Toro Z Master 4000 Series User manual

FormNo.3442-427RevA
4000SeriesZMASTER®Service
Manual
Published:January2021
©2020—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
OriginalInstructions(EN)
Contactusatwww.Toro.com.
AllRightsReserved

RevisionHistory
RevisionHistoryPage24000SeriesZMASTER®ServiceManual
3442-427RevA

Preface
ThisservicemanualwaswrittenexpresslyforToroservicetechnicians.TheT oroCompanyhasmade
everyefforttomaketheinformationinthismanualcompleteandcorrect.
Basicshopsafetyknowledgeandmechanical/electricalskillsareassumed.TheT ableofContentslists
thesystemsandtherelatedtopicscoveredinthismanual.
Wearehopefulthatyouwillndthismanualavaluableadditiontoyourserviceshop.Ifyouhaveany
questionsorcommentsregardingthismanual,pleasecontactusatthefollowingaddress:
TheToroCompany
RLC/SWSCustomerCareDepartment
8111LyndaleAvenueSouth
Bloomington,MN55420
TheToroCompanyreservestherighttochangeproductspecicationsormakechangestothismanual
withoutnotice.
4000SeriesZMASTER®ServiceManualPage3Preface
3442-427RevA

ServiceProcedureIcons
ThefollowingiconsappearthroughoutthisServiceManualtobringattentionto
specicimportantdetailsofaserviceprocedure.
CriticalProcess
Thisiconisusedtohighlight:
•Installingsafetyequipment(shields,guards,seatbelts,brakes,andR.O.P .S.
components)thatmayhavebeenremoved
•Dimensionsorsettingsthatmustbemaintainedforpropermachineoperation
•Aspecicfastenertighteningsequence
•Componentorientationthatmaynotbeobvious
CriticalTorque
Thisiconisusedtohighlightanassemblytorquerequirementthatisdifferent
thanwhatisrecommendedintheStandardT orqueT ables.
FluidSpecications
Thisiconisusedtohighlightuidspecicationsandcapacitiesthatareless
common,andmaynotappearonthemachineservicedecalorinthemachine
Operator’sManual.
Note:RefertotheservicedecalonthemachineandthemachineOperator’s
Manualforcommonlyuseduidspecicationsandcapacities.
PrefacePage44000SeriesZMASTER®ServiceManual
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TableofContents
Preface................................................................................................................3
Chapter1:Safety............................................................................................1–1
SafetyInstructions.......................................................................................1–2
Chapter2:SpecicationsandMaintenance....................................................2–1
Specications...............................................................................................2–2
TorqueSpecications...................................................................................2–7
Chapter3:Troubleshooting.............................................................................3–1
GeneralTroubleshooting..............................................................................3–3
Chapter4:Engine...........................................................................................4–1
GeneralInformation.....................................................................................4–2
ServiceandRepairs.....................................................................................4–3
Chapter5:Chassis..........................................................................................5–1
GeneralInformation.....................................................................................5–2
ServiceandRepairs.....................................................................................5–3
Chapter6:Deck..............................................................................................6–1
GeneralInformation.....................................................................................6–2
ServiceandRepairs.....................................................................................6–3
Chapter7:DriveSystem.................................................................................7–1
GeneralInformation.....................................................................................7–2
ServiceandRepairs.....................................................................................7–3
Chapter8:Electrical........................................................................................8–1
GeneralInformation.....................................................................................8–2
ServiceandRepairs.....................................................................................8–3
AppendixA......................................................................................................A–1
ElectricalDrawingAbbreviations...................................................................A–2
ElectricalSchematic.....................................................................................A–3
ElectricalPTOEngagedSchematic..............................................................A–4
ElectricalRunPosition..................................................................................A–5
ElectricalStartPosition.................................................................................A–6
4000SeriesZMASTER®ServiceManualPage5Preface
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PrefacePage64000SeriesZMASTER®ServiceManual
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Chapter1
Safety
TableofContents
SafetyInstructions................................................................................................................................1–2
ThinkSafetyFirst...............................................................................................................................1–2
4000SeriesZMASTER®ServiceManualPage1–1Safety
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SafetyInstructions
DANGER
Thissafetysymbolmeansdanger.Whenyouseethissymbol,
carefullyreadtheinstructionsthatfollow.Failuretoobeythe
instructionscouldcauseseriouspermanentinjury,disability,or
death.
WARNING
Thissafetysymbolmeanswarning.Whenyouseethissymbol,
carefullyreadtheinstructionsthatfollow.Failuretoobeythe
instructionscanresultinseriousinjury.
CAUTION
Thissafetysymbolmeanscaution.Whenyouseethissymbol,
carefullyreadtheinstructionsthatfollow.Failuretoobeythe
instructionscanresultinminortomoderateinjuryand/ordamage
topropertyorequipment.
ThinkSafetyFirst
Avoidunexpectedstartingofengine…
Alwaysturnofftheengine,removetheignitionkeyanddisconnectthesparkplug
wire(s)beforecleaning,adjusting,orrepair.
Avoidlacerationsandamputations…
Stayclearofallmovingpartswhenevertheengineisrunning.Treatallnormally
movingpartsasiftheyweremovingwhenevertheengineisrunningorhas
thepotentialtostart.
Avoidburns…
Donottouchtheengine,mufer,orothercomponents,whichmaybehotduring
operation,whiletheunitisrunningorshortlyafterithasbeenrunning.
Avoidresandexplosions…
Useextremecareinhandlingfuel.Itisammableanditsvaporsareexplosive.
Extinguishallcigarettes,cigars,pipes,andothersourcesofignition.Avoid
spillingfuelandneversmokewhileworkingwithanytypeoffuelorlubricant.
Wipeupanyspilledfueloroilimmediately.Neverremovethefuelcaporadd
fuelwhentheengineisrunning.Alwaysuseapproved,labeledcontainersfor
storingortransportingfuelandlubricants.Donotaddordrainfuelinanenclosed
space.Donotstorethemachineorfuelcontainerwherethereisanopename,
spark,orpilotlight,suchasonawaterheaterorotherappliance.
Avoidasphyxiation…
Donotoperateanengineinaconnedareawithoutproperventilation.
Avoidinjuryfrombatteries…
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ThinkSafetyFirst(continued)
Batteryacidispoisonousandcancauseburns.Avoidcontactwithskin,eyes
andclothing.Batterygasescanexplode.Keepcigarettes,sparksandames
awayfromthebattery.
Avoidinjuryduetoinferiorparts…
Useonlyoriginalequipmentpartstoensurethatimportantsafetycriteriaaremet.
Avoidinjurytobystanders…
Alwayscleartheareaofbystandersbeforestartingortestingpowered
equipment.
Avoidinjuryduetoprojectiles…
Alwayscleartheareaofsticks,rocksoranyotherdebristhatcouldbepickedup
andthrownbythepoweredequipment.
Avoidmodications…
Neveralterormodifyanypartunlessitisafactoryapprovedprocedure.
Avoidunsafeoperation…
Alwaystestthesafetyinterlocksystemaftermakingadjustmentsorrepairson
themachine.RefertotheElectricalsectioninthismanualformoreinformation.
Avoidelectricalshock…
Nevertouchelectricalwiresorcomponentswhiletheengineisrunning.They
canbesourcesofshock.De-energizethesystemifyouarehavingtodorepairs.
Iftestingelectricalcomponentsensureyouareworkinginadryenvironment.
HydraulicSystem...
Releaseallpressureinthehydraulicsystembeforeperforminganyworkon
thesystem.Keepyourbodyandhandsawayfrompin-holeleaksornozzles
thatejecthydraulicuidunderhighpressure.Donotuseyourhandstosearch
forleaks.Hydraulicuidescapingunderpressurecanhavesufcientforceto
penetrateundertheskinandcauseseriousinjury.Seekmedicalattentionright
awayifhydraulicuidgetsintheskin.
PersonalProtectiveEquipment…
Tiebacklonghair,anddonotwearlooseclothingorjewelry.Useappropriate
personalprotectiveequipment(PPE)forprotectingyourselffrompotential
hazardsintheenvironmentinwhichyouwillwork.Eachprocessoutlinedinthis
manualmayneeddifferentPPEtoprotecttheserviceperson.Usetheproper
PPEforthetaskathand.
Tools…
Alltoolsshouldbeinproperworkingorder.Donotusetoolsthatarebrokenorin
disrepair.Usethepropertoolfortheproperapplication.
Lifts,Hoists,andJacks…
Alllifts,hoists,andjacksshouldbeusedinaccordancewiththemanufacturer
information.Inspectlifts,hoists,andjackspriortouse.Donotoverloadlifts,
hoists,andjacks.Donotworkunderasuspendedload.Ensurechockblocks
areusedonequipmentthatcanmove.Useliftsorjacksandjackstandsthat
areratedtosupportthetotalweightofthemachineandanyattachments.Do
notrelyonjackstosupportthemachine.Ifyouareunsureoftheoperationof
anylifts,hoists,andjacksdonotuse.
FireExtinguishers…
4000SeriesZMASTER®ServiceManualPage1–3Safety:SafetyInstructions
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ThinkSafetyFirst(continued)
Theproperclassofreextinguishershouldbeusedincaseofre.
ClassAextinguishersareforordinarycombustiblematerialssuchaspaper,
wood,cardboard,andmostplastics.Thenumericalratingonthesetypesof
extinguishersindicatestheamountofwateritholdsandtheamountofreitcan
extinguish.Geometricsymbol(greentriangle).
ClassBresinvolveammableorcombustibleliquidssuchasgasoline,
kerosene,greaseandoil.ThenumericalratingforclassBextinguishers
indicatestheapproximatenumberofsquarefeetofreitcanextinguish.
Geometricsymbol(redsquare).
ClassCresinvolveelectricalequipment,suchasappliances,wiring,circuit
breakersandoutlets.NeverusewatertoextinguishclassCres-theriskof
electricalshockisfartoogreat!ClassCextinguishersdonothaveanumerical
rating.TheCclassicationmeanstheextinguishingagentisnon-conductive.
Geometricsymbol(bluecircle).
ABCreextinguishersareadrychemicaltypeusedformultiplepurposes.See
aboveinformationfordescription.Ensurereextinguishersareserviceableand
replaceanythataredischargedoroutofinspectiondates
Safety:SafetyInstructionsPage1–44000SeriesZMASTER®ServiceManual
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