Toro Z400 Series Z Master Manual

FormNo.3356-183RevB
Z400SeriesZMaster®Mowers
ForallZ400SeriesZMasterMowers
SetupInstructions
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
1Nopartsrequired–Removepartsfromthecrate.
2Nopartsrequired–Checkthetirepressure.
3Rearwheels2Installthedrivewheels.
Rollbar,rightsection1
Rollbar,leftsection1
Rollbar,centersection1
Bolt,(3/8x1inch)8
Curvedwasher8
Flangenut,(3/8inch)8
Bolt,(1/2x3–1/4inch)2
4
Flangenut,(1/2inch)2
InstalltheRolloverProtectionSystem
(ROPS).
5Nopartsrequired–Installtheseat.
Rightcontrollever1
Leftcontrollever1
Bolt(3/8x1inch)(2areassembled)4
6Curvedwasher(3/8inch)(2are
assembled)4
Installthemotioncontrollevers.
7Nopartsrequired–Addingfueltothemachine.
8Nopartsrequired–Chargethebattery.
Aircleanercap1
9Hoseclamp1Installtheaircleanercap.
10
Number2generalpurposelithiumbase
ormolybdenumbasegrease.(Purchase
separately.)
1tubeCheckthemachineforgrease.
11Nopartsrequired–Checktheengineoillevel.
12Nopartsrequired–Preparethesidedischargechute.
13Nopartsrequired–Checkthemachinebeforedeliveryto
thecustomer.
©2008—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.Toro.com.OriginalInstructions(EN)
PrintedintheUSA.
AllRightsReserved

ProcedureDescriptionQty.Use
Operator’sManual1
PartsCatalog1
EngineOwner’sManual1
RegistrationCard1
SafetyVideo1
14
Key2
Deliveringthemachinetothecustomer.
1
RemovingPartsfromtheCrate
NoPartsRequired
Procedure
Removethetires,theseatandthepartsfortheROPS
fromtheshippingcrate.
2
CheckingtheTirePressure
NoPartsRequired
Procedure
Pressure:13psi(90kPa)
1.ForEstateModelsonly,checktheairpressureinthe
fronttires.
Note:Ifthereisnovalvestemlocatedinthefront
tires,thenitisasemi-pneumatictireanddoesnot
needtobechecked.
2.Checktheairpressureinthereartires.
Figure1
3
RaisingtheMachineUpand
InstallingtheDriveWheels
Partsneededforthisprocedure:
2Rearwheels
Procedure
1.Removethescrewsholdingtherightangleretaining
platetothecrate.
Figure2
2.Raisethebackofthemachineupandsupportitwith
jack-stands.
2

Figure3
3.Removethewheelnutsfrombothsidesofthe
vehicleandremovetherightangleretainingplate.
Discardthescrewsandretainingplate.
Figure4
4.Mountthewheelswiththevalvestemtotheoutside
andsecurethemwiththewheelnutspreviously
removed.
5.Torquethewheelnutsto95ft-lb(128N·m).
6.Removethejack-stands.
Figure5
4
InstallingtheRollOver
ProtectionSystem
Partsneededforthisprocedure:
1Rollbar,rightsection
1Rollbar,leftsection
1Rollbar,centersection
8Bolt,(3/8x1inch)
8Curvedwasher
8Flangenut,(3/8inch)
2Bolt,(1/2x3–1/4inch)
2Flangenut,(1/2inch)
Procedure
1.Looselyinstalltherightandleftrollbarsectionto
theframe,with8bolts(3/8x1inch),8curved
washers,and8angenuts(3/8inch).
Note:Thecurvewasherconemustbeinstalled
towardthebolthead.
Figure6
3

2.Installthelanyardclipsontothelongbolts(1/2x
3-1/4inch).
Note:Makesurethebenttabpointstowardthe
headofthebolt.
Figure7
3.Lightlyoiltheendsofthecenterrollbarsection.
4.Looselyinstallthecenterrollbarsectionusing2
bolts(1/2x3-1/4inch)and2angenuts(1/2inch).
Note:Makesuretheboltsareinstalledfromthe
outsideoftherollbar.
Note:Makesurethelanyardtabisinstalledasshow
andpointsforward.
Figure8
5.Raisetherollbarintotheuprightpositionandsecure
itwiththepinsandhairpincotterpinsfastenedto
thelanyards
Figure9
6.Torquealllowerfasteners,attachedtothemachine
frame,to30ft-lb.
7.Tightenthecenterrollbarbolts(1/2x3-1/4inch)
soitrotatesfreelywithsomeresistance.
Note:Nomorethanonethreadshouldbeexposed
outsidethenut.
Figure10
8.Tightenthefrontknobsagainstthecenterrollbar
ends.
4

Figure11
5
InstallingtheSeat
NoPartsRequired
Procedure
1.Removetheboltandnutfromtheseatframe.
2.Removethenutsfromthestudsundertheseat.
3.Securetheseatrodtotheseatwiththeboltandnut.
4.Installtheseattotheseatframewiththepreviously
removednuts.
Figure12
5.Installtheseatrodtotheseatframe.
Figure13
6
InstallingtheMotionControl
Levers
Partsneededforthisprocedure:
1Rightcontrollever
1Leftcontrollever
4Bolt(3/8x1inch)(2areassembled)
4Curvedwasher(3/8inch)(2areassembled)
Procedure
1.Rotatethemotioncontrolleverstotheupright
position.
2.Looselyinstallthecontrolleversontheoutsideof
theposts,using4boltsand4curvedwashers.
5

