Toro Z500 Series Z Master Manual

 2003—The Toro 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 MasterrMowers
Form No. 3352–977
Setup Instructions
Loose Parts
Use the chart below to verify all parts have been shipped.
Note: Retain the bolts that hold the center rollbar to the packaging. These are used to install the center rollbar.
Step Description Qty. Use
1No parts needed –Raising the machine up
2
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
4
8
6
2
2
2
Installing the roll over protection system
(ROPS)
3Wheels 2 Installing the drive wheels
4No parts needed –Checking the tire pressure
5
Control lever–right
Control lever–left
Bolt, 3/8 x 1 inch
Curved washer, 3/8 inch
1
1
4
4
Installing the motion control levers
6Seat
Nuts (installed on the seat)
1
4Installing the seat
7Bulk electrolyte with 1.265 specific gravity
(Purchase from a battery supply outlet.)
80
Ounces Activating the battery
8Air cleaner
Hose clamp
1
1
Installing the air cleaner on Kohler
engines
9Air cleaner
Hose clamp
1
1
Installing the air cleaner on 25hp
Kawasakiengines
10 Number 2 general purpose lithium base or
molybdenum base grease. (Purchase
separately.)
1 tube Greasing the bearings
11 No parts needed –Preparing the side discharge chute

2
Step UseQty.Description
12 No parts needed. –Checking the machine before delivery
13
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
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–7793
3. Raise the back of the machine up and support it
with jack-stands.
m–7794
Step
2
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
2 Lanyard
Procedure
Note: If you are installing a DFS bagger while setting
up a machine, install the DFS bagger frame before
the ROPS.
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.

3
m–7795
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.
m–7431

4
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 8. Tighten the
front handles
against the
center roll bar
ends.
m–7406
Step
3
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

5
Step
4
Checking the Tire Pressure
Parts needed for this step:
None
Procedure
Check the air pressure
in the front and rear
tires.
Pressure: 13 psi
(90 kPa)
m–6873
Step
5
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 handles
to the upright position.
2. Loosely install the
levers on the outside,
using 4 bolts and curved
washers.
Note: Install the 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. In the neutral position, raise the levers, bringing
them together, and slide them until they are aligned,
then tighten the bolts.

6
m–8006
Step
6
Installing the Seat
Parts needed for this step:
Qty. Part
1 Seat
4Flange nuts (installed on the seat)
Procedure
1. Remove the seat
from the crate.
2. Remove the 4
flange nuts from the
studs on the bottom of
the seat.
3. Position the seat
into the holes in the seat
frame.
4. Secure the seat with
4 flange nuts.
m–6860
5. If needed, attach the two connectors onto the
seat switch.
m–6877

7
Step
7
Activating the Battery
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.
SDo 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.
SFill the battery where clean water is always
available for flushing the skin.
SFollow 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
6. Charge the battery and then install it on the
machine. Refer to the Operator’s Manual for
instructions.

8
Warning
Charging the battery produces gasses that can
explode and cause serious injury.
SKeep cigarettes, sparks and flames away from
the battery.
SMake sure the ignition switch is off.
SVentilate 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.
Important: Do not jump start an EFI machine, or you
may damage the electronic control unit.
Step
8
Installing the Air Cleaner
on Kohler Engines
Parts needed for this step:
Qty. Part
1Air cleaner
1Hose clamp
Procedure
1. Remove the air cleaner from the crate, keeping
the bracket together with it.
2. Remove the top 2
valve cover mounting
bolts from both valve
covers.
m–8003
3. Remove the plastic
plugs.
m–8004
4. Align the holes in
the air cleaner bracket
with holes in the valve
covers.
5. Secure the bracket
and valve covers with
the 4 bolts removed
previously.
6. Torque the bolts to
70 in-lb (5 N⋅m).
7. Install the air
cleaner hose over the
air intake elbow on the
engine and secure it
with a hose clamp.
m–8005

9
Step
9
Installing the Air Cleaner
on 25hp Kawasaki Engines
Parts needed for this step:
Qty. Part
1Air cleaner
1Hose clamp
Procedure
1. Remove the air cleaner from the crate, keeping
the bracket together with it.
2. Remove the 4
screws holding the front
plastic cover on the front
of the engine.
m–7292
3. Remove the plastic
plug.
m–7297
4. Remove the 2 bolts
from the back of the
engine.
5. Remove the 2 long
bolts that run through
the carborateur.
m–7293
6. Install the hose into
the air cleaner base.
m–7294
7. Align the holes in
the air cleaner bracket
with holes in the valve
covers.
8. Install the long
carburetor bolts into the
air cleaner base and into
the carburetor.
m–7295
9. Install the hose
clamp onto the hose and
install the hose to the air
cleaner.
10. Install the bolts into
the back of the air
cleaner bracket and into
the motor.
11. Tighten the hose
clamps.
m–7296

10
Step
10
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.
m–6824
2. Grease the fittings on the three spindle bearings.
Add grease until it comes out of the lower seals.
m–6822
3. Install the belt covers.
Step
11
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.

11
Step
12
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.
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:

12
Step
13
Delivering the Machine to the Customer
Parts needed for this step:
Qty. Part
1Operator’s Manual
1Parts Catalog
1Engine 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:

13
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
•Spark Plug(s)
•Air Filter
•Radiator Coolant (Liquid Cooled Only)
•Hydraulic fluid reservoir
•Hydraulic filter
•Battery
•Ignition Switch
•Throttle Lever
•Choke (Not on an EFI machine)
•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:

14

15

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