely.
Visitwww.Toro.comforproductsafetyandoperation
trainingmaterials,accessoryinformation,helpnding
adealer,ortoregisteryourproduct.
Wheneveryouneedservice,genuineToroparts,or
additionalinformation,contactanAuthorizedService
DealerorT oroCustomerServiceandhavethemodel
andserialnumbersofyourproductready.Figure1
andFigure2identifythelocationofthemodeland
serialnumbersontheproduct.Writethenumbersin
thespaceprovided.
g375724
Figure1
1.Baggermodelandserialnumberlocation
g375726
Figure2
1.Collectionsystemmodelandserialnumberlocation
ModelNo.
SerialNo.
©2021—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN554202
Contactusatwww.Toro.com.
PrintedintheUSA
AllRightsReserved

Thismanualuses2wordstohighlightinformation.
Importantcallsattentiontospecialmechanical
informationandNoteemphasizesgeneralinformation
worthyofspecialattention.
Thesafety-alertsymbol(Figure3)appearsbothin
thismanualandonthemachinetoidentifyimportant
safetymessagesthatyoumustfollowtoavoid
accidents.Thissymbolwillappearwiththeword
Danger,Warning,orCaution.
•Dangerindicatesanimminentlyhazardous
situationwhich,ifnotavoided,willresultindeath
orseriousinjury.
•Warningindicatesapotentiallyhazardous
situationwhich,ifnotavoided,couldresultin
deathorseriousinjury.
•Cautionindicatesapotentiallyhazardoussituation
which,ifnotavoided,mayresultinminoror
moderateinjury.
sa-black
Figure3
Safety-alertsymbol
Contents
Safety.......................................................................4
TowingSafety.....................................................4
SafetyandInstructionalDecals..........................4
Setup........................................................................6
1PreparingtheMachine.....................................8
2InstallingtheROPSPivotShoulder
Bolts................................................................9
3InstallingtheWeights.......................................9
4InstallingtheBaggerSupportsand
Brackets........................................................14
5InstallingtheHopperAssembly......................15
6InstallingtheHandleAssembly......................17
7RemovingtheExistingBeltCover,Bracket,
andDischargeChute....................................18
8InstallingtheBlower-PulleyAssemblyand
Belt-CoverBracket........................................19
9InstallingtheBafe.........................................21
10InstallingtheBlowerAssembly.....................23
11InstallingtheBlowerBelt,Spring,and
Blower-BeltCover.........................................26
12InstallingtheDischargeTubes.....................27
13CheckingtheTirePressure..........................31
Operation................................................................32
EmptyingtheBagger........................................33
ClearingObstructionsfromtheCollection
System..........................................................33
RemovingtheBagger.......................................33
UsingtheGrassDeector.................................34
TransportingMachines.....................................34
Maintenance...........................................................35
RecommendedMaintenanceSchedule(s)...........35
CleaningtheBaggerScreen.............................35
CleaningtheCollectionSystem........................35
InspectingtheBlowerBelt................................36
ReplacingtheBlowerBelt.................................36
GreasingtheIdlerArmandHandle
Pivot..............................................................37
InspectingtheCollectionSystem......................37
AdjustingtheClosedDoor................................38
AdjustingtheOpenDoor...................................38
AdjustingtheLatches.......................................39
InspectingtheMowerBlades............................39
InstallingtheMowerBlades..............................39
ReplacingtheGrassDeector..........................40
Storage...................................................................41
Troubleshooting......................................................42
3

