Toro Z MASTER Z100 series Manual

 2003—TheToro Company
8111 Lyndale Ave., Blomington, MN 55420, USA Printed in the USA
All Rights Reserved Original Instructions (EN)
Register your product at www.Toro.com
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
2
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
1
1
1
8
8
8
2
2
2
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
1
1
4
4
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

2
Step UseQty.Description
11 No parts needed. –Checking the machine before delivery
12
Key
Operator’s Manual
Engine Owner’s Manual
Parts Catalog
Safety video
Registration card
2
1
1
1
1
1
Delivering the Machine to the Customer
Step
1
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

3
Step
2
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

4
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
5
Step
3
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

5
Step
4
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
5
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
2

6
Step
6
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

7
Step
7
Activating the Battery
Parts needed for this step:
Qty. Part
80
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.

8
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
8
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

9
Step
9
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
10
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.

10
Step
11
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: