Toro Z Master Z500 Series Manual

Form No. 3354-559 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

No parts required

–

Remove parts from the crate.

No parts required

–

Check the tire pressure.

Rear wheels

Install the drive wheels.

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 inch)

Flange nut, (1/2 inch)

Install the Rollover ProtectionSystem (ROPS).

Control lever, right

Control lever, left

Bolt (3/8 x 1 inch) (2 assembled)

Curved washer (3/8 inch) (2assembled)

Install the motion control levers.

Seat

Flange nuts (installed on the seat)

Install the seat.

No parts required

–

Charge the battery.

Air cleaner

Hose Clamp

Install the air cleaner (Models withKohler engines only).

Number 2 general purpose lithiumbase or molybdenum base grease.(Purchase separately.)

1 tube Check the spindles for grease.

No parts required

–

Prepare the side discharge chute.

No parts required

–

Check the engine oil level.

No parts required

–

Add fuel to the machine.

No parts required

–

Check the machine before deliveryto the customer.

Step

Description

Qty.

Use

Operator’s Manual

Parts Catalog

Engine Owner’s Manual

Registration Card

Safety Video

114

Key 2

Delivering the machine to thecustomer.

Step

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

Checking the Tire Pressure

No Parts Required

Procedure

Chec k the air pressure in the front and rear tires .

Pressure: 13 psi (90 kP a)

Figure 1

Step

Raising the Machine Up andInstalling the Drive Wheels

Parts needed for this step:

Rear wheels

Procedure

1. R emo v e the screws holding the right angle

retaining plate to the crate ( Figure 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

Installing the Roll OverProtection System

Parts needed for this step:

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 inch)

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)

( Figure 6 ).

Note: T he cur v e w asher cone m ust be

installed to w ard the bolt head.

Figure 6

2. Install the lanyard clips onto the long bolts

(1/2 x 3-1/4 inc h) ( Figure 7 ).

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) ( Figure 8 ).

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 ).

Figure 9

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

( Figure 10 ).

Note: No more than one thread should be

exposed outside the n ut.

Figure 10

8. Tighten the front knobs ag ainst the center roll

bar ends ( Figure 11 ).

Figure 11

Step

Installing the MotionControl Levers

Parts needed for this step:

Control lever, right

Control lever, left

Bolt (3/8 x 1 inch) (2 assembled)

Curved washer (3/8 inch) (2 assembled)

Procedure

1. R otate the handles to the upright position

( Figure 12 ).

Figure 12

2. Loosely install the lev ers on the outside , using

4 bolts and cur v ed w ashers ( Figure 12 ).

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 13 ).

Figure 13

Step

Installing the Seat

Parts needed for this step:

Seat

Flange nuts (installed on the seat)

Procedure

1. R emo v e the seat from the crate .

2. R emo v e the 4 ﬂang e n uts from the studs on

the bottom of the seat.

3. P osition the seat into the holes in the seat

frame ( Figure 14 ).

Figure 14

4. Secure the seat with 4 ﬂang e n uts ( Figure 14 ).

5. If needed, attac h the tw o connectors onto the

seat switc h ( Figure 15 ).

Figure 15

Step

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 .

Figure 16

Step

Installing the Air Cleaner onKohler Engines

Parts needed for this step:

Air cleaner

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 17 ).

Figure 17

3. R emo v e the plastic plugs ( Figure 18 ).

Figure 18

4. Align the holes in the air cleaner brac k et with

holes in the v alv e co v ers ( Figure 19 ).

Figure 19

5. Secure the brac k et and v alv e co v ers with the 4

bolts remo v ed previously ( Figure 19 ).

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 19 ).

Step

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 20 ).

Figure 20

2. R emo v e the belt co v ers and bolts on

inter national mac hines ( Figure 21 ).

Figure 21

3. Chec k the tensioning ar m for g rease

( Figure 22 ).

4. Chec k the g rease for the three spindle bearings

( Figure 22 ). If needed, add g rease until it

comes out of the lo w er seals .

Figure 22

5. Install the belt co v ers .

Step

Preparing the SideDischarge Chute

No Parts Required

Procedure

R emo v e the plastic tie holding the side disc harg e

c hute up and lo w er the c hute into place .

Step

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

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 .

Step

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:

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