Toro Z400 Series Z-Master Manual

Form No. 3354-664 Rev A
Z400 Series Z Master® Mowers
Model No. For all Z400 Series Z Master Mowers
Setup Instructions
Loose PartsUse the chart below to verify that all parts have been shipped.
Step
Description
Qty.
Use
1
No parts required
–
Remove parts from the crate.
2
No parts required
–
Check the tire pressure.
3
Rear wheels
2
Install the drive wheels.
Roll bar, right section
1
Roll bar, left section
1
Roll bar, center section
1
Bolt, (3/8 x 1 inch)
8
Curved washer
8
Flange nut, (3/8 inch)
8
Bolt, (1/2 x 3–1/4 inch)
2
4
Flange nut, (1/2 inch)
2
Install the Rollover ProtectionSystem (ROPS).
5
Right control lever
1
Left control lever
1
Bolt (3/8 x 1 inch) (2 are assembled)
46
Curved washer (3/8 inch) (2 areassembled)
4
Install the motion control levers.
7
No parts required
–
Adding fuel to the machine.
8
No parts required
–
Charge the battery.
Air cleaner cap
19
Hose clamp
1
Install the air cleaner cap.
10
Number 2 general purpose lithiumbase or molybdenum base grease.(Purchase separately.)
1 tube Check the machine for grease.
11
No parts required
–
Check the engine oil level.
12
No parts required
–
Prepare the side discharge chute.
13
No parts required
–
Check the machine before deliveryto the customer.
© 2005—The Toro® Company8111 Lyndale Avenue SouthBloomington, MN 55420
Register at www.Toro.com. Original Instructions (EN)Printed in the USA.All Rights Reserved

Step
Description
Qty.
Use
Operator’s Manual
1
Parts Catalog
1
Engine Owner’s Manual
1
Registration Card
1
Safety Video
114
Key 2
Delivering the machine to thecustomer.
Step
1
Removing Parts from theCrate
No Parts Required
Procedure
R emo v e the tires , the seat and the par ts for the
R OPS from the shipping crate .
Step
2
Checking the Tire Pressure
No Parts Required
Procedure
Chec k the air pressure in the front and rear tires .
Pressure: 13 psi (90 kP a)
Figure 1
Step
3
Raising the Machine Up andInstalling the Drive Wheels
Parts needed for this step:
2
Rear wheels
Procedure
1. R emo v e the screws holding the right angle
retaining plate to the crate .
Figure 2
2. Raise the bac k of the mac hine up and suppor t
it with jac k-stands .
2

Figure 3
3. R emo v e the wheel n uts from both sides of the
v ehicle and remo v e the right angle retaining
plate . Discard the screws and retaining plate .
Figure 4
4. Mount the wheels with the v alv e stem to the
outside and secure them with the wheel n uts
previously remo v ed.
5. T or que the wheel n uts to 95 ft-lb (128 N·m).
6. R emo v e the jac k-stands .
Figure 5
Step
4
Installing the Roll OverProtection System
Parts needed for this step:
1
Roll bar, right section
1
Roll bar, left section
1
Roll bar, center section
8
Bolt, (3/8 x 1 inch)
8
Curved washer
8
Flange nut, (3/8 inch)
2
Bolt, (1/2 x 3–1/4 inch)
2
Flange nut, (1/2 inch)
Procedure
1. Loosely install the right and left roll bar section
to the frame , with 8 bolts (3/8 x 1 inc h), 8
cur v ed w ashers , and 8 flang e n uts (3/8 inc h).
Note: T he cur v e w asher cone m ust be
installed to w ard the bolt head.
3

Figure 6
2. Install the lanyard clips onto the long bolts
(1/2 x 3-1/4 inc h).
Note: Mak e sure the bent tab points to w ard
the head of the bolt.
Figure 7
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 inc h) and 2 flang e n uts
(1/2 inc h).
Note: Mak e sure the bolts are installed from
the outside of the roll bar .
Note: Mak e sure the lanyard tab is installed
as sho w and points forw ard.
Figure 8
5. Raise the roll bar into the upright position and
secure it with the pins and hair pin cotter pins
fastened to the lanyards
Figure 9
6. T or que all lo w er fasteners , attac hed to the
mac hine frame , to 30 ft-lb .
7. Tighten the center roll bar bolts (1/2 x 3-1/4
inc h) so it rotates freely with some resistance .
Note: No more than one thread should be
exposed outside the n ut.
4

