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Toro Z MASTER Z419, Operator'S Manual

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Toro Z MASTER Z419 Operator'S Manual Download Page 27

Maintenance

Recommended Maintenance Schedule(s)

Maintenance Service

Interval

Maintenance Procedure

After the first 8 hours

• Change the engine oil.
• Check the hydraulic fluid.

After the first 25 hours

• Change the hydraulic filter.

Before each use or daily

• Check the safety system.
• Check the engine oil level.
• Clean the engine air intake screen from grass and debris.
• 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 drive belt idler arm.
• Clean foam air cleaner element (more often in dirty or dusty conditions).
• Check the hydraulic fluid.

Every 50 hours

• Check the paper air cleaner element (more often in dirty or dusty conditions).
• Check the tire pressure.
• Check the pump drive belt.

Every 100 hours

• Change the engine oil.
• Check the spark plugs.
• Check the wheel hub slotted nut.
• Check and clean engine cooling fins and shrouds.
• 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 paper air cleaner element.
• Replace the oil filter.
• Replace the fuel filter or yearly, whichever occurs first.

Every 500 hours

• Adjust the caster pivot bearing.

Yearly

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

Important:

Refer to your

Engine Operator’s Manual

for additional maintenance procedures.

If you leave the key in the ignition switch, someone could accidently start the engine and seriously
injure you or other bystanders.

Remove the key from the ignition and disconnect the wire from the spark plug(s) before you do any
maintenance. Set the wire aside so that it does not accidentally contact the spark plug.

27

Summary of Contents for Z MASTER Z419

Page 1: ...Form No 3359 105 Rev A Z419 Z Master with 122 cm TURBO FORCE Side Discharge Mower Model No 74421TE Serial No 280000001 and Up Register at www Toro com Original Instructions EN ...

Page 2: ...s manual uses 2 other words to highlight information Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention Contents Introduction 2 Safety 3 Safe Operating Practices 3 Toro Riding Mower Safety 5 Sound Pressure 5 Sound Power 5 Vibration 5 Slope Chart 6 Safety and Instructional Decals 7 Product Overview 12 Controls 12 Operation...

Page 3: ... injury To reduce the potential for injury comply with these safety instructions and always pay attention to the safety alert symbol which means CAUTION WARNING or DANGER personal safety instruction Failure to comply with the instruction may result in personal injury or death Safe Operating Practices The following instructions are from the CEN standard EN 836 1997 This product is capable of amputa...

Page 4: ... for humps and hollows and other hidden hazards Use care when pulling loads or using heavy equipment Use only approved drawbar hitch points Limit loads to those you can safely control Do not turn sharply Use care when reversing Watch out for traffic when crossing or near roadways Stop the blades rotating before crossing surfaces other than grass When using any attachments never direct discharge of...

Page 5: ...an 15 degrees Do not mow near drop offs ditches steep banks or water Wheels dropping over edges can cause rollovers which may result in serious injury death or drowning Do not mow slopes when grass is wet Slippery conditions reduce traction and could cause sliding and loss of control Do not make sudden turns or rapid speed changes Use a walk behind mower and or a hand trimmer near drop offs ditche...

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

Page 7: ... keep the deflector in place 3 Cutting dismemberment of hand or foot stay away from moving parts 93 7818 1 Warning read the Operator s Manual for instructions on torquing the blade bolt nut to 115 149 N m 85 110 ft lb 98 4387 1 Warning wear hearing protection 99 8936 1 Machine speed 4 Neutral 2 Fast 5 Reverse 3 Slow 99 8939 1 Read the Operator s Manual 3 Remove the ignition key and read the instru...

Page 8: ...ypass valve in to drive the machine 107 1686 1 Read the Operator s Manual before servicing or performing maintenance 5 Tire pressure 2 Time interval 6 Grease here 3 Air filter 7 Check and perform any maintenance necessary 4 Hydraulic oil level 107 1866 1 Sliding and loss of control hazard and tipping hazard drop offs do not operate the machine near drop offs slopes greater than 15 degrees or water...

Page 9: ...er protection when the roll bar is down 2 To avoid injury or death from a rollover accident keep the roll bar in the raised and locked position and wear the seat belt Lower the roll bar only when absolutely necessary do not wear the seat belt when the roll bar is down 3 Read the Operator s Manual drive slowly and carefully 108 1052 1 Height of cut adjustment 108 1053 1 Height of cut 110 2067 9 ...