Safety
Thefollowinglistcontainssafetyinformationspecic
toToroproductsandothersafetyinformationyou
mustknow.
•Becomefamiliarwiththesafeoperationofthe
equipment,withtheoperatorcontrols,andsafety
signs.
•Useextracarewithgrasscatchersorother
attachments.Thesecanchangetheoperating
characteristicsandthestabilityofthemachine.
•Followthemanufacturer'srecommendations
foraddingorremovingwheelweightsor
counterweightstoimprovestability.
•Donotuseagrasscatcheronsteepslopes.A
heavygrasscatchercouldcauselossofcontrol
oroverturnthemachine.
•Slowdownanduseextracareonhillsides.Be
suretotravelintherecommendeddirectionon
hillsides.Turfconditionscanaffectthestabilityof
themachine.Useextremecautionwhileoperating
neardrop-offs.
•Keepallmovementonslopesslowandgradual.
Donotmakesuddenchangesinspeed,direction,
orturning.
•Thegrasscatchercanobstructtheviewtothe
rear.Useextracarewhenoperatinginreverse.
•Usecarewhenloadingorunloadingthemachine
intoatrailerortruck.
•Neveroperatewiththedischargedeectorraised,
removedoraltered,unlessusingagrasscatcher.
•Keephandsandfeetawayfrommovingparts.Do
notmakeadjustmentswiththeenginerunning.
•Parkthemachineonlevelground,disengage
thedrives,chockthewheels,andshutoffthe
enginebeforeleavingtheoperator'spositionfor
anyreasonincludingemptyingthegrasscatcher
oruncloggingthechute.
•Ifyouremovethegrasscatcher,besuretoinstall
anydischargedeectororguardthatmighthave
beenremovedtoinstallthegrasscatcher.Donot
operatethemowerwithouteithertheentiregrass
catcherorthegrassdeectorinplace.
•Shutofftheenginebeforeremovingthegrass
catcheroruncloggingthechute.
•Donotleavegrassinthegrasscatcherfor
extendedperiodsoftime.
•Grasscatchercomponentsaresubjecttowear,
damageanddeterioration,whichcouldexpose
youtomovingpartsorallowobjectstobethrown.
Frequentlycheckcomponentsandreplacewith
themanufacturer'srecommendedparts,when
necessary.
TowingSafety
•Donotattachtowedequipmentexceptatthehitch
point.
•Followtheattachmentmanufacturer's
recommendationforweightlimitsfortowed
equipmentandtowingonslopes.
•Neverallowchildrenorothersinorontowed
equipment.
•Onslopes,theweightofthetowedequipmentmay
causelossoftractionandlossofcontrol.Reduce
towedweightandslowdown.
•Stoppingdistanceincreaseswiththeweightofthe
towedload.Travelslowlyandallowextradistance
tostop.
•Makewideturnstokeeptheattachmentclearof
themachine.
•Donottowaloadthatweighsmorethanthe
towingmachine.
SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyarea
ofpotentialdanger.Replaceanydecalthatisdamagedormissing.
decal133-8061
133-8061
decal126-4659
126-4659
1.Warning—hotpulley;allowtocool.
4

decal127-2857
127–2857
1.Warning—keepawayfrommovingparts;keepallguards
andsafetiesinplace.
decal126-9595
126-9595
1.Rotationindicator
2.Impeller/RotatingBladeshazard-Keephandsawayfrom
movingparts.Keepallsafetydevicesinplaceandworking.
Donotreachintotheblowerunlesstherotationindicator
hasstopped.DisengagethePTO,shutofftheengine,
removethekey,andwaitforallmovingpartstostop.
decal126-4662
126-4662
1.Warning—readtheOperator’sManualforthecorrect
quantityofcounterbalanceweight(s).
2.Lossoftractionandsteeringorreducedstabilityhazard—Ez
Vaccounterbalanceweight(s)installedwithouttheEzVac
maycauselossoftractionandsteeringcontrol.TheEzVac
installedwithouttheEzVaccounterbalanceweight(s)can
causereducedstability.Installweight(s)onlywhentheEz
Vacisinstalled.
decal126-9451
126-9451
1.Thrownobjectshazard—Donotruntheblowerwithoutthe
entirecollectionsysteminstalledandlatched.
2.Warning–ReadtheOperator’smanualaboutcounterbalance
weightinstallation.
3.Lossoftractionandsteeringorreducedstabilityhazard–Ez
Vaccounterbalanceweight(s)installedwithouttheEzVac
maycauselossoftractionandsteeringcontrol.TheEzVac
installedwithouttheEzVaccounterbalanceweight(s)can
causereducedstability.Installweight(s)onlywhentheEz
Vacisinstalled.
5

