Toro Z449 Z Master Operator'S Manual Download Page 2 | Manualshive

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Warning

CALIFORNIA

Proposition 65 Warning

The engine exhaust from this product
contains chemicals known to the State of
California to cause cancer, birth defects, or
other reproductive harm.

Important:

This engine is not equipped

with a spark arrester mufﬂer. It is a
violation of California Public Resource Code
Section 4442 to use or operate the engine
on any forest-covered, brush-covered, or
grass-covered land. Other states or federal
areas may have similar laws.

This spark ignition system complies with Canadian
ICES-002

The enclosed Engine Owner’s Manual is
supplied for information regarding the US
Environmental Protection Agency (EPA) and
the California Emission Control Regulation of
emission systems, maintenance, and warranty.
Replacements may be ordered through the
engine manufacturer.

Contents

Introduction ....................................................... 3
Safety .................................................................. 5

Safe Operating Practices ...................... 5
Slope Chart ......................................... 8
Safety and Instructional Decals ............ 9

Product Overview ............................................. 14

Controls ............................................ 14

Operation.......................................................... 15

Adding Fuel ...................................... 15
Checking the Engine Oil Level ........... 16
Using the Rollover Protection

System (ROPS).................. 16

Think Safety First .............................. 17
Operating the Parking Brake .............. 18
Starting and Stopping the

Engine .............................. 18

Operating the Power Take Off

(PTO) ............................... 20

The Safety Interlock System............... 20
Driving Forward or Backward ............ 21
Stopping the Machine ........................ 22

Adjusting the Height-of-Cut .............. 22
Adjusting the Anti-Scalp

Rollers............................... 22

Adjusting the Flow Bafﬂe................... 23
Positioning the Flow Bafﬂe ................ 23
Positioning the Seat ........................... 24
Unlatching the Seat............................ 24
Pushing the Machine by Hand ............ 25
Using the Side Discharge ................... 25
Transporting Machines ...................... 25
Loading Machines ............................. 26
Operating Tips .................................. 27

Maintenance...................................................... 28

Recommended Maintenance

Schedule(s) ............................... 28

Lubrication................................................ 29

Greasing and Lubrication................... 29
Greasing the Mower Deck and Belt

Idlers................................. 29

Engine Maintenance.................................. 30

Servicing the Air Cleaner ................... 30
Servicing the Engine Oil .................... 31
Servicing the Spark Plugs ................... 33

Fuel System Maintenance .......................... 33

Replacing the Fuel Filter .................... 33
Servicing the Fuel Tank...................... 34

Electrical System Maintenance................... 34

Servicing the Battery.......................... 34
Servicing the Fuses ............................ 36

Drive System Maintenance......................... 37

Adjusting the Tracking....................... 37
Chec king the Tire Pressure................. 37
Chec king the Wheel Hub Slotted

Nut ................................... 37

Adjusting the Caster Pivot

Bearing.............................. 38

Cooling System Maintenance ..................... 38

Cleaning the Air Intake Screen ........... 38
Cleaning the Cooling System.............. 38

Brake Maintenance .................................... 39

Adjusting the Parking Brake ............... 39

Belt Maintenance....................................... 39

Inspecting the Belts ........................... 39
R eplacing the Mower Belt .................. 40
R eplacing the Pump Drive

Belt ................................... 40

Adjusting the Push Arms ................... 41

Controls System Maintenance.................... 41

Adjusting the Control Handle

Neutral Position ................ 41

Hydraulic System Maintenance .................. 42

© 2005—The Toro® Company

8111 Lyndale Avenue South

Bloomington, MN 55420

2

Contact us at www.Toro.com.

Printed in the USA.

All Rights Reserved

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Summary of Contents for Z449 Z Master

Page 1: ... Rev A Z449 Z Master with 48in or 52in TURBO FORCE Side Discharge Mower Model No 74413 Serial No 260000001 and Up Model No 74415 Serial No 260000001 and Up Register your product at www Toro com Original Instructions EN ...

Page 2: ...21 Stopping the Machine 22 Adjusting the Height of Cut 22 Adjusting the Anti Scalp Rollers 22 Adjusting the Flow Bafﬂe 23 Positioning the Flow Bafﬂe 23 Positioning the Seat 24 Unlatching the Seat 24 Pushing the Machine by Hand 25 Using the Side Discharge 25 Transporting Machines 25 Loading Machines 26 Operating Tips 27 Maintenance 28 Recommended Maintenance Schedule s 28 Lubrication 29 Greasing an...

Page 3: ...ro 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 your product ready Figure 1 identiﬁes the location of the model and serial numbers on the product Write the num...

Page 4: ...This manual uses 2 other words to highlight information Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention 4 ...

Page 5: ...cessories and attachments approved by the manufacturer Wear appropriate clothing including hard hat safety glasses and hearing protection Long hair loose clothing or jewelry may get tangled in moving parts Inspect the 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 gasoline and other fuels The...

Page 6: ...nsfer to the front wheels may cause drive wheels to slip and cause loss of braking and steering Always avoid sudden starting or stopping on a slope If tires lose traction disengage the blades and proceed slowly off the slope Follow the manufacturer s recommendations for wheel weights or counterweights to improve stability Use extreme care with grass catchers or other attachments These can change t...

Page 7: ...nly replace blades Never straighten or weld them Keep hands and feet away from moving parts If possible do not make adjustments with the engine running Charge batteries in an open well ventilated area away from spark and ﬂames Unplug charger before connecting or disconnecting from battery Wear protective clothing and use insulated tools Keep all parts in good working condition and all hardware tig...

Page 8: ...Slope Chart 8 ...

Page 9: ...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 633818 54 9220 58 6520 1 Grease 66 1340 65 2690 68 8340 98 4387 1 Warning wear hearing protection 9 ...

Page 10: ...98 5954 103 2644 105 7798 107 1613 107 1687 107 1688 10 ...

Page 11: ...smoking 7 Wear eye protection explosive gases can cause blindness and other injuries 3 Caustic liquid chemical burn hazard 8 Battery acid can cause blindness or severe burns 4 Wear eye protection 9 Flush eyes immediately with water and get medical help fast 5 Read the Operator s Manual 10 Contains lead do not discard 107 2102 107 2112 108 1050 108 1051 11 ...

Page 12: ...i ed as a part from the original machine manufacturer 107 8445 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 108 5995 1 Fast 2 Slow 3 Neutral 4 Reverse 12 ...

Page 13: ...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 13 ...

Page 14: ...udible alarm 4 Glow plug light 9 Fuel selector valve 5 Engine Temperature light Using the Hour Meter The hour meter Figure 5 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 1 Hour meter Using the Fuel Shutoff Valve The machine has 2 fuel tanks one on the left side and the other on the right side ...

Page 15: ...ystem in place and in proper working condition In certain conditions during fueling static electricity can be released causing a spark which can ignite the gasoline vapors A ﬁre or explosion from gasoline can burn you and others and can damage property Always place gasoline containers on the ground away from your vehicle before ﬁlling Do not ﬁll gasoline containers inside a vehicle or on a truck o...

Page 16: ...Checking Oil Level in Engine Maintenance page 30 Using the Rollover Protection System ROPS To avoid injury or death from rollover keep the roll bar in the raised locked position and use the seat belt Ensure that the rear part of the seat is secured with the seat latch There is no rollover protection when the roll bar is in the down position Lower the roll bar only when absolutely necessary Do not ...

Page 17: ...ymbols in the safety section Knowing this information could help you or bystanders avoid injury 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 th...

Page 18: ...e the motion control levers Figure 18 out to the neutral lock position 2 Pull up and back on the parking brake lever to set the parking brake Figure 12 The parking brake lever should stay ﬁrmly in the engaged position Parking brake may not hold machine parked on a slope and could cause personal injury or property damage Do not park on slopes unless wheels are chocked or blocked Releasing the Parki...

Page 19: ...ds at a time If engine fails to start allow 30 second cool down period between attempts Failure to follow these instructions can burn out starter motor Figure 16 1 Off 3 Start 2 Run 7 After the engine starts move the choke to off Figure 14 If the engine stalls or hesitates move the choke back to on for a few seconds then move the throttle lever to desired setting Repeat this as required Stopping t...

