Toro Z Master Z500 Series Manual

Form No. 3358-222 Rev A
Z500 Series Z Master® Gasoline EngineMowers
Model No. All Z500 Series Gasoline Engine Mower Models
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).
Control lever, right
1
Control lever, left
1
Bolt (3/8 x 1 inch) (2 assembled)
45
Curved washer (3/8 inch) (2assembled)
4
Install the motion control levers.
Seat
16
Flange nuts
4
Install the seat.
7
No parts required
–
Charge the battery.
Air cleaner
18
Hose Clamp
1
Install the air cleaner (Models withKohler engines only).
Air cleaner
1
Hose Clamp
1
Screws
49
Front engine cover
1
Install the air cleaner (Models withKawasaki engines only).
10
Number 2 general purpose lithiumbase or molybdenum base grease.(Purchase separately.)
1 tube Check the spindles for grease.
11
No parts required
–
Prepare the side discharge chute.
12
No parts required
–
Check the engine oil level.
© 2007—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
13
No parts required
–
Add fuel to the machine.
14
No parts required
–
Check the machine before deliveryto the customer.
Operator’s Manual
1
Parts Catalog
1
Engine Owner’s Manual
1
Registration Card
1
Safety Video
115
Key 2
Delivering the machine to thecustomer.
Step
1
Removing Parts from theCrate
No Parts Required
Procedure
R emo v e the tires and the par ts for the R OPS from
the shipping crate .
Step
2
Checking the Tire Pressure
No Parts Required
Procedure
Pressure: 13 psi (90 kP a)
1. F or entr y lev el models only , c hec k the air
pressure in the front tires .
Note: If there is no v alv e stem located in the
front tires , then it is a semi-pneumatic tire and
does not need to be c hec k ed.
2. Chec k the air pressure in the rear tires .
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

Figure 2
2. Raise the bac k of the mac hine up and suppor t
it with jac k-stands ( Figure 3 ).
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 ( Figure 4 ). 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 ( Figure 5 ).
Figure 5
5. T or que the wheel n uts to 95 ft-lb (128 N·m).
6. R emo v e the jac k-stands .
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
4

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.
Figure 10
Step
5
Installing the MotionControl Levers
Parts needed for this step:
1
Control lever, right
1
Control lever, left
4
Bolt (3/8 x 1 inch) (2 assembled)
4
Curved washer (3/8 inch) (2 assembled)
Procedure
1. R otate the handles to the upright position
( Figure 11 ).
Figure 11
2. Loosely install the lev ers on the outside , using
4 bolts and cur v ed w ashers ( Figure 11 ).
Note: Install the lev ers in the top and middle
holes for the high position or the middle and
bottom holes for the lo w position, as desired.
3. In the neutral position, raise the lev ers , bringing
them tog ether , and slide them until they are
aligned, then tighten the bolts ( Figure 12 ).
Figure 12
5

Step
6
Installing the Seat
Parts needed for this step:
1
Seat
4
Flange nuts
Procedure
1. R emo v e the seat from the crate .
2. P osition the seat into the holes in the seat
frame ( Figure 13 ).
Figure 13
3. Secure the seat with 4 flang e n uts ( Figure 13 ).
4. If needed, attac h the tw o connectors onto the
seat switc h ( Figure 14 ).
Figure 14
Step
7
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 .
6

Figure 15
Step
8
Installing the Air Cleaner onKohler Engines
Parts needed for this step:
1
Air cleaner
1
Hose Clamp
Procedure
Note: If the mac hine y ou are setting up does not
ha v e a K ohler engine , skip this procedure .
1. R emo v e the air cleaner from the crate , k ee ping
the brac k et tog ether with it.
2. R emo v e the top 2 v alv e co v er mounting bolts
from both v alv e co v ers ( Figure 16 ).
Figure 16
3. R emo v e the plastic plugs ( Figure 17 ).
Figure 17
4. Align the holes in the air cleaner brac k et with
holes in the v alv e co v ers ( Figure 18 ).
Figure 18
5. Secure the brac k et and v alv e co v ers with the 4
bolts remo v ed previously ( Figure 18 ).
6. T or que the bolts to 70 in-lb (5 N ⋅m).
7. Install the air cleaner hose o v er the air intak e
elbo w on the engine and secure it with a hose
clamp ( Figure 18 ).
7