Setup
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
1Nopartsrequired–Preparethemachine.
Shoulderbolt2
Wavewasher2
2Locknut(1/2inch)2
InstalltheROPSpivotshoulderbolt.
12.5lbweightplate(60-inchmachines
only)2
Carriagebolt(3/8x2-1/2
inches)—60-inchmachinesonly4
Hex-socketangenut(3/8
inch)—60-inchmachinesonly4
Casterweight2
Carriagebolt(3/8x1inch)8
Flangenut(3/8inch)8
Weightbracketassembly1
Suitcaseweight2
Locknut(3/8inch)2
3
Carriagebolt(3/8x5inches)2
Installtheweights.
Upperbaggersupport1
Supportplate1
Pivotmount1
Leftupperbracket1
Rightupperbracket1
Hex-headbolt(5/16x3-1/4inches)4
Washer4
Flange-headbolt(5/16x1-1/4inches)2
Hex-headbolt(3/8x1-1/4inches)2
Locknut(3/8inch)2
4
Locknut(5/16inch)6
Installthebaggersupportsandbrackets.
Leftlowersupport1
Rightlowersupport1
Backerplate2
Locknut(5/16inch)4
Carriagebolt(5/16x2-1/4inches)4
Locknut(3/8inch)1
Carriagebolt(3/8x7/8inch)1
Hopperassembly1
5
Pinandhairpincotterassembly2
Installthehopperassembly.
Handleassembly1
Clevis-pinspring1
Linkage1
Washer1
Cotterpin1
Carriagebolt(3/8x7/8inch)1
6
Locknut(3/8inch)1
Installthehandleassembly.
6

ProcedureDescriptionQty.Use
7Nopartsrequired–Removetheexistingbeltcover,bracket,
anddischargechute.
Blowerpulley1
Pulleymount1
Locknut(3/8inch)3
Belt-coverbracket1
Speednut1
Carriagebolt(1/4x3/4inch)2
8
Locknut(1/4inch)2
Installtheblower-pulleyassembly.
Bafe1
Carriagebolt(5/16x7/8inch)1
Flangenut(5/16inch)1
Carriagebolt(3/8x7/8inch)2
9
Flangenut(3/8inch)2
Installthebafe.
Blowerassembly1
Pivotpin1
Latch1
Hex-headbolt(3/8x1-1/2inches)1
Spacer1
10
Locknut(3/8inch)1
Installtheblowerassembly.
Blower-beltcover1
11Coverknob1
Installthebaggerbelt,spring,and
blower-beltcover.
Uppertube1
Lowertube1
Bolt(#10x3/4inch)3
Locknut(#10)3
12
Washer(7/32inch)3
Installthedischargetubes.
13Nopartsrequired–Checkthetirepressure.
Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.
7

Important:Ifthereinforcementplates(Figure4)arenotinstalledonthemachine,youcannotinstall
theDFSCollectionSystemontothemachine.
g376188
Figure4
Leftsideshown
1.Reinforcementplate
1
PreparingtheMachine
NoPartsRequired
Procedure
1.Parkthemachineonalevelsurface.
2.Movethemotion-controlleverstotheNEUTRAL-LOCKposition.
3.Engagetheparkingbrake.
4.Shutofftheengineandremovethekey.
g037289
Figure5
8

2
InstallingtheROPSPivot
ShoulderBolts
Partsneededforthisprocedure:
2Shoulderbolt
2Wavewasher
2Locknut(1/2inch)
Procedure
1.Securetheshoulderbolttotherollbarusinga
wavewasherandlocknut(1/2inch)asshown
inFigure6.
2.Repeatthisprocedureontheotherside.
g341473
Figure6
1.Locknut(1/2inch)3.Shoulderbolt
2.Wavewasher
3
InstallingtheWeights
Partsneededforthisprocedure:
212.5lbweightplate(60-inchmachinesonly)
4Carriagebolt(3/8x2-1/2inches)—60-inchmachines
only
4Hex-socketangenut(3/8inch)—60-inchmachines
only
2Casterweight
8Carriagebolt(3/8x1inch)
8Flangenut(3/8inch)
1Weightbracketassembly
2Suitcaseweight
2Locknut(3/8inch)
2Carriagebolt(3/8x5inches)
9

60-inchMachines
1.Removetheexisting2carriageboltsand2nutsfromthetopofthecasterweight(Figure7).
Discardthe2carriageboltsand2nuts.
2.Securethe12.5lbweightplatetothecasterweightandbracketusingthe2carriagebolts(3/8x2-1/2
inches)and2hex-socketangenuts(3/8inch)asshowninFigure7.
g375819
Figure7
10