Page 20: ...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 PTO Off Disengaging the PTO To disengage push the PTO switch to the off position Figure 17 The Safety Interlock System If safety interlock switches are disconnected or damaged t...

Page 21: ... 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 in the fast position for best performance Always operate in the f...

Page 22: ...ting the clevis pin into different hole locations 1 Raise the height of cut lever to the transport position also the 4 1 2 inch 114 mm cutting height position Figure 19 2 To adjust remove the clevis pin from the height of cut bracket Figure 19 3 Select a hole in the height of cut bracket corresponding to the height of cut desired and insert the clevis pin Figure 19 4 Move the lever to the selected...

Page 23: ...sired discharge ﬂow 5 Swing the lever back over to tighten the bafﬂe and cam lock Figure 22 6 If the cam does 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 22 1 Cam lock 3 Rotate cam to increase or decrease locking pressure 2 Lever 4 Slot Positioning the Flow Baf e The followi...

Page 24: ... is similar to the beneﬁts of the Toro SFS mower Figure 25 Positioning the Seat The seat can move forward and backward Position the seat where you have the best control of the machine and are most comfortable Important To adjust move the lever sideways to unlock seat Figure 26 Slide the seat to the desired position and release lever to lock in position Figure 26 1 Adjustment lever Unlatching the S...

Page 25: ... are turned in Figure 28 1 Side console controls 3 Hydraulic pumps 2 By pass valve Using the Side Discharge The mower has a hinged grass deﬂector that disperses clippings to the side and down toward the turf Without the grass deﬂector discharge cover or complete grass catcher assembly mounted in place you and others are exposed to blade contact and thrown debris Contact with rotating mower blade s...

Page 26: ...es do not exceed 15 degrees Figure 29 A steeper angle may cause mower components to get caught as the unit moves from ramp to trailer or truck Steeper angles may also cause the unit to tip backward If loading on or near a slope position the trailer or truck so it is on the down side of the slope and the ramp extends up the slope This will minimize the ramp angle The trailer or truck should be as l...

Page 27: ...s 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 conditions Avoid Cutting Too Low If the cutting width of the mower is wider than the mower you previously used raise the cutting height to ensure that uneven turf is not cut too shor...

Page 28: ...eck the spark plugs Check and clean engine cooling ns and shrouds Inspect the belts for cracks and wear Check the hydraulic hoses Every 150 hours Lubricate the machine with light oil Refer to Lubrication Every 200 hours Replace the paper air cleaner element Replace the oil lter Replace the fuel lter Change the hydraulic lter and oil Every 500 hours Check the wheel hub slotted nut Adjust the caster...

Page 29: ...the Caster Pivot Bearing in Drive System Maintenance page 37 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 30 Figure 30 Where to Add Light Oil or S...

Page 30: ...y 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 leaving the operating position 3 Clean around the air cleaner ...

Page 31: ...ne Oil Service Interval Speci cation Change the engine oil as follows After the ﬁrst 8 operating hours After every 100 operating hours 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 Crankcase Capacity 58 ounces 1 7 liter with the ﬁlter removed 51 ounces 1 5 liter without the ﬁlter removed Viscosity Re...

Page 32: ...0 of the speciﬁed oil into the ﬁller tube Figure 34 10 Check the oil level refer to Checking the Engine Oil Level 11 Slowly add the additional oil to bring it to the Full mark Changing the Oil Filter Replace the oil ﬁlter every 200 operating hours or every other oil change Note Change the oil ﬁlter more frequently when the operating conditions are extremely dusty or sandy 1 Drain the oil from the ...

Page 33: ...ay on the insulator the engine is operating properly A black coating on the insulator usually means that the air cleaner is dirty 2 If needed clean the spark plug with a wire brush to remove carbon deposits Figure 38 1 Center electrode insulator 3 Air gap not to scale 2 Side electrode Important Always replace the spark plugs when it has a black coating worn electrodes an oily ﬁlm or cracks 3 Check...

