Toro Z400 Series Z Master Handbuch

 2004—TheToro Company

8111 Lyndale Ave., Blomington, MN 55420, USA Printed in the USA

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

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

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

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

Step UseQty.Description

12 No parts needed –Preparing the side discharge chute

13 No parts needed –Checking the machine before delivery

Key

Operator’s Manual

Engine Owner’s Manual

Parts Catalog

Safety video

Registration card

Delivering the machine to the customer

Step

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

Step

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

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

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

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

Step

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

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

Step

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.

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

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

Step

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

Step

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

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

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.

Step

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:

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