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

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

Install the seat.

No parts required

–

Charge the battery.

Air cleaner

Hose Clamp

Install the air cleaner (Models withKohler engines only).

Air cleaner

Hose Clamp

Screws

Front engine cover

Install the air cleaner (Models withKawasaki 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.

Step

Description

Qty.

Use

No parts required

–

Add fuel to the machine.

No parts required

–

Check the machine before deliveryto the customer.

Operator’s Manual

Parts Catalog

Engine Owner’s Manual

Registration Card

Safety Video

115

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

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

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).

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).

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

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

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 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

Step

Installing the Seat

Parts needed for this step:

Seat

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

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 15

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 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 ).

Step

Installing the Air Cleaner onKawasaki Engines

Parts needed for this step:

Air cleaner

Hose Clamp

Screws

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

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

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 ).

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

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.

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