3.Securetheassembledcasterweighttothecasterarmusing2carriagebolts(3/8x1inch)and2ange
nuts(3/8inch)asshowninFigure8.
g375807
Figure8
1.Carriagebolt(3/8x1inch)3.Flangenut(3/8inch)
2.Weight
4.Repeatsteps1through3ontheotherside.
5.Securetheweightbracketassemblytotheframeusing4carriagebolts(3/8x1inch)and4ange
nuts(3/8inch)asshowninFigure9.
6.Insertthe2suitcaseweightsintotheweightbracketassemblyandsecurethemusing2carriagebolts(3/8
x5inches)and2locknuts(3/8inch)asshowninFigure9.
11

g375806
Figure9
12

72-inchMachines
1.Securetheweighttothecasterarmusing2
carriagebolts(3/8x1inch)and2angenuts
(3/8inch)asshowninFigure10.
2.Repeatthisprocedureontheotherside.
g341474
Figure10
1.Carriagebolt(3/8x1inch)3.Flangenut(3/8inch)
2.Weight
3.Securetheweightbracketassemblytothe
frameusing4carriagebolts(3/8x1inch)and4
angenuts(3/8inch)asshowninFigure9.
4.Insertthe2suitcaseweightsintotheweight
bracketassemblyandsecurethemusing2
carriagebolts(3/8x5inches)and2locknuts
(3/8inch)asshowninFigure9.
13

4
InstallingtheBagger
SupportsandBrackets
Partsneededforthisprocedure:
1Upperbaggersupport
1Supportplate
1Pivotmount
1Leftupperbracket
1Rightupperbracket
4Hex-headbolt(5/16x3-1/4inches)
4Washer
2Flange-headbolt(5/16x1-1/4inches)
2Hex-headbolt(3/8x1-1/4inches)
2Locknut(3/8inch)
6Locknut(5/16inch)
Procedure
1.Securetheupperbaggersupportandsupport
platetothecenter,rearguardusing2
ange-headbolts(5/16x1-1/4inches)and2
locknuts(5/16inch)asshowninFigure11.
g375853
Figure11
1.Locknut(5/16inch)3.Upperbaggersupport
2.Supportplate4.Flange-headbolt(5/16x
1-1/4inches)
2.Removethe2torx-headboltsand2nutsfrom
theleft,rearguard(Figure12).
Note:Performthestepaboveon1sideofthe
machine,thentheother.
g341515
Figure12
1.Left,rearguard3.T orx-headbolt
2.Nut
14

3.Securethepivotmountandleftupperbracketto
theleft,rearguardandbaggersupportusing2
hex-headbolts(5/16x3-1/4inches),2washers,
2locknuts(5/16inch),1hex-headbolt(3/8x
1-1/4inches),and1locknut(3/8inch)asshown
inFigure13.
g375902
Figure13
Leftsideshown
1.Hex-headbolt(5/16x
3-1/4inches)
5.Locknut(5/16inch)
2.Washer6.Locknut(3/8inch)
3.Pivotmount7.Hex-headbolt(3/8x1-1/4
inches)
4.Leftupperbracket
4.Securetherightupperbrackettotheright,rear
guardandbaggersupportusing2hex-head
bolts(5/16x3-1/4inches),2washers,2locknuts
(5/16inch),1hex-headbolt(3/8x1-1/4inches),
and1locknut(3/8inch)asshowninFigure13.
5
InstallingtheHopper
Assembly
Partsneededforthisprocedure:
1Leftlowersupport
1Rightlowersupport
2Backerplate
4Locknut(5/16inch)
4Carriagebolt(5/16x2-1/4inches)
1Locknut(3/8inch)
1Carriagebolt(3/8x7/8inch)
1Hopperassembly
2Pinandhairpincotterassembly
Procedure
1.Securetheleftlowersupporttothemachine
frameandpivotmountusing2carriagebolts
(5/16x2-1/4inches),1backerplate,2locknuts
(5/16inch),1carriagebolt(3/8x7/8inch),and
1locknut(3/8inch)asshowninFigure14.
2.Securetherightlowersupporttothemachine
frameusing2carriagebolts(5/16x2-1/4
inches),1backerplater,and2locknuts(5/16
inch)asshowninFigure14.
15

g375897
Figure14
Leftsideshown
1.Carriagebolt(5/16x2-1/4
inches)
4.Locknut(3/8inch)
2.Backerplate5.Locknut(5/16inch)
3.Carriagebolt(3/8x7/8
inch)
6.Leftlowersupport
3.Positionthehopperassemblyonitsback.
4.Slidethehooksontothelowermountingbracket
(Figure15).
5.Rotatethehopperassemblyontothelower
hoppermountingbracket(Figure15).
6.Aligntheholeinthehopperwiththeupper
mountingbracket.
7.Installthepinandsecureitusingthehairpin
cotteronbothsides(Figure15).g375929
Figure15
16

