Toro Z400 Series Z Master Manual

 2004—TheToro Company
8111 Lyndale Ave., Blomington, MN 55420, USA Printed in the USA
All Rights Reserved Original Instructions (EN)
Register your product at www.Toro.com
Z400 Series Z MasterMowers Form No. 3351-723 Rev A
Setup Instructions
Loose Parts
Use the steps in the following chart to verify all parts have been shipped and to guide you through the setup.
Step Description Qty. Use
1No parts needed –Raising the machine
2
Roll bar, right section
Roll bar, left section
Roll bar, center section
Bolt, 3/8 x 1 inch
Curved washer, 3/8 inch
Flange nut, 3/8 inch
Bolt, 1/2 x 3-1/4 inches
Flange nut, 1/2 inch
Lanyard
1
1
1
8
8
8
2
2
2
Installing the rollover protection system
(ROPS)
3Wheels 2 Installing the drive wheels
4No parts needed –Checking the tire pressure
5Seat
Nuts (installed on the seat) 1 4Installing the seat
6Control lever–right
Control lever–left
Bolt, 3/8 x 1 inch
Curved washer, 3/8 inch
1
1
4
4
Installing the motion control levers
7Bulk electrolyte with 1.265 specific gravity
(Purchase from a battery supply outlet) 80 oz. Activating the battery
8No parts needed –Charging the battery
9Air cleaner cap
Hose clamp 1 1Installing the air cleaner cap
10 No.2 general purpose lithium-base or
molybdenum-base grease. (Purchase
separately) 1 tube Greasing the bearings
11 No parts needed –Checking the height-of-cut level of the
mower

2
Step UseQty.Description
12 No parts needed –Preparing the side discharge chute
13 No parts needed –Checking the machine before delivery
14
Key
Operator’s Manual
Engine Owner’s Manual
Parts Catalog
Safety video
Registration card
2
1
1
1
1
1
Delivering the machine to the customer
Step
1
Raising the Machine
Parts Needed for This Step
None
Procedure
1. Remove the wheel
nuts from both sides of
the vehicle.
2. Remove the right
angle retaining plate
from the crate and the
wheel hub. m-6918
3. Raise the back of the machine up and support it
with jack stands.
m-6919

3
Step
2
Installing the Rollover
Protection System (ROPS)
Parts Needed for This Step
Qty. Part
1Roll bar, right section
1Roll bar, left section
1Roll bar, center section
8Bolt, 3/8 x 1 inch
8Curved washer
8Flange nut, 3/8 inch
2Bolt, 1/2 x 3-1/4 inches
2Flange nut, 1/2 inch
2 Lanyard
Procedure
1. Loosely install the right and left roll bar sections
to the frame, using 8 bolts (3/8 x 1 inch), 8 curved
washers, and 8 flange nuts (3/8 inch).
m-6916
2. Install the lanyard
clips onto the 2 bolts
(1/2 x 3-1/4 inches).
Note: Make sure the
bent tab points toward
the head of the bolt. m-7410
3. Lightly oil the ends
of the center roll bar
section.
4. Loosely install the
center roll bar section,
using 2 bolts
(1/2 x 3-1/4 inches) and
2 flange nuts (1/2 inch).
Note: Make sure the
bolts are installed on the
outside of the roll bar.
Note: Make sure the
lanyard tab is installed
as shown and points
forward.
m-7432

4
5. Raise the roll bar
into the upright position
and secure it with the
pins and hairpin cotter
pins fastened to the
lanyards.
6. Torque all the lower
fasteners that are
attached to the machine
frame to 30 ft-lb.
m-7431
7. Tighten the center
roll bar bolts
(1/2 x 3-1/4 inches) so
that the roll bar rotates
freely with some
resistance.
Note: Make sure that no
more than one thread is
exposed outside the nut.
m-7432
8. Tighten the front
handles against the
center roll bar ends.
m-7406
Step
3
Installing the Drive Wheels
Parts Needed for This Step
Qty. Part
2Rear wheels
Procedure
1. Mount the wheels
with the valve stem to
the outside and secure
them with the nuts you
previously removed in
step 1.
2. Torque the nuts to
95 ft-lb (128 N⋅m).
m-6917
Step
4
Checking the Tire Pressure
Parts Needed for This Step
None
Procedure
Check the air pressure
in the front and rear tires
and make sure that they
are set to 13 psi
(90 kPa).
m-6873

