Toro Z Master G3 Parts list manual

FormNo.3362-716RevD
ZMaster®G3Mowers
forInternationalZMaster®G3Mowers
SetupInstructions
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
1Nopartsrequired–Removepartsfromthecrate.
2Nopartsrequired–Checkthetirepressure.
3Rearwheels2Installthedrivewheels.
4RolloverProtectionSystemKit(ROPS)1InstalltheRolloverProtectionSystem
(ROPS).
Seat1
Seatplate1
Flangenuts(3/8inch)8
5Spacers(3/8inch)4
Installtheseat(Modelsthathaveaxed
ornonipupseat).
Seat1
Flangenuts(3/8inch)4
Longspacers(deluxeseatsonly)2
6Shortspacers(deluxeseatsonly)4
Installtheseat(Modelsthathavea
TiltingorFlipUpSeat).
7Nopartsrequired–Checktheseatbelt.
Rightcontrollever1
Leftcontrollever1
Bolt(3/8x1inch)(2areassembled)4
8Nut(3/8inch)(2areassembled)4
Installthemotioncontrollevers.
Carriagebolt(3/8x1-1/2inches)1
9Flangelocknut(3/8inch)1Installtheliftassistpedal.
Aircleanercap1
10Hoseclamp1Installtheaircleanercap.
Clamp1
Wingnut(1/4inch)2
11Batteryholddown2
InstallaBattery(Modelnumbersthat
endwithCPonly)
12Nopartsrequired–Chargethebattery.
13Nopartsrequired–Checktheengineoillevel.
14Nopartsrequired–Addfueltothemachine.
15
Number2generalpurposelithiumbase
ormolybdenumbasegrease.(Purchase
separately.)
1tubeCheckthemachineforgrease.
16Nopartsrequired–Preparethesidedischargechute.
©2011—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.Toro.com.OriginalInstructions(EN)
PrintedintheUSA.
AllRightsReserved

ProcedureDescriptionQty.Use
17Nopartsrequired–Checkthemachinebeforedeliveryto
thecustomer.
Operator’sManual1
EngineOwner’sManual1
Operatortrainingmaterial1
18Key2
Deliveringthemachinetothecustomer.
1
RemovingPartsfromtheCrate
NoPartsRequired
Procedure
Removethetires,theseatandtheRolloverProtection
System(ROPS)Kitfromtheshippingcrate.
2
CheckingtheTirePressure
NoPartsRequired
Procedure
Pressure:13psi(90kPa)
Note:Thefrontcasterwheelisasemi-pneumatictire
anddoesnotneedtobechecked.
Checktheairpressureinthedrivetires.
Figure1
3
RaisingtheMachineUpand
InstallingtheDriveWheels
Partsneededforthisprocedure:
2Rearwheels
Procedure
1.Removethescrewsholdingtherightangleretaining
platetothecrate.
Figure2
2.Raisethebackofthemachineupandsupportitwith
jack-stands.
Figure3
2

3.Removethewheelnutsfrombothsidesofthe
vehicleandremovetherightangleretainingplate.
Discardthescrewsandretainingplate.
4.Mountthewheelswiththevalvestemtotheoutside
andsecurethemwiththewheelnutspreviously
removed.
5.Torquethewheelnutsto95ft-lb(128N·m).
6.Removethejack-stands.
Figure4
4
InstallingtheRollOver
ProtectionSystem
Partsneededforthisprocedure:
1RolloverProtectionSystemKit(ROPS)
Procedure
InstalltheRolloverProtectionSystemKit.Followthe
instructionsincludedwiththeROPSKit.
5
InstallingtheSeat(Models
thathaveaxedornonipup
seat)
Partsneededforthisprocedure:
1Seat
1Seatplate
8Flangenuts(3/8inch)
4Spacers(3/8inch)
Procedure
1.Removethehydraulicunitshroudfromthemachine.
Figure5
1.Hydraulicunitshroud2.Bolts
2.Removethe4nutsholdingtheseatplatetothe
machine.Discardthesenuts,theyareusedfor
shippingonly.
3

Figure6
3.Securetheseatplatetotheseatwith4spacersand
4angenuts(3/8inch).
Figure7
4.Plugtheharnessconnectorintotheseatswitch
locatedundertheseattowardsthefront.
5.Installtheseattothemachineframewith4ange
nuts(3/8inch).
Figure8
1.Harnessconnector2.Flangenuts
6
InstallingtheSeat(Modelsthat
haveatiltingoripupseat)
Partsneededforthisprocedure:
1Seat
4Flangenuts(3/8inch)
2Longspacers(deluxeseatsonly)
4Shortspacers(deluxeseatsonly)
Procedure
1.Tilttheseatframeup.
2.Fordeluxeseatsonly,installthespacersasshown
inFigure9.
4

Figure9
Formowerswithadeluxeseatonly
1.Deluxeseat3.Seatframe
2.Longspacer4.Shortspacers
3.Installtheseattotheseatframewith4angenuts
(3/8inch)(Figure10).
4.Plugtheharnessconnectorintotheseatswitch
locatedundertheseattowardsthefront.
Figure10
1.Seatswitch3.Harnessconnector
2.Flangenuts
7
CheckingtheSeatBelt
NoPartsRequired
Procedure
Important:Ensurethebolttorqueissetbetween
49to61ft-lb(67to83N-m).
Theseatbeltangleandtheseatbeltbolttorqueneedto
becheckedbeforeoperating.
1.Checktheangleoftheseatbeltcomparedtothe
bottomoftheseat.Theangleneedstobe47
degrees.See(Figure11)
2.Ifneeded,settheseatbelttothecorrectangle.
3.Checkandsetthebolttorquebetween49to61ft-lb
(67to83N-m).
3
2
1
g014862
Figure11
1.Sideofseat3.47degrees
2.Seatbeltbolt,Settorque
between49to61ft-lb(67
to83N-m)
5

8
InstallingtheMotionControl
Levers
Partsneededforthisprocedure:
1Rightcontrollever
1Leftcontrollever
4Bolt(3/8x1inch)(2areassembled)
4Nut(3/8inch)(2areassembled)
Procedure
1.Rotatethemotioncontrolleverstotheupright
position.
2.Looselyinstallthecontrolleversontheoutsideof
theposts,using4boltsand4nuts.
Note:Installthecontrolleversinthetopand
middleholesforthehighpositionorthemiddleand
bottomholesforthelowposition,asdesired.
Figure12
1.Bolt(3/8x1inch)3.Controllever
2.Handle4.Nut(3/8inch)
3.Raisetheleversandalignthemtogetherinthe
neutralpositionandtightenthebolts.
Figure13
Note:Ifthemachineisnotproperlytracking,refer
toAdjustingtheTrackinginyourOperator’sManual.
9
InstallingtheLiftAssistPedal
Partsneededforthisprocedure:
1Carriagebolt(3/8x1-1/2inches)
1Flangelocknut(3/8inch)
Procedure
1.Ifneeded,loosentheexistingboltandnutforthe
liftassistpedal.
2.Rotatetheliftassistpedaltothecorrectposition
andinstallthecarriagebolt(3/8x1-1/2inches)and
locknut(3/8inch)(Figure14).Tightenbothbolts.
6

1 2
3g016346
Figure14
1.Liftassistpedal3.Carriagebolt(3/8x1-1/2
inches)
2.Flangelocknut(3/8inch)
10
InstallingtheAirCleanerCap
Partsneededforthisprocedure:
1Aircleanercap
1Hoseclamp
Procedure
Note:Notallunitscomewithaheavydutyaircleaner.
Thisprocedureonlyappliestomodelsthathaveaheavy
dutyaircleaner.
1.Removetheplasticplugortapecoveringtheair
cleaner.
Figure15
2.Removetheaircleanercapfromthemachine.
3.Installthehoseclampontotheaircleanercap.
Figure16
4.Installtheaircleanercapontotheaircleanerand
secureitwiththehoseclamp.
Figure17
7

11
InstallingaBattery(Model
numbersthatendwithCP
only)
Partsneededforthisprocedure:
1Clamp
2Wingnut(1/4inch)
2Batteryholddown
Procedure
1.Purchasea12Vbattery.
Modelswitha29hpengineandbelowrequirea
batterywithaminimumof260CCA.
Modelswitha30hpengineandhigherrequirea
batterywithaminimumof340CCA.
2.Locatethebatterymountinghardwareandinstallit
intothemachine.RefertoInstallingtheBatteryin
theOperator’sManual.
12
ChargingtheBattery
NoPartsRequired
Procedure
Chargingthebatteryproducesgassesthatcan
explodeandcauseseriousinjury.
•Keepcigarettes,sparksandamesaway
fromthebattery.
•Makesuretheignitionswitchisoff.
•Ventilatewhenchargingorusingthebattery
inanenclosedspace.
Important:Donotrunthemachinewiththe
batterydisconnected;electricaldamagemayoccur
totheengine.
Chargethebattery.RefertotheOperator’sManualfor
instructions.
Figure18
13
CheckingtheEngineOilLevel
NoPartsRequired
Procedure
Beforeyoustarttheengineandusethemachine,check
theoillevelintheenginecrankcase;refertoServicing
theEngineOilLevelinOperator’sManual.
14
AddingFueltotheMachine
NoPartsRequired
Procedure
Addgasolinetothemachinebeforestartingit.Refer
toyourOperator’sManual.forthecorrectfueland
procedure.
8