6
InstallingtheHandle
Assembly
Partsneededforthisprocedure:
1Handleassembly
1Clevis-pinspring
1Linkage
1Washer
1Cotterpin
1Carriagebolt(3/8x7/8inch)
1Locknut(3/8inch)
Procedure
1.Insertthelinkageintothehandleassemblyand
installthewasher(Figure16).
2.Securethelinkagetothehandleassemblyusing
thecotterpin(Figure16).
3.Securethehandleassemblytothepivotmount
usingthecarriagebolt(3/8x7/8inch)and
locknut(3/8inch)asshowninFigure16.
4.Rotatethehopper-handlelinkageuptothe
hopperassemblyandsecureitusingthe
clevis-pinspring(Figure16).
Note:Loosenandrotatetheyokeifneededto
alignitwiththehopperassembly.
g376003
Figure16
1.Washer5.Handleassembly
2.Linkage6.Locknut(3/8inch)
3.Cotterpin7.Yoke
4.Carriagebolt(3/8x7/8
inch)
8.Clevis-pinspring
17

7
RemovingtheExisting
BeltCover,Bracket,and
DischargeChute
NoPartsRequired
Procedure
Note:Cleantheareaaroundthebeltcoverbefore
removingit.
1.Lowerthemowerdecktothelowestheight-of-cut
position.
2.Removetherightbeltcover(Figure17).
g038092
Figure17
3.Removetherightbelt-coverbracket,2washers,
and2angenutsfromthemowerdeck(Figure
18).
Note:Retainthehardwarethatyouremoved
duringthisproceduresothatitisavailablefor
changeover.
g038093
Figure18
1.Rightbelt-coverbracket3.Flangenuts
2.Washers
4.Removethelocknut,bolt,spring,andspacer
holdingthedeectortothepivotbrackets
(Figure19).
g015594
Figure19
1.Bolt5.Springinstalled
2.Spacer6.Grassdeector
3.Locknut7.J-hookendofspring
4.Spring
5.Removethegrassdeector(Figure19).
Note:Retainthehardwarethatyouremoved
duringthisproceduresothatitisavailablefor
changeover.
18

8
InstallingtheBlower-Pulley
AssemblyandBelt-Cover
Bracket
Partsneededforthisprocedure:
1Blowerpulley
1Pulleymount
3Locknut(3/8inch)
1Belt-coverbracket
1Speednut
2Carriagebolt(1/4x3/4inch)
2Locknut(1/4inch)
Procedure
1.Usea3/8-inchratchetinthesquareholeinthe
idlerarmtoremovetensionontheidlerspring
(Figure20).
g334846
Figure20
1.Spring4.Spring-loadedidler
assembly
2.Clutchpulley5.Ratchet
3.Mowerbelt6.Squareholeintheidler
armfortheratchet
2.Removethebeltfromtherightmower-deck
pulley.
19

3.Useawrench(1-1/2inches)toholdthespindle
shaft,asyouremovethehexnut(3/4inch)and
washerfromthespindleshaft(Figure21).
Note:Retainthehexnut(3/4inch)andwasher.
g341576
Figure21
1.Hexnut(3/4inch)3.Rightspindleshaft
2.Washer
4.Insertthethreadedstudsonpulleymount
throughtheholesinthedeckpulley(Figure22).
5.Securethedeckpulleytothespindleshaftusing
thepreviouslyremovedhexnut(3/4inch)and
washer(Figure22).
6.Torquethehexnut(3/4inch)to176to217N∙m
(130to160ft-lb).
7.Arrangetheblowerpulleyontothethreaded
studsandlooselyinstallthe3locknuts(3/8inch)
asshowninFigure22.
8.Rotatetheblowerpulleyuntilthenarrowslots
stoponthestuds.
9.Torquethe3locknuts(3/8inch)to18N∙m(13
ft-lb).
Ensurethatthepulleydoesnotrotatewhile
torquingthelocknuts.
Note:Iftheblowerpulleyisnotcenteredon
thestuds,itcouldcauseprematuredamageto
theblowerbelt.
g341574
Figure22
1.Locknut(3/8inch)5.Existingdeckpulley
2.Blowerpulley6.Pulleymount
3.Hexnut(3/4inch)7.Rightspindleshaft
4.Washer
20