Toro Z500 Series Z Master Handbuch

 2003—The Toro Company

8111 Lyndale Ave., Blomington, MN 55420, USA

Printed in the USA

Original Instructions (EN)

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

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)

3Wheels 2 Installing the drive wheels

4No parts needed –Checking the tire pressure

Control lever–right

Control lever–left

Bolt, 3/8 x 1 inch

Curved washer, 3/8 inch

Installing the motion control levers

6Seat

Nuts (installed on the seat)

4Installing the seat

7Bulk electrolyte with 1.265 specific gravity

(Purchase from a battery supply outlet.)

Ounces Activating the battery

8Air cleaner

Hose clamp

Installing the air cleaner on Kohler

engines

9Air cleaner

Hose clamp

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

Step UseQty.Description

12 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

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

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.

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

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

Check the air pressure

in the front and rear

tires.

Pressure: 13 psi

(90 kPa)

m–6873

Step

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.

m–8006

Step

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

Step

Activating the Battery

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.

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.

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

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

Step

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

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.

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

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.

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