Toro 107-0038 Installation Instructions

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. Use

1

2

3
4
5

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

No parts needed – Installing the drive wheels

No parts needed – Removing the existing seat frame

Seat frame 1 Installing the new seat frame

1
1
1
4
2
6
6
2
2
2
2
2

Installing the roll over protection system
(ROPS)

Seat latch catch

6
7
8

9

 2003—The Toro Company
8111 Lyndale A ve., Blomington, MN 55420, USA

Bolt, 5/16 x 3/4 inch
Locknut, 5/16 inch

Template 1

Seat latch catch
Side locknut, 5/16 inch
Serrated locknut, 5/16 inch

Seat belt
Bolt, 7/16 x 1 inch
Locknut, 7/16 inch

1
2
2

1
2
2

1
2
2

Printed in the USA

All Rights Reserved

Installing a seat latch catch on 500 Series
machines

Drilling holes for a seat latch catch on 200
Series Machines

Installing a seat latch catch on 200 Series
machines

Installing the seat belt on a standard seat

Original Instructions (EN)

Register your product at www.Toro.com

Step UseQty.Description

2

10

11

Seat belt
Bolt, 7/16 x 1 inch
Washer, 7/16 inch

Footrest decal 1 Installing the Decals

1
2
2

Installing the seat belt on a deluxe seat

3

Step

1

Removing the Drive Wheels

Parts needed for this step:

None

Procedure

1. Loosen the wheel

nuts or bolts on both
sides of the machine.

m–6858

2. Raise the back of the machine up and support it
with jack-stands.

Step

2

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.

Parts needed for this step:

Qty. Part

1 Roll bar, right section
1 Roll bar, left section
1 Roll bar, center section
2 Bolt, 3/8 x 4–1/2 inches
2 Bolt, 3/8 x 1–1/2 inch
2 Lock nut, 3/8 inch
2 Internal lock washer, 3/8 inch
4 Bolt, 3/8 x 1 inch
6 Curved washer
6 Flange nut, 3/8 inch
2 Bolt, 1/2 x 3-1/4 inches
2 Flange nut, 1/2 inch

3. Remove the wheel
nuts on both sides of the
machine.

4. Remove the drive
wheels from the
machine.

m–6859

Procedure

1. Remove and discard

the fuel tank mounting
bolt and nut from under
the tank on each side.

m–6857

4

2. For an air cooled machine, loosen the two bottom
bolts in the rear bumper.

m–6886

3. For a liquid cooled machine, loosen the two side
and four back bolts in the rear bumper.

m–6885

4. Install the bolts in the order shown in the figure
below.

5. Loosely install the right and left roll bar sections
to the frame, in numbered order as follows:

Lock nut (3/8 inch), internal tooth lock washer, and
Bolt (3/8 x 1–1/2 inch)

Bolt (3/8 x 1 inch), curved washer, and flange nut
(3/8 inch)

Bolt (3/8 x 1 inch), curved washer, and flange nut
(3/8 inch)

Bolt (3/8 x 4-1/2 inches), curved washer, and
flange nut (3/8 inch)

m–7125

6. 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

5

5

7. Lightly oil the ends
of the center roll bar
section.

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).

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. Raise the roll bar
into the upright position
and secure it with the
pins and hairpin cotter
pins fastened to the
lanyards.

m–6891

m–6893

12. Tighten the front
handles against the
center roll bar ends.

13. Tighten the rear
bumper bolts.

m–683

Step

10. Tighten the center

roll bar bolts
(1/2 x 3-1/4 inches) so it
rotates freely with some
resistance.

Note: No more than one
thread should be
exposed outside the nut.

11. Torque all lower
fasteners, attached to
the machine frame, to
30 ft–lb.

m–6891

3

Installing the Drive Wheels

Parts needed for this step:

Qty. Part

2 Rear wheels

Procedure

1. Mount the wheels

with the valve stem to
the outside and secure
them with the nuts or
bolts previously
removed in Step 1.

2. Torque the nuts or
bolts to 95 ft-lb
(128 N⋅m).

m–6859

6

Step

4

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.

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.

Steps needed for a Deluxe Seat

1. Remove the two connectors from the seat switch.

2. Remove the cable ties from the seat frame.

m–6877

3. Remove the seat
frame from the existing
seat by removing the
four locknuts. Discard
the seat frame.

4. Remove the nut and
bolt from the seat
retaining rod.

m–7021
m–7023

m–7108

Step

5

Installing the New Seat
Frame

Parts needed for this step:

Qty. Part

1 Seat frame

Procedure

Note: Standard seat shown only.

1. Install the seat to

the new seat frame with
the four locknuts
previously removed.

7

3. Install the seat
retaining rod with the nut
and bolt previously
removed.

Note: Do not over
tighten the nut and bolt
to allow the retaining rod
to pivot.

m–7108

4. If needed, attach the two connectors onto the
seat switch.

m–7022

2. Install the seat at
the hinges with the 2
bolts and 2 locknuts
previously removed.

m–6877

m–7029

8

Step

6

Replacing a Seat Latch
Catch on 500 Series
Machines

Parts needed for this step:

Qty. Part

1 Seat latch catch
2 Bolt, 5/16 x 3/4 inches
2 Locknut, 5/16 inch

Procedure

1. Remove the existing latch catch.

2. Install the new seat latch catch to the frame with

2 bolts (5/16 x 3/4 inch) and 2 locknuts (5/16 inch).
Note: The bent part of the latch catch needs to point

downward.

Step

7

Drilling Holes for a Seat
Latch Catch on 200 Series
Machines

Parts needed for this step:

Qty. Part

1 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.

m–7103

m–7101

2. Mark the holes in the template and drill two holes
(11/32 inch diameter) into the side of the frame.

m–7102

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

Procedure

The diagram to the right
shows a serrated
locknut. Notice the
grooves on the flange
side of the nut.

9

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.

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.

Side View

m–7111

The diagram to the right
shows a side locknut.
Notice the dimples in the
side of the nut.

m–7111

1. Install the serrated locknuts onto the seat latch
catch as far as they can go on by hand.

Note: The 200 Series seat latch catch is shown
below.

m–7111

m–7116

10

Step

9

Installing the Seat Belt on a
Standard Seat

Parts needed for this step:

Qty. Part

1 Seat belt
2 Bolt, 7/16 x 1 inch
2 Locknut, 7/16 inch

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).

Step

10

Installing the Seat Belt on a
Deluxe Seat

Parts needed for this step:

Qty. Part

1 Seat belt
2 Bolt, 7/16 x 1 inch
2 Washer, 7/16 inch

Procedure

1. Install the receiver

part of the seat belt to
the outside of the metal
seat frame with 1 bolt
(7/16 x 1 inch) and
1 washer (7/16 inch).

m–7109

2. Install the long seat
belt strap between the
cushion and the metal
seat frame with 1 bolt
(7/16 x 1 inch) and
1 locknut (7/16 inch).

m–7024

m–7025

2. Install the long seat
belt strap to the outside
of the metal seat frame
with 1 bolt (7/16 x
1 inch) and 1 washer
(7/16 inch).

m–7110

Step

11

Installing the Decals

Parts needed for this step:

Qty. Part

1 Footrest decal

Installing the Footrest Decal

1. Install the footrest

decal onto the footrest
as shown.

m–7030

11

12