G008942
12
4
3
Figure19
15
CheckingtheMachinefor
Grease
Partsneededforthisprocedure:
1tubeNumber2generalpurposelithiumbaseor
molybdenumbasegrease.(Purchaseseparately.)
Procedure
1.Checkthegreaseforthethreespindlebearingsand
theidlerpulley.Ifneeded,addgreaseuntilitcomes
outofthelowerseals.
Figure20
2.Checkthegreaseforthepumpdrivebeltidlerarm.
Figure21
9

16
CheckingtheSideDischarge
Chute
NoPartsRequired
Procedure
Ifthereareplastictiesholdingthesidedischargechute
up,removethemandlowerthechuteintoplace.
Anuncovereddischargeopeningcouldallow
thelawnmowertothrowobjectsinthe
operator’sorbystander’sdirectionandresultin
seriousinjuryordeath.Also,contactwiththe
bladecouldoccur.
Neveroperatethelawnmowerwiththegrass
deectorremovedunlessyouinstallacover
plate,amulchplate,oragrasschuteand
catcher.
1.MakesureoneJendofthespringisinstalledbehind
thedeckedgebeforeinstallingtheboltasshownin
Figure22.
2.PlaceoneJhookendofthespringaroundthegrass
deector(Figure22).
Important:Thegrassdeectormustbefreeto
rotatewithdownwardtension.Liftthedeector
uptothefullopenpositionandensurethatit
rotatesfreely,withoutbindingintothefulldown
position.
g015594
1
6 2 4
7
3
5
Figure22
1.Bolt5.Springinstalled(around
thegrassdeectorand
behindthedeckedge)
2.Spacer6.GrassDeector
3.Locknut7.Jhookendofspring
4.Spring
10

17
CheckingtheMachineBeforeDeliverytotheCustomer
NoPartsRequired
Procedure
Beforedeliveringthemachinetothecustomer,ensurethatyouperformorhaveperformedtheprocedureslistedin
thefollowingtableandinitialeachwhennished.RefertotheOperator’sManualforinstructionsonperforming
theseprocedures.
InitialCheckProcedure
Checkthetirepressure.
Checkthelevelofthemower.
Checkthatallmowerspindlesaregreased.
Checktheengineoillevel.
Checkthehydraulicuidlevel.
CheckROPSissecure.
Onliquidcooledmachines,checkthelevelofthecoolantintheradiatorandoverowbottle.
Checktheadjustmentoftheparkingbrake.
Ensurethatthemachinetrackscorrectly;refertotheOperator’sManualfortheadjustmentprocedure.
Checkthesafetyinterlocksystem;refertotheOperator’sManual.
EnsurethatthePTOworks.
Checkallfastenersyouinstalledtoensurethattheyaretight.
Whenyounishsettingupthemachine,signanddateinthespaceprovidedbelow:
Signature:Date:
11

18
DeliveringtheMachinetotheCustomer
Partsneededforthisprocedure:
1Operator’sManual
1EngineOwner’sManual
1Operatortrainingmaterial
2Key
Procedure
Atdelivery,Fillinthemodelandserialnumberandcompletetheitemslistedinthefollowingtableandinitial
eachwhennished.
ModelNo.SerialNo.
12

DealerInitialCustomerInitialCheckProcedure
Showthecustomerwherethefollowingfeaturesarelocatedandhowtheyfunction:
•Hourmeter/SafetyInterlockSymbols/BatteryIndicator/FuelGauge
•Fueltankcap(s)
•Oilllcap/Oildipstick
•Sparkplug(s)
•Engineoillter
•Engineoildrain
•Fuellter(s)
•Airlter
•Radiatorcoolant(ifapplicable)
•Hydraulicuidreservoir
•Hydrauliclter
•Battery
•Ignitionswitch
•Throttlelever
•Choke(ifapplicable)
•Powertakeoffswitch(PTO)
•Motioncontrollevers
•Parkingbrake
•Mowerheight-of-cut
•Height-of-cutdeckliftpedal/TransportLock
•ZStand®(ifapplicable)
•Adjustableseat
•Hydraulicbypassvalves
•RolloverProtectionSystem(ROPS)
•Mowerdeckowbafe
RefertotheOperator’sManualtopointoutsafetyprocedures,operation,and
maintenanceprocedures.
ReviewthewarrantystatementasshownintheOperator’sManual.
Describethepostsaleserviceproceduresforyourstore.
Assistthecustomerinllingoutandmailingtheregistrationcardorregisteronlineat
www.T oro.com
MakesurethatthecustomerreceivestheOperator’sManual,EngineOwner’sManual,
SetUpInstructions,andoperatortrainingmaterial.
MakesurethecustomerknowsthePartsCatalogisavailableatwww.Toro.com.
Assistthecustomerinloadingthemower.
Note:Whenyou,thedealerrepresentative,havenisheddeliveringthemachinetothecustomer,signanddatein
thespaceprovidebelowandkeepacopyofthispagefordealerrecords.
Signature:Date:
Signature:Date:
13

Notes:
14

Notes:
15