Page 34: ...completely 2 Disengage the power takeoff PTO set the parking brake stop the engine and remove the key 3 Close the fuel shutoff valve Figure 39 4 Loosen the hose clamp at the fuel ﬁlter and slide it up the fuel line away from the fuel ﬁlter Figure 39 5 Disconnect the fuel line from the fuel ﬁlter Figure 39 6 Open the fuel shutoff valve Note Allow gasoline to drain into a fuel container can or drain...

Page 35: ...ving the operating position 3 Unlatch the seat and tilt the seat up 4 First disconnect the negative battery cable and ground wire from the negative battery terminal Figure 40 5 Slide the red terminal boot off the positive red battery terminal Then remove the positive red battery cable Figure 40 Figure 40 1 Battery 7 Washer 1 4 inch 2 Terminal boot 8 Locknut 1 4 inch 3 Positive battery cable 9 Batt...

Page 36: ...arger Lead 2 Negative Battery Post 4 Black Charger Lead 3 Install the battery in the machine and connect the battery cables refer to Installing the Battery Note Do not run the machine with the battery disconnected electrical damage may occur Servicing the Fuses The electrical system is protected by fuses It requires no maintenance however if a fuse blows check component circuit for malfunction or ...

Page 37: ...machine go left turn the knob towards the leftside of the machine Refer to Figure 43 6 Repeat adjustment until the tracking is correct Figure 43 1 Pump rod 3 Tracking knob 2 Turn this way to track left 4 Turn this way to track right Checking the Tire Pressure Check the pressure at the valve stem after every 50 operating hours or monthly whichever occurs ﬁrst Figure 44 Maintain the air pressure in ...

Page 38: ...n to properly set the pre load on the bearings Figure 46 Important Make sure spring washers are installed correctly as shown in Figure 46 5 Install the dust cap Figure 46 Figure 46 1 Spring Washers 3 Dust Cap 2 Lock Nut Cooling System Maintenance Cleaning the Air Intake Screen Before each use remove any build up of grass dirt or other debris from the cylinder and cylinder head cooling ﬁns air inta...

Page 39: ...ighten the nut directly below the yoke Figure 48 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 the nuts clockwise to shorten the spring length counterclockwise to lengthen the spring 5 Engage the parking brake with the lever up 6 Measure the distance between the trunnion roller and the collar on the brake...

Page 40: ...or a breaker bar into the square hole in the ﬁxed idler arm Figure 50 Figure 50 1 Ratchet with short extension or breaker bar 2 Square hole 8 To increase the belt tension rotate the ratchet or breaker bar counterclockwise to move the ﬁxed idler arm until you feel increased resistance and the spring loaded idler pulley stops moving Note Do not increase the belt tension beyond the point where the ﬁx...

Page 41: ...ance Adjusting the Control Handle Neutral Position If the motion control levers do not align or move easily into the console notch adjustment them Adjust each lever spring and rod separately Note The motion control levers must be installed correctly See Installing the Motion Control Levers in the Setup instructions 1 Disengage the PTO move the motion control levers to the neutral locked position a...

Page 42: ...e oil speciﬁed or equivalent Other ﬂuids could cause system damage Hydraulic System Oil Capacity 67 ounces 2 0 l Check the hydraulic ﬂuid level Before the engine is ﬁrst started After the ﬁrst 8 operating hours After every 25 operating 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 dep...

Page 43: ...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 a drain pan under ﬁlter remove the old ﬁlter and wipe the ﬁlter adapter gasket surface clean Figure 56 Figure 56 1 Hydraulic lter 4 Apply a...

Page 44: ...reas around the hydraulic system clean from grass and debris build up Hydraulic ﬂuid escaping under pressure can penetrate skin and cause injury If hydraulic ﬂuid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury Gangrene may result if this is not done Keep body and hands away from pin hole leaks or nozzles that eject high pres...

Page 45: ...reverse Figure 58 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 remains stopped or slightly creeps in reverse adjust if necessary Figure 58 1 Tracking knob 3 Adjustment bolt 2 Pump rod Setting the Right hand Hydraulic Pump Neutral Position 1 Loosen the locknuts at the bal...

