Toro Z MASTER Z100 series Manual

 2003—TheToro Company

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

Z100 Series Z MasterMowers Form No. 3329-965

Setup Instructions

Loose Parts

Use steps 1 trough 12 in the following chart to verify all parts have been shipped and as a guide through the

setup.

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, 3/8 inch

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

5Seat

Nuts (installed on the seat) 1

4Installing the seat

6Control lever–right

Control lever–left

Bolt, 3/8 x 1 inch

Curved washer, 3/8 inch

Installing the motion control levers

7Bulk electrolyte with 1.265 specific gravity

(Purchase from a battery supply outlet.) 80

ounces Activating the battery

8Air cleaner cap

Hose clamp 1

1Installing the air cleaner cap

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

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–6918

3. Raise the back of the machine up and support it

with jack-stands.

m–6919

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

1. Loosely install the right and left roll bar sections

to the frame, using 8 bolts (3/8 x 1 inch), 8 curved

washers, and 8 flange nuts (3/8 inch).

m–6916

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–6892

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–6891

5. Raise the roll bar

into the upright position

and secure it with the

pins and hairpin cotter

pins fastened to the

lanyards.

6. Torque all lower

fasteners, attached to

the machine frame, to

30 ft–lb.

m–6893

7. Tighten the center

roll bar bolts

(1/2 x 3-1/4 inches) so

the roll bar rotates freely

with some resistance.

Note: No more than one

thread should be

exposed outside the nut.

m–6891

8. Tighten the front

handles against the

center roll bar ends.

m–683

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–6917

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 Seat

Parts needed for this step:

None

Procedure

1. Remove the bolt

and nut from the seat

frame.

2. Secure the seat rod

to the seat with the bolt

and nut.

m–571

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 of

the posts, 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–6867

m–6868

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.

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

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.

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.

Important: Do not jump start an EFI machine, or you

may damage the electronic control unit.

Step

Installing the Air Cleaner

Cap

Parts needed for this step:

Qty. Part

1Air cleaner cap

1Hose clamp

Procedure

1. Remove the plastic

plug. m–6912

2. Remove the air cleaner cap from the machine.

3. Install the hose

clamp onto the air

cleaner cap.

m–6914

4. Install the air

cleaner cap onto the air

cleaner and secure it

with the hose clamp.

m–6913

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.

2. Grease the fittings on the three spindle bearings.

m–5531

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.

On liquid cooled machines, check the level of the coolant.

Check the adjustment of the parking brake.

Ensure that the machine tracks (drives) correctly.

Check the safety interlock system.

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:

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