Page 10: ... Manual 10 Contains lead do not discard Manufacturer s Mark 1 Indicates the blade is identified as a part from the original machine manufacturer 108 1054 1 Parking brake 3 Disengage 5 Return levers to the neutral locked position engage the parking brake and remove the ignition key before leaving the machine 7 Cutting dismemberment mower blade do not carry passengers 2 Engage 4 Warning read the Ope...

Page 11: ...or s Manual for information on charging the battery contains lead do not discard 2 Read the Operator s Manual 110 0439 1 Choke 3 Engine run 5 Fast 7 Slow 2 Engine stop 4 Engine start 6 Continuous variable setting 8 Power take off PTO 11 ...

Page 12: ... Choke Use the choke to start a cold engine Blade Control Switch PTO The blade control switch PTO is used to engage the electric clutch to drive the mower blades with the motion control levers in the center un locked position Pull the switch up to engage the blades and release To disengage the blades push the blade control switch PTO down Ignition Switch This switch is used to start the mower engi...

Page 13: ... highly explosive A fire or explosion from gasoline can burn you and others and can damage property Fill the fuel tank outdoors in an open area when the engine is cold Wipe up any gasoline that spills Never fill the fuel tank inside an enclosed trailer Do not fill the fuel tank completely full Add gasoline to the fuel tank until the level is 1 4 to 1 2 inch 6 to 13 mm below the bottom of the fille...

Page 14: ... the machine to provide the following benefits Keeps gasoline fresh during storage of 90 days or less For longer storage it is recommended that the fuel tank be drained Cleans the engine while it runs Eliminates gum like varnish buildup in the fuel system which causes hard starting Important Do not use fuel additives containing methanol or ethanol Add the correct amount of gas stabilizer condition...

Page 15: ...positions See Figure 7 for the positions 3 Install the two pins and secure them with the hairpin cotter pins Figure 8 Figure 7 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 8 5 Raise the roll bar to the upright position an...

Page 16: ... near drop offs and water This machine produces sound levels in excess of 85 dBA at the operators ear and can cause hearing loss through extended periods of exposure Wear hearing protection when operating this machine Use protective equipment for your eyes ears feet and head Figure 10 1 Warning wear hearing protection Operating the Parking Brake Always set the parking brake when you stop the machi...

Page 17: ...e starting a cold engine Figure 13 Note A warm or hot engine may not require choking After engine starts move choke control to Run position Figure 13 1 Choke on 2 Choke off 5 Move the throttle control to the Fast position before starting a cold engine Figure 14 Figure 14 1 Throttle fast 2 Throttle slow 6 Turn the ignition key to Start When the engines starts release the key Figure 15 Important Do ...

Page 18: ...arking 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 cold allow the engine 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 pla...

Page 19: ... 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 to neutral lock position Try starting the engine the engine sh...

Page 20: ... 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 Height of Cut The height of cut is adjusted from 1 1 2 to 4 1 2 inch 38 to 114 mm in 1 4 inch 6 mm increments by relocating the clevis pin into different hole locati...

Page 21: ...Figure 20 1 Anti scalp roller 3 Bolt 2 Bushing 4 Flange Nut Adjusting the Flow Baffle The mower discharge flow can be adjusted for different types of mowing conditions Position the cam lock 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 the key and wait for all moving pa...

Page 22: ...onditions For smaller grass clippings Propels grass clippings farther away from the mower Figure 22 Position B Use this position when bagging Figure 23 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 in wet conditions Lowers the engine power consumption Allows increased ground speed in heavy conditions This p...

Page 23: ...king 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 27 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 valv...

Page 24: ...ommended instead of individual ramps for each side of the unit Figure 28 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 a f...

Page 25: ...rates at different times So to maintain the same cutting height which is a good practice mow more often in early spring As the grass growth rate slows in mid summer mow less frequently If you cannot mow for an extended period first mow at a high cutting height then mow again two days later at a lower height setting Cutting Speed To improve cut quality use a slower ground speed in certain condition...

Page 26: ...isease 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 is damaged or worn replace it immediately with a genuine TORO replacement blade 26 ...

Page 27: ... Every 100 hours Change the engine oil Check the spark plugs Check the wheel hub slotted nut Check and clean engine cooling fins and shrouds 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 paper air cleaner element Replace the oil filter Replace the fuel filter or yearly whichever occurs first Every 50...

