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

Dealer Initial Customer Initial Check Procedure
Show the customer where the following features are located and howthey function:
Fuel tank caps
Oil ll cap/ Oil dipstick
Engine oil lter
Engine oil drain
Fuel lters
Air lter
Hydraulic uid reservoir
Hydraulic lter
Battery
Ignition switch
Throttle lever
Power take off switch (PTO)
Motion control levers
Parking brake
Mower height-of-cut
Adjustable seat
Hydraulic bypass valves
Rollover Protection System (ROPS)
Mower deck ow bafe
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 lling out and mailing the registration card orregister 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: W hen y ou, the dealer re presentati v e , ha v e finished deli v ering the mac hine to the customer , sign
and date in the space pro vide belo w and k ee p a copy of this pag e for dealer records .
Signature: Date:
Signature: Date:
11