5
Step
5
Installing the Seat
Parts Needed for This Step
None
Procedure
1. Remove the seat from the crate.
2. Remove the bolt
and nut from the seat
frame.
3. Secure the seat rod
to the seat with the bolt
and nut.
m-5712
Step
6
Installing the Motion
Control Levers
Parts Needed for This Step
Qty. Part
1Control lever–right
1Control lever–left
4Bolt, 3/8 x 1 inch (2 assembled)
4Curved washer, 3/8 inch (2 assembled)
Procedure
1. Rotate the control
levers to the upright
position.
2. Loosely install the
control levers on the
outside of the posts,
using 4 bolts and 4
curved washers.
Note: Install the control
levers in the top and
middle holes for the high
position or the middle
and bottom holes for the
low position, as desired.
m-6866
3. Raise the levers and align them together in the
neutral position and tighten the bolts.
m-6867
m-6868
Note: If the machine is not properly tracking, refer to
Adjusting the Tracking in your Operator’s Manual .

6
Step
7
Activating the Battery on
International Machines
Parts Needed for This Step
Qty. Part
80 oz. Bulk electrolyte with 1.265 specific gravity
(Purchase from a battery supply outlet)
Procedure
Danger
Battery electrolyte contains sulfuric acid, a
deadly poison that can cause severe burns.
Do not drink electrolyte and avoid contact
with skin, eyes, or clothing. Wear safety
glasses to shield your eyes and rubber gloves
to protect your hands.
Fill the battery where clean water is always
available for flushing the skin.
Follow all instructions and comply with all
safety messages on the electrolyte container.
Warning
CALIFORNIA
Proposition 65 Warning
Battery posts, terminals, and related accessories
contain lead and lead compounds, chemicals
known to the State of California to cause cancer
and reproductive harm. Wash hands after
handling.
1. Remove the battery.
Refer to the Operator’s
Manual for instructions.
Important: Do not add
electrolyte while the
battery is in the
machine. You could spill
it, causing corrosion.
m-6850
2. Clean the top of the
battery and remove the
vent caps.
m-6851
3. Slowly pour
electrolyte into each
battery cell until the level
is up to the upper line
on the battery case.
Important: Do not
overfill the battery.
m-6853
4. Wait 5 to 10 minutes, then add electrolyte, if
necessary, until the electrolyte level is up to the
upper line on the battery case.

7
5. Install the battery
filler caps.
m-6852
6. Charge the battery and then install it on the
machine. Refer to the Operator’s Manual for
instructions.
Warning
Charging the battery produces gasses that can
explode and cause serious injury.
Keep cigarettes, sparks, and flames away
from the battery.
Ensure that the ignition switch is off.
Ventilate when charging or using the battery
in an enclosed space.
Step
8
Charging the Battery
Parts Needed for This Step
None
Procedure
Warning
Charging the battery produces gasses that can
explode and cause serious injury.
Keep cigarettes, sparks, and flames away
from the battery.
Ensure that the ignition switch is off.
Ventilate when charging or using the battery
in an enclosed space.
1. Charge the battery
for an international
machine and then install
it on the machine. Refer
to the Operator’s
Manual for instructions.
m4970
2. Charge the battery
for a domestic machine
and then install it on the
machine. Refer to the
Operator’s Manual for
instructions.
m-7509