Page 46: ...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 the 3 inch 76 mm height of cut position 6 Inspect the four chains The chains need to have tension Note Adjust the rear chains to the top of the slot where they are attached to the mower If one rear chain is loose lower loosen the front support ar...

Page 47: ...e adjusted the same distance 9 Tighten the jam nut under the rear support arm and tighten the bolt securing the chain to the rear support arm 10 Adjust the opposite side if needed Figure 61 1 Rear chain 5 Adjustment bolt 2 Rear support arm 6 Front swivel 3 Bolt 7 Front support arm 4 Jam Nut Adjusting the Front to Rear Mower Pitch 1 Position the right blade front to rear Figure 62 2 Measure the rig...

Page 48: ...s Figure 63 3 Adjust this distance by loosening the spring jam nut and turning the nut in front of each spring Figure 63 Note Turning the nut clockwise will shorten the spring counter clockwise will lengthen the spring 4 Lock the nut into position by tightening the spring jam nut Figure 63 Figure 63 1 10 1 2 inch 26 7 cm 5 Swivel jam nut 2 Front nut 6 Lift nut 3 Spring jam nut 7 Front support arm ...

Page 49: ...a level surface to the cutting edge position A of the blades Figure 65 Note this dimension Figure 65 1 Measure here from blade to hard surface 2 Position A 4 Rotate the opposite ends of the blades forward 5 Measure from a level surface to the cutting edge of the blades at the same position as in step 3 above The difference between the dimensions obtained in steps 3 and 4 must not exceed 1 8 inch 3...

Page 50: ...area only Figure 68 Repeat this procedure until the blade is balanced Figure 67 1 Blade 2 Balancer Installing the Blades 1 Install the blade onto the spindle shaft Figure 68 Important The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting 2 Install the spring disk and blade bolt The spring disk cone must be installed toward the bolt head Figure...

Page 51: ...rass De ector 3 Locknut 7 L end of spring place behind deck edge before installing bolt 4 Spring 8 J hook end of spring Cleaning Cleaning Under the Mower Remove the grass buildup under the mower daily 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 o...

Page 52: ...ower then wash the mower with a garden hose Note Run the machine with the PTO engaged and the engine at high idle for 2 to 5 minutes after washing 11 Check the condition of the blades refer to Servicing the Cutting Blades in Mower Deck Maintenance page 46 12 Prepare the machine for storage when non use occurs over 30 days Prepare the machine for storage as follows A Add a petroleum based stabilize...

Page 53: ...d or fails to keep running 4 Dirt water or stale fuel is in the fuel system 4 Contact an Authorized Service Dealer 1 Engine load is excessive 1 Reduce the ground speed 2 Air cleaner is dirty 2 Clean the air cleaner element 3 Oil level in the crankcase is low 3 Add oil to the crankcase 4 Cooling ns and air passages above the engine are plugged 4 Remove the obstruction from the cooling ns and air pa...

Page 54: ...unting bolts are loose 3 Tighten the engine mounting bolts 4 Loose engine pulley idler pulley or blade pulley 4 Tighten the appropriate pulley 5 Engine pulley is damaged 5 Contact an Authorized Service Dealer 6 Blade spindle is bent 6 Contact an Authorized Service Dealer Abnormal vibration 7 Motor mount is loose or worn 7 Contact an Authorized Service Dealer 1 Blade s not sharp 1 Sharpen the blade...

Page 55: ...rive 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 55 ...

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

Page 57: ......

Page 58: ......

Page 59: ...cheduled for replacement as required maintenance in the written instructions must be warranted for the warranty period of two years If any such part fails during the period of warranty coverage it must be repaired or replaced by The Toro Company Any such part repaired or replaced under the warranty must be warranted for a time not less than the remaining warranty period B Any warranted part that i...

Page 60: ... maintenance service or parts such as lters fuel lubricants tune up parts blade sharpening brake and clutch adjustments Any product or part which has been altered or misused or required replacement or repair due to normal wear accidents or lack of proper maintenance Repairs necessary due to improper fuel contaminants in the fuel system or failure to properly prepare the fuel system prior to any pe...

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