Page 28: ... in Drive System Maintenance page 36 2 Remove the hex plug Thread a grease zerk into the hole 3 Pump grease into the zerk until it oozes out around the top bearing 4 Remove the grease zerk in the hole Install the hex plug and cap Where to Add Grease Lubricate the grease fittings as shown on the Check Service Reference Aid decal Figure 29 Figure 29 Where to Add Light Oil or Spray Lubrication Servic...

Page 29: ...ts and replace them if they are damaged or excessively dirty Note Service the air cleaner more frequently every few operating hours if the operating conditions are extremely dusty or sandy Important Do not oil the foam or paper element Removing the Foam and Paper Elements 1 Disengage the PTO and set the parking brake 2 Stop the engine remove the key and wait for all moving parts to stop before lea...

Page 30: ... the paper air cleaner element Figure 31 2 Place the air cleaner assembly onto the air cleaner base and secure it with the 2 wing nuts Figure 31 3 Place the air cleaner cover into position and tighten the cover knob Figure 31 Servicing the Engine Oil Note Change the oil more frequently when the operating conditions are extremely dusty or sandy Oil Type Detergent oil API service SF SG SH or SJ Cran...

Page 31: ...he 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 34 7 When oil has drained completely close the drain valve 8 Remove the drain hose Figure 34 Note Dispose of the used oil at a recycling ce...

Page 32: ...e remove the key and wait for all moving parts to stop before leaving the operating position 3 Disconnect the wires from the spark plugs Figure 36 Figure 36 1 Spark plug wire spark plug 4 Clean around the spark plugs to prevent dirt from falling into the engine and potentially causing damage 5 Remove the spark plugs and the metal washers Checking the Spark Plugs Service Interval Every 100 hours 1 ...

Page 33: ...rtain conditions gasoline is extremely flammable and highly explosive A fire or explosion from gasoline can burn you and others and can damage property Drain gasoline from the fuel tank when the engine is cold Do this outdoors in an open area Wipe up any gasoline that spills Never smoke when draining gasoline and stay away from an open flame or where a spark may ignite the gasoline fumes 1 Park th...

Page 34: ... terminals and metal parts of the machine Incorrect battery cable routing could damage the machine and cables causing sparks Sparks can cause the battery gasses to explode resulting in personal injury Always Disconnect the negative black battery cable before disconnecting the positive red cable Always Reconnect the positive red battery cable before reconnecting the negative black cable 1 Disengage...

Page 35: ...fic gravity This is especially important to prevent battery damage when the temperature is below 32 F 0 C 1 Charge battery for 10 to 15 minutes at 25 to 30 amps or 30 minutes at 4 6 amps 2 When the battery is fully charged unplug the charger from the electrical outlet then disconnect the charger leads from the battery posts Figure 40 Figure 40 1 Positive Battery Post 3 Red Charger Lead 2 Negative ...

Page 36: ...ydraulic Pump Neutral in Hydraulic System Maintenance page 43 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 4 To make the machine go right turn the knob towards the rightside of the machine Refer to Figure 42 5 To make the ma...

Page 37: ...Two threads or less showing 4 Washer if needed 5 Check the distance from bottom of slot in nut to inside edge of hole Two threads or less should be showing Figure 44 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 44 8 Tighten the nut until the next set of slots line up with the hole in the shaft Figure 4...

Page 38: ...adequate cooling and correct engine speed and will reduce the possibility of overheating and mechanical damage to the engine Cleaning the Cooling System Service Interval Every 100 hours Yearly whichever comes first 1 Disengage the PTO 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 air intake screen...

Page 39: ...6 to 1 4 inch 5 to 7 mm 2 Spring 2 3 4 inch 74 mm 6 Jam nut and yoke 3 Adjusting nuts 7 Trunnion 4 Collar on brake rod 3 If an adjustment is necessary do the following A Loosen the jam nut below the spring and tighten the nut directly below the yoke Figure 47 B Turn the nut until you obtain the correct measurement C Tighten the 2 nuts together and repeat on the opposite side of the machine 4 Turn ...

Page 40: ...g while you are cutting grass frayed belt edges burn marks and cracks Replace the mower belt if you detect any of these signs 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 belt covers over the outside spindles 4 Loos...

