Toro Z500 Z Master, With 152cm TURBO FORCE Side Discharge Mower User manual

Form No. 3355-163 Rev A

Z500 Z Master, With 152cm

Turbo Force® Side Discharge

Mower

Model No. 74262TE —Serial No. 260000001 and Up

T his spark ignition system complies with Canadian

ICES-002

Introduction

R ead this infor mation carefully to lear n ho w to

operate and maintain y our product properly and

to a v oid injur y and product damag e . Y ou are

responsible for operating the product properly

and safely .

Y ou ma y contact T oro directly at www .T oro .com

for product and accessor y infor mation, help

ﬁnding a dealer , or to register y our product.

W henev er y ou need ser vice , g en uine T oro par ts ,

or additional infor mation, contact an A uthorized

Ser vice Dealer or T oro Customer Ser vice and ha v e

the model and serial n umbers of y our product

ready . Figure 1 identiﬁes the location of the model

and serial n umbers on the product. W rite the

n umbers in the space pro vided.

Figure 1

1. Model and serial number location

Model No.

Serial No.

T his man ual identiﬁes potential hazards and has

safety messag es identiﬁed b y the safety aler t

symbol ( Figure 2 ), whic h signals a hazard that ma y

cause serious injur y or death if y ou do not follo w

the recommended precautions .

Figure 2

1. Safety alert symbol

T his man ual uses 2 other w ords to highlight

infor mation. Impor tant calls attention to special

mec hanical infor mation and Note emphasizes

g eneral infor mation w or th y of special attention.

Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safe Operating Practices . . . . . . . . . . . . . . . . . . . . . . 4

T oro Riding Mo w er Safety . . . . . . . . . . . . . . . . . . . 5

Sound Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Sound P o w er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Slope Char t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Safety and Instr uctional Decals . . . . . . . . . . . . 8

Product Ov er view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Adding Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Chec king the Engine Oil Lev el . . . . . . . . . . . 16

Using the R ollo v er Protection

System (R OPS) . . . . . . . . . . . . . . . . . . 16

T hink Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Operating the P arking Brak e . . . . . . . . . . . . . . 18

Star ting and Stopping the

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Operating the P o w er T ak e Off

(PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

T he Safety Interloc k System . . . . . . . . . . . . . . . 20

Dri ving F orw ard or Bac kw ard . . . . . . . . . . . . 21

Stopping the Mac hine . . . . . . . . . . . . . . . . . . . . . . . . 22

Adjusting the Height-of-Cut . . . . . . . . . . . . . . 22

Adjusting the Anti-Scalp

R ollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Adjusting the Flo w Bafﬂe . . . . . . . . . . . . . . . . . . . 23

P ositioning the Flo w Bafﬂe . . . . . . . . . . . . . . . . 24

Using the Lift Assist Lev er . . . . . . . . . . . . . . . . . 25

P ositioning the Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Unlatc hing the Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Pushing the Mac hine b y Hand . . . . . . . . . . . . 25

Using the Side Disc harg e . . . . . . . . . . . . . . . . . . . 26

Breaking In a New Mac hine . . . . . . . . . . . . . . . 26

T ranspor ting Mac hines . . . . . . . . . . . . . . . . . . . . . . 26

8111 Lyndale Avenue South

Bloomington, MN 55420

Printed in the USA.

Loading Mac hines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Using the Z Stand® . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Operating Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

R ecommended Maintenance

Sc hedule(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Greasing and Lubrication . . . . . . . . . . . . . . . . . . . 31

Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Ser vicing the Air Cleaner . . . . . . . . . . . . . . . . . . . 33

Ser vicing the Engine Oil . . . . . . . . . . . . . . . . . . . . 34

Ser vicing the Spark Plugs . . . . . . . . . . . . . . . . . . . 35

Fuel System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 36

R e placing the Fuel Filter . . . . . . . . . . . . . . . . . . . . 36

Ser vicing the Fuel T ank . . . . . . . . . . . . . . . . . . . . . . 37

Electrical System Maintenance . . . . . . . . . . . . . . . . . . . 37

Ser vicing the Batter y . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Ser vicing the Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Dri v e System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 39

Adjusting the T rac king . . . . . . . . . . . . . . . . . . . . . . . 39

Chec king the Tire Pressure . . . . . . . . . . . . . . . . . 40

Chec king the W heel Hub Slotted

Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Adjusting the Caster Pi v ot

Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Cooling System Maintenance . . . . . . . . . . . . . . . . . . . . . 41

Cleaning the Engine Screen and the

Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . 41

Cleaning the Engine Fins . . . . . . . . . . . . . . . . . . . 41

Brak e Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Adjusting the P arking Brak e . . . . . . . . . . . . . . . 41

Belt Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Inspecting the Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

R e placing the Mo w er Belt . . . . . . . . . . . . . . . . . . 42

Adjusting the Mo w er Belt

T ension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

R e placing the Pump Dri v e

Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Controls System Maintenance . . . . . . . . . . . . . . . . . . . . 45

Adjusting the Control Handle

Neutral P osition . . . . . . . . . . . . . . . . 45

Hy draulic System Maintenance . . . . . . . . . . . . . . . . . . 46

Chec king the Hy draulic Fluid . . . . . . . . . . . . . 46

R e placing the Hy draulic Filter and

Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Bleeding the Hy draulic System . . . . . . . . . . . 48

Chec king the Hy draulic Hoses . . . . . . . . . . . 48

Setting the Hy draulic Pump

Neutral P osition . . . . . . . . . . . . . . . . 48

Mo w er Dec k Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 50

Lev eling the Mo w er at T hree

P ositions . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Ser vicing the Cutting Blades . . . . . . . . . . . . . . . 52

R e placing the Grass Deﬂector . . . . . . . . . . . . 54

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Cleaning Under the Mo w er . . . . . . . . . . . . . . . . 55

W aste Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Storag e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

T roubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Sc hematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Safety

T his mac hine meets or ex ceeds European

Standards in effect at the time of production.

Ho w ev er , improper use or maintenance b y the

operator or o wner can result in injur y . T o reduce

the potential for injur y , comply with these safety

instr uctions and alw a ys pa y attention to the

safety aler t symbol, whic h means CA UTION ,

W ARNING , or D ANGER-"personal safety

instr uction." F ailure to comply with the instr uction

ma y result in personal injur y or death.

Safe Operating Practices

T he follo wing instr uctions are from the CEN

standard EN 836:1997.

T his product is capable of amputating hands and

feet and thro wing objects . Alw a ys follo w all safety

instr uctions to a v oid serious injur y or death.

Training

• R ead the instr uctions carefully . Be familiar

with the controls and the proper use of the

equipment.

• Nev er allo w c hildren or people unfamiliar with

these instr uctions to use the la wnmo w er . Local

regulations can restrict the ag e of the operator .

• Nev er mo w while people , especially c hildren,

or pets are nearb y .

• K ee p in mind that the operator or user is

responsible for accidents or hazards occur ring

to other people or their proper ty .

• Do not car r y passeng ers .

• All dri v ers should seek and obtain professional

and practical instr uction. Suc h instr uction

should emphasize:

– the need for care and concentration when

w orking with ride-on mac hines;

– control of a ride-on mac hine sliding on a

slope will not be reg ained b y the application

of the control lev ers . T he main reasons for

loss of control are:

◊ insufﬁcient wheel g rip , especially on

w et g rass;

◊ being dri v en too fast;

◊ inadequate braking;

◊ the type of mac hine is unsuitable for its

task;

◊ lac k of a w areness of the effect of

g round conditions , especially slopes;

◊ incor rect hitc hing and load distribution.

Preparation

• W hile mo wing, alw a ys w ear substantial

footw ear and long trousers . Do not operate

the equipment when barefoot or w earing open

sandals .

• T horoughly inspect the area where the

equipment is to be used and remo v e all objects

whic h ma y be thro wn b y the mac hine .

• W ar ning –Fuel is highly ﬂammable .

– Store fuel in containers speciﬁcally designed

for this pur pose .

– R efuel outdoors only and do not smok e

while refuelling .

– Add fuel before star ting the engine . Nev er

remo v e the cap of the fuel tank or add fuel

while the engine is r unning or when the

engine is hot.

– If fuel is spilled, do not attempt to star t the

engine but mo v e the mac hine a w a y from

the area of spillag e and a v oid creating any

source of ignition until fuel v apors ha v e

dissipated.

– R e place all fuel tanks and container caps

securely .

• R e place faulty silencers .

• Before using, alw a ys visually inspect to see that

the blades , blade bolts and cutter assembly

are not w or n or damag ed. R e place w or n or

damag ed blades and bolts in sets to preser v e

balance .

• On m ulti-bladed mac hines , tak e care as rotating

one blade can cause other blades to rotate .

Operation

• Be aler t, slo w do wn and use caution when

making tur ns . Look behind and to the side

before c hanging directions .

• Do not operate the engine in a conﬁned space

where dang erous carbon mono xide fumes can

collect.

• Mo w only in da ylight or in g ood ar tiﬁcial light.

• Before attempting to star t the engine ,

diseng ag e all blade attac hment clutc hes and

shift into neutral.

• Do not use on slopes g reater than 15 deg rees .

• R emember there is no suc h thing as a safe

slope . T ra v el on g rass slopes requires par ticular

care . T o guard ag ainst o v er tur ning:

– - do not stop or star t suddenly when on

a slope;

– - use slo w speeds on slopes and during

tight tur ns;

– - sta y aler t for humps and hollo ws and

other hidden hazards;

• Use care when pulling loads or using hea vy

equipment.

– - Use only appro v ed dra wbar hitc h points .

– - Limit loads to those y ou can safely

control.

– - Do not tur n shar ply . Use care when

rev ersing .

• W atc h out for trafﬁc when crossing or near

roadw a ys .

• Stop the blades rotating before crossing

surfaces other than g rass .

• W hen using any attac hments , nev er direct

disc harg e of material to w ard b ystanders

nor allo w any one near the mac hine while in

operation.

• Nev er operate the mac hine with damag ed

guards or without safety protecti v e devices in

place .

• Do not c hang e the engine g o v er nor settings or

o v erspeed the engine . Operating the engine

at ex cessi v e speed can increase the hazard of

personal injur y .

• Before lea ving the operator’ s position:

– diseng ag e the po w er tak e-off and lo w er the

attac hments;

– c hang e into neutral and set the parking

brak e;

– stop the engine and remo v e the k ey .

• Diseng ag e dri v e to attac hments , stop the

engine , and disconnect the spark plug wire(s)

or remo v e the ignition k ey

– before clearing bloc kag es or unclog ging

c hute;

– before c hec king, cleaning or w orking on

the la wnmo w er;

– after striking a foreign object. Inspect

the la wnmo w er for damag e and mak e

re pairs before restar ting and operating the

equipment; if the mac hine star ts to vibrate

abnor mally (c hec k immediately).

• Diseng ag e dri v e to attac hments when

transpor ting or not in use .

• Stop the engine and diseng ag e dri v e to

attac hment

– before refuelling;

– before remo ving the g rass catc her;

– before making height adjustment unless

adjustment can be made from the operator’ s

position.

• R educe the throttle setting during engine

r un-out and, if the engine is pro vided with

a shut-off v alv e , tur n the fuel off at the

conclusion of mo wing .

Maintenance and Storage

• K ee p all n uts , bolts and screws tight to be sure

the equipment is in safe w orking condition.

• Nev er store the equipment with fuel in the

tank inside a building where fumes can reac h

an open ﬂame or spark.

• Allo w the engine to cool before storing in any

enclosure .

• T o reduce the ﬁre hazard, k ee p the engine ,

silencer , batter y compar tment and fuel storag e

area free of g rass , lea v es , or ex cessi v e g rease .

• Chec k the g rass catc her frequently for w ear or

deterioration.

• R e place w or n or damag ed par ts for safety .

• If the fuel tank has to be drained, this should

be done outdoors .

• On m ulti-bladed mac hines , tak e care as rotating

one blade can cause other blades to rotate .

• W hen mac hine is to be park ed, stored or left

unattended, lo w er the cutting means unless a

positi v e mec hanical loc k is used.

Toro Riding Mower Safety

T he follo wing list contains safety infor mation

speciﬁc to T oro products or other safety

infor mation that y ou m ust kno w that is not

included in the CEN standard.

• Engine exhaust contains carbon mono xide ,

whic h is an odorless , deadly poison that can

kill y ou. Do not r un engine indoors or in an

enclosed area.