8
Step
9
Installing the Air Cleaner
Cap
Parts Needed for This Step
Qty. Part
1Air cleaner cap
1Hose clamp
Procedure
1. Remove the plastic
plug.
m-6912
2. Remove the air cleaner cap from the machine.
3. Install the hose
clamp onto the air
cleaner cap.
m–6914
4. Install the air
cleaner cap onto the air
cleaner and secure it
with the hose clamp.
m-6913

9
Step
10
Checking the Spindles for
Grease
Parts Needed for This Step
Qty. Part
1 tube No. 2 general purpose lithium-base or
molybdenum-base grease. (Purchase separately)
Procedure
Important: Before starting the engine, check the
cutting unit spindles to ensure that they have grease.
1. Remove the belt covers.
2. Grease the fittings on the 3 spindle bearings and
the deck idler arm.
m–6822
m–7706
Note: Greasing the spindles allows you to purge the
old grease out by flushing new grease through. When
the spindles are full of grease, any excess grease
discharges at the blade retainer under the housing.
Step
11
Checking the Height-of-cut
Level of the Mower
Parts Needed for This Step
None
Procedure
Refer to Leveling the Mower at Three Positions in
your Operator’s Manual .
Step
12
Preparing the
Side Discharge Chute
Parts Needed for This Step
None
Procedure
Remove the plastic tie that holds the side discharge
chute up and lower the chute in place.
Note: The discharge chute should pivot freely. If it
does not, loosen the fasteners that secure the rubber
chute to the hinge bracket and then tighten the
fasteners. Check to ensure that the hinge bolt is not
overtightened.

10
Step
13
Checking the Machine before Delivering It to the Customer
Parts Needed for This Step
None
Procedure
Before delivering the machine to the customer, ensure that you perform or have performed the procedures listed
in the following table and initial each when finished. Refer to the Operator’s Manual for instructions on performing
these procedures.
Initial Check Procedure
Check the tire pressure.
Check the level of the mower.
Check that all mower spindles are greased.
Check the engine oil level.
Check the hydraulic fluid level.
On liquid cooled machines, check the level of the coolant.
Check the adjustment of the parking brake.
Ensure that the machine tracks (drives) correctly.
Check the safety interlock system.
Ensure that the PTO works.
Check all fasteners you installed to ensure that they are tight.
When you finish setting up the machine, sign and date in the space provided below:
Signature: Date:

11
Step
14
Delivering the Machine to the Customer
Parts Needed for This Step
Qty. Part
1 Operator’s Manual
1 Parts Catalog
1 Engine Owner’s Manual
1Registration card
1Safety video
2 Key
Procedure
At delivery, complete the items listed in the following table and initial each when finished.
Model Number: Serial Number:

12
Dealer
Initial Customer Initial Check Procedure
Show the customer where the following features are located and how they function:
•Fuel Tank Caps
•Oil Fill Tube/ Oil dipstick
•Oil Filter
•Oil Drain
•Spark Plug(s)
•Air Filter
•Radiator Coolant
•Hydraulic fluid reservoir
•Hydraulic filter
•Battery
•Ignition Switch
•Throttle Lever
•Choke
•Power Take Off Switch (PTO)
•Motion Control Levers
•Parking Brake
•Mower Height–of–Cut Lever
•Adjustable Seat
•Hydraulic Bypass
•Rollover Protection System (ROPS)
Refer to the operator’s manual to point out safety procedures, operation, and
maintenance procedures.
Review the warranty statement as shown in the Operator’s Manual .
Describe the post sale service procedures for your store.
Assist the customer in filling out and mailing the registration card or register online at
www.Toro.com.
Make sure that the customer receives the Operator’s Manual , Parts Catalog , and Engine
Owner’s Manual, Set Up Instructions
, and safety video.
Assist the customer in loading the mower.
Note: When you, the dealer representative, have finished delivering the machine to the customer, sign and date
in the space provided below and keep a copy of this page for dealer records:
Signature: Date:
Signature: Date: