Toro Z Master Z597-D Manual

 2004—TheToro Company
8111 Lyndale Ave., Blomington, MN 55420, USA Printed in the USA
All Rights Reserved Original Instructions (EN)
Register your product at www.Toro.com
Z500 Series Z MasterDiesel Mowers
Form No. 3351–414 Rev A
Setup Instructions
Loose Parts
Use the chart below to verify all parts have been shipped.
Step Description Qty. Use
1No parts needed –Adding fuel to the machine
2No parts needed –Raising the machine up
3
Roll bar, right section
Roll bar, left section
Roll bar, center section
Bolt, 3/8 x 1 inch
Curved washer
Flange nut, 3/8 inch
Bolt, 1/2 x 3-1/4 inches
Flange nut, 1/2 inch
Lanyard
1
1
1
8
8
8
2
2
2
Installing the roll over protection system
(ROPS)
4Wheels 2 Installing the drive wheels
5No parts needed –Checking the tire pressure
6Control lever–right
Control lever–left
Bolt, 3/8 x 1 inch
Curved washer, 3/8 inch
1
1
4
4
Adjusting the motion control levers
7Bulk electrolyte with 1.265 specific gravity
(Purchase from a battery supply outlet.) 1 US Gallon Activating the battery for international machines only
8No parts needed –Charging the battery for international and
domestic machines
9Number 2 general purpose lithium base or
molybdenum base grease. (Purchase
separately.) 1 tube Greasing the bearings
10 No parts needed –Preparing the side discharge chute

2
Step UseQty.Description
11 No parts needed. –Checking the machine before delivery
12
Key
Operator’s Manual
Engine Owner’s Manual
Parts Catalog
Safety video
Registration card
2
1
1
1
1
1
Delivering the machine to the customer
Step
1
Adding Fuel to the Machine
Parts needed for this step:
None
Procedure
Note: Add fuel to the machine before starting it. Refer
to your Owners Operator manual for the correct fuel
and procedure.
Step
2
Raising the Machine Up
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–7425
3. Raise the back of the machine up and support it
with jack-stands.
m–7424

3
Step
3
Installing the Roll Over
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
Procedure
1. Loosely install the right and left roll bar sections
to the frame, with 8 bolts (3/8 x 1 inch), 8 curved
washers and 8 flange nuts (3/8 inch).
Note: The spring disk cone must be installed toward the
bolt head.
m–7369
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 install 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.
m–7431
6. Torque all lower
fasteners, attached to
the machine frame, to
30 ft–lb.
7. Tighten the center
roll bar bolts
(1/2 x 3-1/4 inches) so it
rotates freely with some
resistance.
Note: No more than one
thread should be
exposed outside the nut.
m–7432

4
8. Tighten the front
handles against the
center roll bar ends.
m–7406
Step
4
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
previously removed in
Step 1.
2. Torque the nuts to
95 ft-lb (128 N⋅m).
m–6859
Step
5
Checking the Tire Pressure
Parts needed for this step:
None
Procedure
1. Check the air
pressure in the front and
rear tires.
Pressure: 13 psi
(90 kPa)
2. Remove the jack
stands and lower the
machine. m–6873

5
Step
6
Adjusting the Motion
Control Levers
Parts needed for this step:
Qty. Part
1Control lever–right (assembled)
1Control lever–left (assembled)
4Bolt, 3/8 x 1 inch (assembled)
4Curved washer, 3/8 inch (assembled)
Procedure
1. Check the control
levers for the correct
alignment.
2. If adjustment is
needed, loosen the
4 bolts on the outside of
the levers.
Note: If desired, install
the levers in the top and
middle holes for the high
position or the middle
and bottom holes for the
low position.
m–6866
3. In the neutral position, raise the levers, bringing
them together, and slide them until they are aligned,
then tighten the bolts.
m–6867
m–6868

6
Step
7
Activating the Battery for
International Machines
Only
Parts needed for this step:
Qty. Part
80
ounces Bulk electrolyte with 1.265 specific gravity (Purchase from a battery supply outlet.)
Procedure
Danger
Battery electrolyte contains sulfuric acid which is
a deadly poison and causes 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 five to ten minutes, then add electrolyte, if
necessary, until the electrolyte level is up to the
upper line on the battery case.
5. Install battery filler
caps.
m–6852

7
Step
8
Charging the Battery for
International and Domestic
Machines
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.
Make sure the ignition switch is off.
Ventilate when charging or using the battery
in an enclosed space.
Important: Do not run the machine with the battery
disconnected; electrical damage may occur to the
engine computer.
1. Charge international
battery and then install it
on the machine. Refer to
the Operator’s Manual
for instructions.
m-4970
2. Charge the
domestic battery and
then install it on the
machine. Refer to the
Operator’s Manual for
instructions.
m–7509
Step
9
Checking the Spindles for
Grease
Parts needed for this step:
Qty. Part
1 tube Number 2 general purpose lithium base or
molybdenum base grease. (Purchase
separately.)
Procedure
Important: Check the cutting unit spindles to
make sure they are greased before starting the
engine.
1. Remove the belt covers on domestic machines as
shown below.
m–6824
2. Remove the belt covers and bolts on international
machines as shown below.
m–7418

8
3. Grease the fittings on the three spindle bearings.
Add grease until it comes out of the lower seals.
m–7420
4. Install the belt covers.
5. Grease the cooling fan belt idler arm.
6. Grease the drive belt idler arms.
m–7416
7. Grease the pump belt idler arm in the front of the
engine.
m–7512
Step
10
Preparing the Side
Discharge Chute
Parts needed for this step:
None
Procedure
Remove the plastic tie holding the side discharge
chute up and lower the chute into place.

9
Step
11
Checking the Machine Before Delivery 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.
Check ROPS is secure.
On liquid cooled machines, check the level of the coolant in the radiator.
Check the adjustment of the parking brake.
Ensure that the machine tracks correctly; refer to the Operator’s Manual for the adjustment procedure.
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.
When you finish setting up the machine, sign and date in the space provided below:
Signature: Date:

10
Step
12
Delivering the Machine to the Customer
Parts needed for this step:
Qty. Part
1 Operator’s Manual
1 Parts Catalog
1 Engine Owner’s Manual
1Registration card
1Safety video
2 Key
Procedure
At delivery, complete the items listed in the following table and initial each when finished.
Model Number: Serial Number:

11
Dealer
Initial Customer Initial Check Procedure
Show the customer where the following features are located and how they function:
•Fuel Tank Caps
•Oil Fill Tube/ Oil dipstick
•Oil Filter
•Oil Drain
•Fuel Filter
•Air Filter
•Radiator Coolant (Liquid Cooled Only)
•Hydraulic fluid reservoir
•Hydraulic filter
•Battery
•Ignition Switch
•Throttle Lever
•Glow plug light and Water in Fuel Light
•Power Take Off Switch (PTO)
•Motion Control Levers
•Parking Brake
•Mower Height–of–Cut Lever
•Lift Assist Lever
•Z Stand
•Adjustable Seat
•Hydraulic Bypass
•Rollover Protection System (ROPS)
•Flow Baffle
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 filling out and mailing the registration card or register 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: When you, the dealer representative, have finished delivering the machine to the customer, sign and date
in the space provided below and keep a copy of this page for dealer records:
Signature: Date:
Signature: Date:

12