Note:Installthecontrolleversinthetopand
middleholesforthehighpositionorthemiddleand
bottomholesforthelowposition,asdesired.
Figure14
3.Raisetheleversandalignthemtogetherinthe
neutralpositionandtightenthebolts.
Figure15
Note:Ifthemachineisnotproperlytracking,refer
toAdjustingtheTrackinginyourOperator’sManual.
7
AddingFueltotheMachine
NoPartsRequired
Procedure
Addfueltothemachinebeforestartingit.Refertoyour
Operator’sManual.forthecorrectfuelandprocedure.
8
ChargingtheBattery
NoPartsRequired
Procedure
Chargingthebatteryproducesgassesthatcan
explodeandcauseseriousinjury.
•Keepcigarettes,sparksandamesaway
fromthebattery.
•Makesuretheignitionswitchisoff.
•Ventilatewhenchargingorusingthebattery
inanenclosedspace.
Important:Donotrunthemachinewiththe
batterydisconnected;electricaldamagemayoccur
totheengine.
Chargethebattery.RefertotheOperator’sManualfor
instructions.
6

Figure16
9
InstallingtheAirCleanerCap
Partsneededforthisprocedure:
1Aircleanercap
1Hoseclamp
Procedure
Note:DonotusethisprocedureforEstatemodels.
1.Removetheplasticplug.
Figure17
2.Removetheaircleanercapfromthemachine.
3.Installthehoseclampontotheaircleanercap.
Figure18
4.Installtheaircleanercapontotheaircleanerand
secureitwiththehoseclamp.
Figure19
7

10
CheckingtheMachinefor
Grease
Partsneededforthisprocedure:
1tubeNumber2generalpurposelithiumbaseor
molybdenumbasegrease.(Purchaseseparately.)
Procedure
1.Removethebeltcovers.
2.Checkthetensioningarmforgrease.
3.Checkthegreaseforthethreespindlebearings.If
needed,addgreaseuntilitcomesoutofthelower
seals.
4.Installthebeltcovers.
Figure20
11
CheckingtheEngineOilLevel
NoPartsRequired
Procedure
Beforeyoustarttheengineandusethemachine,check
theoillevelintheenginecrankcase;refertoChecking
OilLevelinOperator’sManual.
12
PreparingtheSideDischarge
Chute
NoPartsRequired
Procedure
Removetheplastictieholdingthesidedischargechute
upandlowerthechuteintoplace.
Checkandensurethespringisinstalledcorrectly.The
grassdeectormustbeabletolowerdownintoposition.
Liftthedeectoruptotestthatitlowersintothefull
downposition.
Ifneeded,refertoReplacingtheGrassDeectorinthe
Operator’sManual.
8

13
CheckingtheMachineBeforeDeliverytotheCustomer
NoPartsRequired
Procedure
Beforedeliveringthemachinetothecustomer,ensurethatyouperformorhaveperformedtheprocedureslistedin
thefollowingtableandinitialeachwhennished.RefertotheOperator’sManualforinstructionsonperforming
theseprocedures.
InitialCheckProcedure
Checkthetirepressure.
Checkthelevelofthemower.
Checkthatallmowerspindlesaregreased.
Checktheengineoillevel.
Checkthehydraulicuidlevel.
CheckROPSissecure.
Checktheadjustmentoftheparkingbrake.
Ensurethatthemachinetrackscorrectly;refertotheOperator’sManualfortheadjustmentprocedure.
Checkthesafetyinterlocksystem;refertotheOperator’sManual.
EnsurethatthePTOworks.
Checkallfastenersyouinstalledtoensurethattheyaretight.
Whenyounishsettingupthemachine,signanddateinthespaceprovidedbelow:
Signature:Date:
9

14
DeliveringtheMachinetotheCustomer
Partsneededforthisprocedure:
1Operator’sManual
1PartsCatalog
1EngineOwner’sManual
1RegistrationCard
1SafetyVideo
2Key
Procedure
Atdelivery,completetheitemslistedinthefollowingtableandinitialeachwhennished.
ModelNo.SerialNo.
10

DealerInitialCustomerInitialCheckProcedure
Showthecustomerwherethefollowingfeaturesarelocatedandhowtheyfunction:
Fueltankcaps
Oilllcap/Oildipstick
Engineoillter
Engineoildrain
Fuellters
Airlter
Hydraulicuidreservoir
Hydrauliclter
Battery
Ignitionswitch
Throttlelever
Powertakeoffswitch(PTO)
Motioncontrollevers
Parkingbrake
Mowerheight-of-cut
Adjustableseat
Hydraulicbypassvalves
RolloverProtectionSystem(ROPS)
Mowerdeckowbafe
RefertotheOperator’sManualtopointoutsafetyprocedures,operation,and
maintenanceprocedures.
ReviewthewarrantystatementasshownintheOperator’sManual.
Describethepostsaleserviceproceduresforyourstore.
Assistthecustomerinllingoutandmailingtheregistrationcardorregisteronlineat
www.Toro.com
MakesurethatthecustomerreceivestheOperator’sManual,PartsCatalog,andEngine
Owner’sManual,SetUpInstructions,andsafetyvideo.
Assistthecustomerinloadingthemower.
Note:Whenyou,thedealerrepresentative,havenisheddeliveringthemachinetothecustomer,signanddatein
thespaceprovidebelowandkeepacopyofthispagefordealerrecords.
Signature:Date:
Signature:Date:
11