Step
9
Installing the Air Cleaner onKawasaki Engines
Parts needed for this step:
1
Air cleaner
1
Hose Clamp
4
Screws
1
Front engine cover
Procedure
Note: If the mac hine y ou are setting up does not
ha v e a K a w asaki engine , skip this procedure .
1. R emo v e the air cleaner from the crate , k ee ping
the brac k et tog ether with the air cleaner .
2. R emo v e the plug from the air intak e on the
engine .
Figure 19
3. R emo v e the hose from the air cleaner and
install it onto the air intak e on the engine . T his
will mak e it easier to install the hose when the
air cleaner is installed to the engine ( Figure 20
and Figure 22 ).
Figure 20
4. R emo v e the 2 bolts from the bac k of the
engine ( Figure 21 ).
5. R emo v e the 2 long bolts that r un through the
carburetor ( Figure 21 ).
Figure 21
6. Install the hose into the air cleaner base
( Figure 22 ).
Figure 22
8

7. Align the holes in the air cleaner brac k et with
holes in the v alv e co v ers ( Figure 24 ).
8. Install the long carburetor bolts into the
air cleaner base and into the carburetor
( Figure 23 ).
Figure 23
9. Install the hose clamp onto the hose and install
the hose to the air cleaner ( Figure 24 ).
10. Install the bolts into the bac k of the air cleaner
brac k et and into the motor ( Figure 24 ).
11. Tighten the hose clamp .
Figure 24
12. Install the front engine co v er with 4 screws .
Figure 25
Step
10
Checking the Spindles 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 on domestic mac hines
( Figure 26 ).
Figure 26
2. R emo v e the belt co v ers and bolts on
inter national mac hines ( Figure 27 ).
9

Figure 27
3. Chec k the tensioning ar m for g rease
( Figure 28 ).
4. Chec k the g rease for the three spindle bearings
( Figure 28 ). If needed, add g rease until it
comes out of the lo w er seals .
Figure 28
5. Install the belt co v ers .
Step
11
Checking the Side DischargeChute
No Parts Required
Procedure
If there are plastic ties holding the side disc harg e
c hute up , remo v e them and lo w er the c hute into
place .
An unco v er ed discharge opening could
allo w the la wn mo w er to thr o w objects in the
operator’ s or bystander’ s dir ection and r esult
in serious injur y or death. Also, contact with
the blade could occur .
Nev er operate the la wn mo w er with the
g rass deflector r emo v ed unless y ou install a
co v er plate, a mulch plate, or a g rass chute
and catcher .
1. Mak e sure the Lend of spring is installed
behind the dec k edg e before installing the bolt
as sho wn in Figure 29 .
2. Place the Jhook end of spring around g rass
deflector ( Figure 29 ).
Important: T he g rass deflector must be
fr ee to r otate with do wnw ard tension. Lift
the deflector up to the full open position
and ensur e that it r otates fr eel y ,without
binding into the full do wn position.
10

Figure 29
1. Grass Deector 4. Lend of spring, placebehind deck edge beforeinstalling bolt2. Spring
5. Deck edge3. Jhook end of spring
Step
12
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 the Engine Oil Lev el in the Operator’ s
Manual.
Step
13
Adding Fuel to the Machine
No Parts Required
Procedure
Add g asoline to the mac hine before star ting it.
R efer to y our Operator’ s Manual. for the cor rect fuel
and procedure .
11

Step
14
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 Manual
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.
On liquid cooled machines, check the level of the coolant in the radiator and overow bottle.
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:
12

Step
15
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 , Fill in the model and serial n umber and complete the items listed in the follo wing table
and initial eac h when finished.
Model No. Serial No.
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
•
Spark plug(s)
•
Engine oil lter
•
Engine oil drain
•
Fuel lters
•
Air lter
•
Radiator coolant (if applicable)
•
Hydraulic uid reservoir
•
Hydraulic lter
•
Battery
•
Ignition switch
•
Throttle lever
•
Choke (if applicable)
•
Power take off switch (PTO)
•
Motion control levers
•
Parking brake
•
Mower height-of-cut
•
Lift assist lever (if applicable)
13

Dealer Initial Customer Initial
Check Procedure
•
Z Stand® (if applicable)
•
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 ,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:
14