Figure 10
8. Tighten the front knobs ag ainst the center roll
bar ends .
Figure 11
Step
5
Installing the Seat
Parts needed for this step:
Procedure
1. R emo v e the bolt and n ut from the seat frame .
2. R emo v e the n uts from the studs under the seat.
3. Secure the seat rod to the seat with the bolt
and n ut.
4. Install the seat to the seat frame with the
previously remo v ed n uts .
Figure 12
5. Install the seat rod to the seat frame .
Figure 13
5

Step
6
Installing the MotionControl Levers
Parts needed for this step:
1
Right control lever
1
Left control lever
4
Bolt (3/8 x 1 inch) (2 are assembled)
4
Curved washer (3/8 inch) (2 are assembled)
Procedure
Step
7
Adding Fuel to the Machine
No Parts Required
Procedure
Add fuel to the mac hine before star ting it. R efer
to y our Operator’ s Manual. for the cor rect fuel and
procedure .
Step
8
Charging the Battery
No Parts Required
Procedure
Charging the batter y pr oduces gasses that
can explode and cause serious injur y .
• K eep cigar ettes, spar ks and flames a w ay
fr om the batter y .
• Mak e sur e the ignition s witch is of f.
• V entilate when charging or using the
batter y in an enclosed space.
Important: Do not r un the machine with
the batter y disconnected; electrical dama ge
may occur to the engine.
Charg e the batter y . R efer to the Operator’ s Manual
for instr uctions .
Figure 14
6

Step
9
Installing the Air CleanerCap
Parts needed for this step:
1
Air cleaner cap
1
Hose clamp
Procedure
1. R emo v e the plastic plug .
Figure 15
2. R emo v e the air cleaner cap from the mac hine .
3. Install the hose clamp onto the air cleaner cap .
Figure 16
4. Install the air cleaner cap onto the air cleaner
and secure it with the hose clamp .
Figure 17
7

Step
10
Checking the Machine forGrease
Parts needed for this step:
1 tube
Number 2 general purpose lithium baseor molybdenum base grease. (Purchaseseparately.)
Procedure
1. R emo v e the belt co v ers .
2. Chec k the tensioning ar m for g rease .
3. Chec k the g rease for the three spindle bearings .
If needed, add g rease until it comes out of the
lo w er seals .
4. Install the belt co v ers .
Figure 18
Step
11
Checking the Engine OilLevel
No Parts Required
Procedure
Before y ou star t the engine and use the mac hine ,
c hec k the oil lev el in the engine crankcase; refer to
Chec king Oil Lev el in Operator’ s Manual.
Step
12
Preparing the SideDischarge Chute
No Parts Required
Procedure
R emo v e the plastic tie holding the side disc harg e
c hute up and lo w er the c hute into place .
8

Step
13
Checking the Machine Before Delivery to the Customer
No Parts Required
Procedure
Before deli v ering the mac hine to the customer , ensure that y ou perfor m or ha v e perfor med the
procedures listed in the follo wing table and initial eac h when finished. R efer to the Operator’ s Man ual
for instr uctions on perfor ming 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 uid level.
Check ROPS is secure.
Check the adjustment of the parking brake.
Ensure that the machine tracks correctly; refer to the Operator’s Manual for the adjustmentprocedure.
Check the safety interlock system; refer to the Operator’s Manual .
Ensure that the PTO works.
Check all fasteners you installed to ensure that they are tight.
W hen y ou finish setting up the mac hine , sign and date in the space pro vided belo w:
Signature: Date:
9

Step
14
Delivering the Machine to the Customer
Parts needed for this step:
1
Operator’s Manual
1
Parts Catalog
1
Engine Owner’s Manual
1
Registration Card
1
Safety Video
2 Key
Procedure
At deli v er y , complete the items listed in the follo wing table and initial eac h when finished.
Model No. Serial No.
10