Installation Instructions

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 2003—The Toro Company

8111 Lyndale Ave., Blomington, MN 55420, USA

Printed in the USA

Original Instructions (EN)

Roll Over Protection System Kit

200 and 500 Series Z Masters

Part No. 107–0038

Form No. 3350-454

Installation Instructions

Note: This kit is used for replacing an existing ROPS or adding it to a machine without an existing ROPS.

Loose Parts

Note: Use the chart below to identify parts for assembly.

Step Description Qty. Use

No parts needed – Removing the drive wheels

Roll bar, right section

Roll bar, left section

Roll bar, center section

Bolt, 3/8 x 1 inch

Bolt, 3/8 x 1–1/2 inch

Curved washer, 3/8 inch

Flange nut, 3/8 inch

Locknut, 3/8 inch

Internal lock washer

Bolt, 1/2 x 3-1/4 inches

Flange nut, 1/2 inch

Lanyard

Installing the roll over protection system

(ROPS)

No parts needed – Installing the drive wheels

No parts needed – Removing the existing seat frame

Seat frame 1 Installing the new seat frame

Seat latch catch

Bolt, 5/16 x 3/4 inch

Locknut, 5/16 inch

Installing a seat latch catch on 500 Series

machines

Template 1

Drilling holes for a seat latch catch on 200

Series Machines

Seat latch catch

Side locknut, 5/16 inch

Serrated locknut, 5/16 inch

Installing a seat latch catch on 200 Series

machines

Seat belt

Bolt, 7/16 x 1 inch

Locknut, 7/16 inch

Installing the seat belt on a standard seat

Summary of content (12 pages)

PAGE 1
Form No. 3350-454 Roll Over Protection System Kit 200 and 500 Series Z Masters Part No. 107–0038 Installation Instructions Note: This kit is used for replacing an existing ROPS or adding it to a machine without an existing ROPS. Loose Parts Note: Use the chart below to identify parts for assembly. Step Description Qty.
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Step 10 11 Description Qty.
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Step Step 1 2 Removing the Drive Wheels Parts needed for this step: Installing the Roll Over Protection System (ROPS) Note: When installing the ROPS with a previously installed bagger, contact an Authorize Service Dealer for the correct procedure. None Procedure Parts needed for this step: 1. Loosen the wheel nuts or bolts on both sides of the machine. Qty.
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2. For an air cooled machine, loosen the two bottom bolts in the rear bumper. 4. Install the bolts in the order shown in the figure below. 5.
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7. Lightly oil the ends of the center roll bar section. m–6891 8. Loosely install the center roll bar section, using 2 bolts (1/2 x 3-1/4 inches) and 2 flange nuts (1/2 inch). 12. Tighten the front handles against the center roll bar ends. 13. Tighten the rear bumper bolts. 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. 9.
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Steps needed for a Deluxe Seat Step 1. Remove the two connectors from the seat switch. 4 2. Remove the cable ties from the seat frame. Removing the Existing Seat Frame Parts needed for this step: Qty. Part 1 Seat 4 Flange nuts (installed on the seat) Procedure Note: Standard seat is shown in the following two diagrams. m–6877 1. Remove the 2 bolts and 2 locknuts at the front of the seat where it is hinged. Save the hardware. 2. Remove the seat assembly from the machine. m–7021 m–7023 3.
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3. Install the seat retaining rod with the nut and bolt previously removed. Step 5 Note: Do not over tighten the nut and bolt to allow the retaining rod to pivot. Installing the New Seat Frame m–7108 Parts needed for this step: Qty. 1 4. If needed, attach the two connectors onto the seat switch. Part Seat frame Procedure Note: Standard seat shown only. 1. Install the seat to the new seat frame with the four locknuts previously removed. m–7022 m–6877 2.
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Step Step 6 7 Replacing a Seat Latch Catch on 500 Series Machines Drilling Holes for a Seat Latch Catch on 200 Series Machines Parts needed for this step: Parts needed for this step: Qty. Part 1 Seat latch catch 2 Bolt, 5/16 x 3/4 inches 2 Locknut, 5/16 inch Qty. 1 Part Template Procedure 1. Position the template, by locating it with the second existing hole from the right side of the frame. The existing hole is on the top of the frame. Procedure 1. Remove the existing latch catch. 2.
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2. Install the new seat latch catch and serrated locknuts to the frame with 2 side locknuts (5/16 inch). Torque the side locknuts to 33 ft–lb. Step 8 Installing the Seat Latch Catch for 200 Series Machines Parts needed for this step: Qty. Part 1 Seat latch catch 2 Side locknut, 5/16 inch 2 Serrated locknut, 5/16 inch m–7104 3. Ensure the seat latch catch is installed 5/8 inches (16 mm) from the frame as shown below. If it is not correct, adjust the nuts to achieve this dimension.
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Step Step 9 10 Installing the Seat Belt on a Standard Seat Installing the Seat Belt on a Deluxe Seat Parts needed for this step: Parts needed for this step: Qty. Part Qty. Part 1 Seat belt 1 Seat belt 2 Bolt, 7/16 x 1 inch 2 Bolt, 7/16 x 1 inch 2 Locknut, 7/16 inch 2 Washer, 7/16 inch Procedure Procedure 1. Install the receiver part of the seat belt between the cushion and the metal seat frame with 1 bolt (7/16 x 1 inch) and 1 locknut (7/16 inch). 1.
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Step 11 Installing the Decals Parts needed for this step: Qty. 1 Part Footrest decal Installing the Footrest Decal 1. Install the footrest decal onto the footrest as shown.
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