Page 41: ...h stop and unplug the clutch electrical wire Figure 50 3 Pull the spring loaded idler to the side 4 Remove the traction belt from the engine and the hydraulic pump pulleys Figure 50 5 Install the new belt around the engine and the hydraulic pump pulleys Figure 50 6 Pull the spring loaded idler to the side and align the belt 7 Release the pressure on the spring loaded idler Figure 50 8 Install the ...

Page 42: ...l the lever back until the clevis pin on the arm below the pivot shaft contacts the end of the slot just beginning to put pressure on the spring Figure 53 Figure 53 1 Clevis pin in slot 6 Double nuts 2 Nut 7 Jam nut 3 Nut Left hand thread 8 Yoke 4 Adjustment bolt 9 Ball joint 5 Pump rod 7 Check where the control lever is relative to the notch in the console Figure 52 It should be centered allowing...

Page 43: ...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 54 8 Install the cap on filler neck Figure 54 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 injec...

Page 44: ...ls will not drive refer to Bleeding Hydraulic System 10 Recheck the fluid level while the fluid is warm The fluid should be between cold and hot 11 If required add fluid to the hydraulic tank Do not overfill Figure 56 1 Hydraulic filter 3 Adapter 2 Gasket Bleeding the Hydraulic System The traction system is self bleeding however it may be necessary to bleed the system if fluid is changed or after ...

Page 45: ...rts 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 install a jumper wire across terminals in the wiring harness connector 3 Unlatch the seat an...

Page 46: ...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 58 Figure 58 1 Double nuts 3 Locknut 2 Pump rod 4 Ball joint Electrical system will not perform proper safety shut off with jumper wire installed Remove jumper wire from wire harness connector and plug connector into seat swit...

Page 47: ...Front to Rear Mower Pitch Leveling the Mower Side to Side 1 Position the right blade front to rear Figure 59 2 Measure the right blade at the B location from a level surface to the cutting edge of the blade tip Figure 59 3 Record this measurement This measurement needs to be 3 1 8 to 3 1 4 inches 4 Position the left blade front to rear Figure 59 5 Measure the left blade at the C location Figure 59...

Page 48: ...hain 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 60 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 60 9 Tighten both swivel jam nuts against the front swivel to lock the height 10 Check to make sure there i...

Page 49: ...he blade periodically for wear or damage Replace a worn or damaged blade Inspect and check the blades every 8 hours 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 Inspecting the Blades Service Interval Before each use or daily 1 Inspect the cutting edges Figure 63 If...

Page 50: ... replacement blades Replacement blades made by other manufacturers may result in nonconformance with safety standards Contact with a sharp blade 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 67 Sharpening the Blades When sharpening ...

Page 51: ...ss you install a cover plate a mulch plate or a grass chute and catcher Make sure the grass deflector is in the down position 1 Remove the locknut bolt spring and spacer holding the deflector to the pivot brackets Figure 68 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 ...

Page 52: ...aulic pumps and motors 3 Check the brake refer to Servicing the Brake in Maintenance 4 Service the air cleaner refer to Servicing the Air Cleaner in Maintenance 5 Grease the machine refer to Greasing and Lubrication in Maintenance 6 Change the crankcase oil refer to Servicing the Engine Oil in Maintenance 7 Check the tire pressure refer to Checking the Tire Pressure in Maintenance 8 Change the hyd...

Page 53: ...er 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 from the ignition switch and keep it out of reach of children or other unauthorized users Cover the ma...

Page 54: ...p is 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 ...

Page 55: ...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 56: ...Schematics Wire Diagram Rev A 56 ...

Page 57: ...Notes 57 ...

Page 58: ...Notes 58 ...

Page 59: ...f the product If for any reason it is impossible for you to contact your seller you may contact any Toro Authorized Distributor to arrange service 2 Bring the product and your proof of purchase sales receipt to your seller or the Service Dealer If for any reason you are dissatis ed with the Service Dealer s analysis or with the assistance provided contact the Toro importer or contact us at Custome...

Page 60: ... A Italy 39 0331 853611 Irriamc Portugal 351 21 238 8260 Jean Heybroek b v Netherlands 31 30 639 4611 Lely U K Limited United Kingdom 44 1480 226 800 Maquiver S A Columbia 57 1 236 4079 Maruyama Mfg Co Inc Japan 81 3 3252 2285 Metra Kft Hungary 36 1 326 3880 Mount eld a s Czech Republic 420 255 704 220 Munditol S A Argentina 54 11 4 821 9999 Oslinger Turf Equipment SA Ecuador 593 4 239 6970 Oy Hak...

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