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Toro Z450 Z Master, Operator'S Manual

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Toro Z450 Z Master Operator'S Manual Download Page 8

Safety and Instructional

Decals

Safety decals and instructions 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.

8

Summary of Contents for Z450 Z Master

Page 1: ...Form No 3354 561 Rev B Z450 Z Master with a 52in TURBO FORCE Side Discharge Mower Model No 74414 Serial No 260000001 and Up Register your product at www Toro com Original Instructions EN ...

Page 2: ...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 numbers in the space provid...

Page 3: ...tenance 32 Replacing the Fuel Filter 32 Servicing the Fuel Tank 33 Electrical System Maintenance 33 Servicing the Battery 33 Servicing the Fuses 35 Drive System Maintenance 36 Adjusting the Tracking 36 Checking the Tire Pressure 36 Checking the Wheel Hub Slotted Nut 36 Adjusting the Caster Pivot Bearing 37 Cooling System Maintenance 37 Cleaning the Air Intake Screen 37 Cleaning the Cooling System ...

Page 4: ...tachments 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 They are flammable a...

Page 5: ...s 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 the stability of the mach...

Page 6: ...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 7: ...Slope Chart 7 ...

Page 8: ...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 8 ...

Page 9: ...98 5954 103 2644 105 7798 107 1613 107 1687 107 1688 9 ...

Page 10: ...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 10 ...

Page 11: ...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 11 ...

Page 12: ...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 12 ...

Page 13: ...ke lever 8 Fuel cap 4 Throttle control 9 Hourmeter 5 Choke 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 Each tank connects to...

Page 14: ...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 15: ...o Checking Oil Level in Engine Maintenance page 29 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 no...

Page 16: ...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 17: ... Move 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 P...

Page 18: ...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 19: ...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 20: ... 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 21: ...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 22: ...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 23: ... 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 24: ... 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 25: ...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 26: ...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 27: ...racks and wear Check the hydraulic hoses Every 150 hours Lubricate the machine with light oil Refer to Lubrication Every 200 hours Check and or replace the primary air lter Replace the oil lter Check the spark plugs Replace the fuel lter Change the hydraulic lter and oil Every 500 hours Check the wheel hub slotted nut Adjust the caster pivot bearing Every 600 hours Replace the safety lter Yearly G...

Page 28: ...the Caster Pivot Bearing 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 30 Figure 30 Where to Add Light Oil or S...

Page 29: ...pull the air cleaner cover off the air cleaner body Figure 32 Figure 32 1 Air cleaner body 4 Air cleaner cover 2 Primary lter 5 Safety lter 3 Latch 4 Clean the inside of the air cleaner cover with compressed air 5 Gently slide the primary filter out of the air cleaner body Figure 32 Note Avoid knocking the filter into the side of the body 6 Remove the safety filter only if you intend to replace it Im...

Page 30: ...the Engine Oil Change the engine oil 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 or SH Crankcase Capacity w filter 67 oz 2 l Viscosity See the table below Figure 33 Checking the Engine Oil Level 1 Park the machine on a level surface 2 Disengage the PTO turn the ignition key to...

Page 31: ...tions are extremely dusty or sandy 1 Drain the oil from the engine refer to Changing the Engine Oil 2 Remove the old filter and wipe the filler adapter gasket surface Figure 36 Figure 36 1 Oil lter 3 Adapter 2 Adapter gasket 3 Pour new oil in through the center hole of the filter Fill it up to the bottom of the threads inside 4 Allow the filter material to absorb the new oil for 1 to 2 minutes 5 Apply...

Page 32: ...rake 2 Stop the engine 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 38 Figure 38 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 Installing the Spark Plugs 1 Install th...

Page 33: ...nks drain 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 ca...

Page 34: ...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 35: ...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 36: ...machine go left turn the knob towards the left side 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 37: ... brake 2 Stop the engine remove the key and wait for all moving parts to stop before leaving the operating position 3 Remove the dust cap from caster and tighten lock nut Figure 46 4 Tighten the locknut until the spring washers are flat and then back off a 1 4 turn to properly set the pre load on the bearings Figure 46 Important Make sure spring washers are installed correctly as shown in Figure 46...

Page 38: ... 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 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...

Page 39: ...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 40: ...nce 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 an...

Page 41: ...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 42: ...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 43: ...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 44: ...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 45: ...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 46: ...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 47: ...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 48: ...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 49: ...6 1 Sharpen at original angle 2 Check the balance of the blade by putting it on a blade balancer Figure 67 If the blade stays in a horizontal position the blade is balanced and can be used If the blade is not balanced file some metal off the end of the sail 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 on...

Page 50: ...e the J hook end of the spring around the grass deflector Figure 69 Important The grass deflector must be able to lower down into position Lift the deflector up to test that it lowers into the full down position Figure 69 1 Bolt 5 Spring installed 2 Spacer 6 Grass 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...

Page 51: ...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 45 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 52: ...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 53: ...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 54: ...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 54 ...

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

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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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