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