Toro Z Master Z597-D Manual

 2004—TheToro Company

8111 Lyndale Ave., Blomington, MN 55420, USA Printed in the USA

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

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

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

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

Step UseQty.Description

11 No parts needed. –Checking the machine before delivery

Key

Operator’s Manual

Engine Owner’s Manual

Parts Catalog

Safety video

Registration card

Delivering the machine to the customer

Step

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

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

Step

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

8. Tighten the front

handles against the

center roll bar ends.

m–7406

Step

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

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

Step

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

Step

Activating the Battery for

International Machines

Only

Parts needed for this step:

Qty. Part

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

Step

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

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

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

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.

Step

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:

Step

Delivering the Machine to the Customer

Parts needed for this step:

Qty. Part

Operator’s Manual

Parts Catalog

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:

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