• K ee p hands , feet, hair and loose clothing a w a y

from attac hment disc harg e area, underside of

mo w er and any mo ving par ts while engine is

r unning .

• Do not touc h equipment or attac hment par ts

whic h ma y be hot from operation. Allo w to

cool before attempting to maintain, adjust, or

ser vice .

• Batter y acid is poisonous and can cause bur ns .

A v oid contact with skin, eyes and clothing .

Protect y our face , eyes , and clothing when

w orking with a batter y .

• Batter y g ases can explode . K ee p cig arettes ,

sparks and ﬂames a w a y from batter y .

• Use only g en uine T oro re placement par ts to

ensure that original standards are maintained.

• Use only T oro-appro v ed attac hments .

W ar ranty ma y be v oided if used with

unappro v ed attac hments .

Slope Operation

• Do not mo w slopes g reater than 15 deg rees .

• Do not mo w near drop-offs , ditc hes , stee p

banks or w ater . W heels dropping o v er edg es

can cause rollo v ers , whic h ma y result in serious

injur y , death or dro wning .

• Do not mo w slopes when g rass is w et. Slipper y

conditions reduce traction and could cause

sliding and loss of control.

• Do not mak e sudden tur ns or rapid speed

c hang es .

• Use a w alk behind mo w er and/or a hand

trimmer near drop-offs , ditc hes , stee p banks

or w ater .

• R educe speed and use extreme caution on

slopes .

• R emo v e or mark obstacles suc h as roc ks , tree

limbs , etc . from the mo wing area. T all g rass

can hide obstacles .

• W atc h for ditc hes , holes , roc ks , dips , and rises

that c hang e the operating angle , as rough

ter rain could o v er tur n the mac hine .

• A v oid sudden star ts when mo wing uphill

because the mo w er ma y tip bac kw ards .

• Be a w are that loss of traction ma y occur g oing

do wnhill. W eight transfer to the front wheels

ma y cause dri v e wheels to slip and cause loss

of braking and steering .

• Alw a ys a v oid sudden star ting or stopping on

a slope . If tires lose traction, diseng ag e the

blades and proceed slo wly off the slope .

• F ollo w the man ufacturer’ s recommendations

for wheel w eights or counterw eights to

impro v e stability .

• Use extreme care with g rass catc hers or other

attac hments . T hese can c hang e the stability of

the mac hine and cause loss of control.

Sound Pressure

T his unit has a maxim um sound pressure lev el

at the operator’ s ear of 90 dB A, based on

measurements of identical mac hines per EN 11094

and EN 836.

Sound Power

T his unit has a guaranteed sound po w er lev el of

105 dB A, based on measurements of identical

mac hines per EN 11094.

Vibration

T his unit does not ex ceed a hand/ar m vibration

lev el of 2.15 m/s

, based on measurements

of identical mac hines per EN 1033. T his unit

does not ex ceed a whole body vibration lev el of

0.08 m/s

, based on measurements of identical

mac hines per EN 1032.

Slope Chart

Safety and Instructional

Decals

Safety decals and instr uctions are easily visible to the operator and are located near any

area of potential dang er . R e place any decal that is damag ed or lost.

1-643339

58-6520

1. Grease

93-7010

1. Thrown object hazard—

2. Thrown object hazard, mower—keep the deector in place.

3. Cutting/dismemberment of hand or foot—stay away from

moving parts.

93-7818

1. Warning—read the Operator’s Manual for instructions on

torquing the blade bolt/nut to 115-149 N•m (85-110 ft-lb).

93-7824

1. Thrown object hazard—stay a safe distance from the

machine.

2. Thrown object hazard, mower—keep the deector in place.

3. Cutting/dismemberment of hand or foot—stay away from

moving parts.

98-1977

1. Entanglement hazard, belt—stay away from moving parts.

98-4387

1. Warning—wear hearing protection.

99-8939

1. Read the Operator’s

Manual .

3. Remove the ignition key

and read the instructions

before servicing or

performing maintenance.

2. Height of cut

105-7797

107-1866

1. Sliding and loss of control hazard and tipping hazard,

drop-offs—do not operate the machine near drop-offs,

slopes greater than 15 degrees, or water; keep a safe

distance from drop-offs; do not turn sharply while traveling

fast, instead, slow down and turn gradually; if the roll bar is

raised, wear the seat belt; if the roll bar is lowered, do not

wear the seat belt.

107-2131

1. Hydraulic oil level 2. Warning—do not touch the

hot surface.

107-3069

1. Warning—there is no rollover protection when the roll bar is

down.

2. To avoid injury or death from a rollover accident, keep the

roll bar in the raised and locked position and wear the seat

belt. Lower the roll bar only when absolutely necessary; do

not wear the seat belt when the roll bar is down.

3. Read the Operator’s Manual ; drive slowly and carefully.

107-3961

1. Height of cut in millimeters

107-3962

1. Height of cut in millimeters

107-3963

1. Cutting/dismemberment

hazard, mower blade—do

not carry passengers and

keep bystanders away.

2. Cutting/dismemberment

hazard of hand or foot,

mower blade—remove the

ignition key and read the

instructions before servicing

or performing maintenance;

stay away from moving

parts.

3. Thrown object hazard—keep

bystanders a safe distance

from the machine and keep

the deector in place.

4. Before starting the engine,

clean grass and debris from

the mower belt and pulleys,

insert the ignition key, and

start the engine.

107-3964

1. Warning—do not use drugs or alcohol. 3. Warning—engage the parking brake,

stop the engine, and remove the

ignition key before leaving the machine.

5. Read the Operator’s Manual .

2. Warning—read the Operator’s Manual

and receive training.

4. Warning—wear hearing protection.

107-3968

1. Disengage

3. Parking brake

2. Engage

107-3969

1. Warning—read the Operator’s Manual .

2. Crushing hazard, mower—engage the parking brake, stop

the engine, and remove the ignition key before working

under the mower.

107-3978

1. Cutting/dismemberment hazard, fan and entanglement

hazard, belt—stay away from moving parts.

2. Before starting the engine, clean grass and debris from the

mower belt and pulleys, insert the ignition key, and start

the engine.

107-3982

1. Operator’s Manual location

107-3984

1. Read the instructions before

servicing or performing

maintenance.

4. Grease

2. Hourly interval

5. Tire pressure

3. Engine

6. Hydraulic oil level

107-3993

1. Short, sparse grass and dry

conditions.

3. Long, thick grass and wet

conditions.

2. Bagging

107-3996

1. Engine

2. Cutting blade

Battery Symbols

Some or all of these symbols are on your battery

1. Explosion hazard 6. Keep bystanders a safe

distance from the battery.

2. No re, open ame, or

smoking.

7. Wear eye protection;

explosive gases can cause

blindness and other injuries

3. Caustic liquid/chemical

burn hazard

8. Battery acid can cause

blindness or severe burns.

4. Wear eye protection

9. Flush eyes immediately

with water and get medical

help fast.

5. Read the Operator’s

Manual.

10. Contains lead; do not

discard.

Manufacturer’s Mark

1. Indicates the blade is identied as a part from the original

machine manufacturer.

108-5278

1. Read the Operator’s Manual .

110-5721

1. Engine—stop

5. Fast

2. Engine—run

6. Continuous variable setting

3. Engine—start

7. Slow

4. Power take-off (PTO)

8. Choke

107-8077

1. Fast

3. Neutral 5. Warning-read— the

Operator’s Manual.

7. Explosion hazard—no re,

open ames, or smoking;

avoid sparks.

2. Slow

4. Reverse

6. Poison and caustic

liquid/chemical burn

hazard—keep children a

safe distance from the

battery.

8. To unlock the traction

drive, turn the by-pass

valve 1 complete revolution

counterclockwise using a

5/8 inch or 16 mm wrench.

Product Overview

Figure 3

1. Motion control lever 5. Controls

2. Parking brake lever 6. Seat belt

3. Height-of-cut lever 7. Roll bar

4. Fuel cap (both sides)

Controls

Become familiar with all the controls before y ou

star t the engine and operate the mac hine ( Figure 3

and Figure 4 ).

Figure 4

1. Ignition switch

4. Power take off (PTO)

2. Throttle

5. Hour meter

3. Choke

6. Gas cap

Hour Meter

T he hour meter records the n umber of hours the

engine has operated. It operates when the engine

is r unning . Use these times for sc heduling regular

maintenance ( Figure 4 ).

Operation

Note: Deter mine the left and right sides of the

mac hine from the nor mal operating position.

Adding Fuel

Use Unleaded R egular Gasoline suitable for

automoti v e use (85 pump octane minim um).

Leaded regular g asoline ma y be used if unleaded

regular is not a v ailable .

Important: Nev er use methanol, gasoline

containing methanol, or gasohol containing

mor e than 10% ethanol because the fuel

system could be dama ged. Do not mix oil

with gasoline.

In cer tain conditions, gasoline is extr emel y

ﬂamma ble and highl y explosi v e. A ﬁr e or

explosion fr om gasoline can bur n y ou and

other s and can dama ge pr oper ty .

• Fill the fuel tank outdoor s, in an open

ar ea, when the engine is cold. W ipe up

an y gasoline that spills.

• Nev er ﬁll the fuel tank inside an enclosed

trailer .

• Do not ﬁll the fuel tank completel y full.

Add gasoline to the fuel tank until the

lev el is 1/4 to 1/2 inch (6 to 13 mm)

belo w the bottom of the ﬁller neck. T his

empty space in the tank allo ws gasoline

to expand.

• Nev er smok e when handling gasoline,

and stay a w ay fr om an open ﬂame or

wher e gasoline fumes may be ignited by

a spar k.

• Stor e gasoline in an appr o v ed container

and k eep it out of the r each of childr en.

Nev er buy mor e than a 30-day suppl y of

gasoline.

• Do not operate without entir e exhaust

system in place and in pr oper w or king

condition.

In cer tain conditions during fueling , static

electricity can be r eleased causing a spar k

which can ignite the gasoline v apor s. A ﬁr e

or explosion fr om gasoline can bur n y ou and

other s and can dama ge pr oper ty .

• Al w ays place gasoline container s on the

g r ound a w ay fr om y our v ehicle bef or e

ﬁlling .

• Do not ﬁll gasoline container s inside

a v ehicle or on a tr uck or trailer bed

because interior car pets or plastic tr uck

bed liner s may insulate the container and

slo w the loss of an y static charge.

• W hen practical, r emo v e gas-po w er ed

equipment fr om the tr uck or trailer and

r efuel the equipment with its wheels on

the g r ound.

• If this is not possible, then r efuel such

equipment on a tr uck or trailer fr om a

por ta ble container , rather than fr om a

gasoline dispenser nozzle.

• If a gasoline dispenser nozzle must be

used, k eep the nozzle in contact with the

rim of the fuel tank or container opening

at all times until fueling is complete.

Gasoline is har mful or f atal if s w allo w ed.

Long-ter m exposur e to v apor s can cause

serious injur y and illness.

• A v oid pr olonged br eathing of v apor s.

• K eep f ace a w ay fr om nozzle and gas tank

or conditioner opening .

• K eep gas a w ay fr om ey es and skin.

Using Stabilizer/Conditioner

Use a fuel stabilizer/conditioner in the mac hine to

pro vide the follo wing beneﬁts:

• K ee ps g asoline fresh during storag e of 90 da ys

or less . F or long er storag e it is recommended

that the fuel tank be drained.

• Cleans the engine while it r uns

• Eliminates gum-lik e v ar nish buildup in the fuel

system, whic h causes hard star ting

Important: Do not use fuel additi v es

containing methanol or ethanol.

Add the cor rect amount of g as

stabilizer/conditioner to the g as .

Note: A fuel stabilizer/conditioner is most

effecti v e when mix ed with fresh g asoline . T o

minimize the c hance of v ar nish de posits in the fuel

system, use fuel stabilizer at all times .

Filling the Fuel Tank

1. Shut the engine off and set the parking brak e .

2. Clean around eac h fuel tank cap and remo v e

the cap .

3. Add unleaded regular g asoline to both fuel

tanks , until the lev el is 1/4 to 1/2 inc h (6 mm

to 13 mm) belo w the bottom of the ﬁller nec k.

T his space in the tank allo ws g asoline to

expand. Do not ﬁll the fuel tanks completely

full.

4. Install fuel tank caps securely .

5. Wipe up any g asoline that ma y ha v e spilled.

Checking the Engine Oil

Level

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 Oil Lev el in Engine Maintenance ,

pag e 33

Using the Rollover

Protection System (ROPS)

T o a v oid injur y or death fr om r ollo v er : k eep

the r oll bar in the raised lock ed position and

use the seat belt.

Ensur e that the r ear par t of the seat is

secur ed with the seat latch.

T her e is no r ollo v er pr otection when the r oll

bar is in the do wn position.

• Lo w er the r oll bar onl y when a bsolutel y

necessar y .

• Do not w ear the seat belt when the r oll

bar is in the do wn position.

• Dri v e slo wl y and car efull y .

• R aise the r oll bar as soon as clearance

per mits.

• Check car efull y f or o v erhead clearances

(i.e. branches, doorw ays, electrical wir es)

bef or e dri ving under an y objects and do

not contact them.

Important: Lo w er the r oll bar onl y when

a bsolutel y necessar y .

1. T o lo w er the roll bar , loosen the front knobs

( Figure 7 ).

2. R emo v e the hair pin cotter pins and remo v e the

tw o pins ( Figure 6 ).

3. Lo w er the roll bar to the do wn position. T here

are tw o do wn positions . See Figure 5 for the

positions .

4. Install the tw o pins and secure them with the

hair pin cotter pins ( Figure 6 ).

Figure 5

1. Full down position 2. Down position with bagger

installed

Important: Ensur e that the r ear par t of

the seat is secur ed with the seat latch.

5. T o raise the roll bar , remo v e the hair pin cotter

pins and remo v e the tw o pins ( Figure 6 ).

6. Raise the roll bar to the upright position and

install the tw o pins and secure them with the

hair pin cotter pins ( Figure 6 ).

Important: Al w ays use the seat belt with

the r oll bar in the raised position.

Figure 6

1. Roll bar

3. Pin

2. Raised position

4. Hairpin cotter pin

Important: Tighten the fr ont knobs

a gainst the center r oll bar ends ( Figur e 7 ).

Figure 7

1. Front handle

Think Safety First

Please read all safety instr uctions and symbols

in the safety section. Kno wing this infor mation

could help y ou or b ystanders a v oid injur y .

Operating on w et g rass or steep slopes can

cause sliding and loss of contr ol.

W heels dr opping o v er edges can cause

r ollo v er s, which may r esult in serious injur y ,

death or dr o wning .

T her e is no r ollo v er pr otection when the r oll

bar is do wn.

Al w ays k eep the r oll bar in the raised and

lock ed position and use the seat belt.

R ead and f ollo w the r ollo v er pr otection

instr uctions and w ar nings.

T o a v oid loss of contr ol and possibility of

r ollo v er :

• Do not operate near dr op-of fs or near

w ater .

• Do not operate on slopes g r eater than

15 deg r ees.

• R educe speed and use extr eme caution

on slopes.

• A v oid sudden tur ns or rapid speed

changes.

Figure 8

1. Safe Zone-use the Z Master

here on slopes less than

15 degrees or at areas.

3. Water

2. Use walk behind mower

and/or hand trimmer near

drop-offs and water.

T his machine pr oduces sound lev els in

ex cess of 85 dB A at the operator s ear and

can cause hearing loss thr ough extended

periods of exposur e.

W ear hearing pr otection when operating

this machine.

W ear protecti v e equipment for y our eyes , ears ,

feet, and head when using this mac hine .

Figure 9

1. Warning— wear hearing protection

Operating the Parking

Brake

Alw a ys set the parking brak e when y ou stop the

mac hine or lea v e it unattended.

Setting the Parking Brake

1. Mo v e the motion control lev ers ( Figure 16 ) out

to the neutral loc k position.

2. Pull up and bac k on the parking brak e lev er to

set the parking brak e ( Figure 10 ). T he parking

brak e lev er should sta y ﬁr mly in the eng ag ed

position.

P ar king brak e may not hold machine

par k ed on a slope and could cause

per sonal injur y or pr oper ty dama ge.

Do not par k on slopes unless wheels ar e

chock ed or block ed

Releasing the Parking Brake

Push forw ard and do wn on the parking brak e

lev er to release the parking brak e ( Figure 10 ). T he

parking brak e is diseng ag ed and the lev er will rest

ag ainst the brak e stop .

Figure 10

1. Parking brake-ON 3. Brake Stop

2. Parking brake-OFF

Starting and Stopping the

Engine

Starting the Engine

1. Sit on the seat and mo v e the motion controls

to neutral loc k ed position.

2. Set the parking brak e; refer to Setting the

P arking Brak e .

3. Mo v e the PTO (po w er tak e off) switc h to the

Off position ( Figure 11 ).

Figure 11

1. PTO—on

2. PTO—off

4. Mo v e the c hok e control to the on position

before star ting a cold engine ( Figure 12 ).

Note: A w ar m or hot engine ma y not require

c hoking . After engine star ts , mo v e c hok e

control to R un position.

Figure 12

1. Choke—on 2. Choke—off

5. Mo v e the throttle control to the F ast position

before star ting a cold engine ( Figure 13 ).

Figure 13

1. Throttle—fast 2. Throttle—slow

6. T ur n the ignition k ey to Star t ( Figure 14 ).

W hen the engines star ts , release the k ey .

Important: Do not enga ge star ter f or

mor e than 10 seconds at a time. If engine

f ails to star t allo w 30 second cool-do wn

period betw een attempts. F ailur e to f ollo w

these instr uctions can bur n out star ter

motor .

Figure 14

1. Off

3. Start

2. Run

7. After the engine star ts , mo v e the c hok e to off

( Figure 12 ). If the engine stalls or hesitates ,

mo v e the c hok e bac k to on for a few seconds ,

then mo v e the throttle lev er to desired setting .

R e peat this as required.

Stopping the Engine

1. Push the PTO to the off position ( Figure 11 ).

2. Mo v e the throttle lev er midw a y betw een the

slo w and fast positions ( Figure 13 ).

3. Let the engine idle for 60 seconds .

4. T ur n the ignition k ey to the off position and

remo v e the k ey ( Figure 14 ).

5. Close the fuel shut off v alv e before

transpor ting or storing the mac hine . R efer to

Fuel System Maintenance , pag e 36 .

Important: Mak e sur e that the fuel

shut of f v alv e is closed bef or e transpor ting

or storing the machine, as fuel leaka ge

may occur . Set the par king brak e bef or e

transpor ting . Mak e sur e to r emo v e the k ey

as the fuel pump may r un and cause the

batter y to lose charge.

Childr en or bystander s may be injur ed

if they mo v e or attempt to operate the

tractor while it is unattended.

Al w ays r emo v e the ignition k ey and

set the par king brak e when lea ving the

machine unattended, ev en if just f or a

few min utes.

Operating the Power Take

Off (PTO)

T he po w er tak e off (PTO) switc h star ts and stops

the mo w er blades and any po w ered attac hments .

Engaging the PTO

1. If the engine is cold, allo w the engine to w ar m

up 5 to 10 min utes before eng aging the PTO .

2. W hile seated in the seat, release the pressure on

the traction control lev ers and place in neutral.

3. Place the throttle in the fast position.

Note: Eng aging the PTO with the throttle

at the half or less position will cause ex cessi v e

w ear to the dri v e belts .

4. Pull out on the po w er tak e off (PTO) switc h to

eng ag e it ( Figure 15 ).

Figure 15

1. PTO-On

2. PTO-Off

Disengaging the PTO

T o diseng ag e , push the PTO switc h to the of f

position ( Figure 15 ).

The Safety Interlock System

If safety inter lock s witches ar e disconnected

or dama ged the machine could operate

unexpectedl y causing per sonal injur y .

• Do not tamper with the inter lock

s witches.

• Check the operation of the inter lock

s witches dail y and r eplace an y dama ged

s witches bef or e operating the machine.

Understanding the Safety Interlock

System

T he safety interloc k system is designed to prev ent

the engine from star ting unless:

• Y ou are sitting on the seat.

• T he parking brak e is eng ag ed.

• T he po w er tak e off (PTO) is diseng ag ed.

• T he motion control lev ers are in the neutral

loc k ed position

T he safety interloc k system also is designed to stop

the engine when the traction controls are mo v ed

from the loc k ed position with the parking brak e

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Toro Z500 Z Master, With 152cm TURBO FORCE Side Discharge Mower User manual

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