TORO 139-2638 Roll-Over Protection System Kit Instructions

139-2638 Roll-Over Protection System Kit
Instructions

TimeCutter® HD or Titan® Zero-Turn-Radius Riding Mower
Store this document with the Operator’s Manual for the traction unit.

Safety

Rollover Protection System (ROPS) Safety

• The ROPS is an integral safety device. Do not remove any of the ROPS components from the machine.
• Ensure that the seat belt is attached and that you can release it quickly in an emergency.
• Keep the roll bar in the fully raised and locked position and always wear your seat belt whenever the roll bar is up.
• Check carefully for overhead objects before you drive under them, and do not contact them.
• Replace damaged ROPS components. Do not repair or alter them.
• There is no rollover protection when the roll bar is down.
• Wheels dropping over edges, over steep banks, or into the water can cause a rollover, which may result in serious injury or death.
• Do not wear the seat belt when the roll bar is down.
• Lower the roll bar only when absolutely necessary; raise it as soon as clearance permits.
• In the event of a rollover, take the machine to an Authorized Service Dealer to inspect the ROPS.
• Use only Toro-approved accessories and attachments for the ROPS.

Safety and Instructional Decals
Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or missing.

decal 107-3069

1. Warning-there is no rollover protection when the roll bar is down.
2. To avoid injury or death from a rollover accident, keep the roll bar in the raised and locked position and wear the seat belt. Lower the roll bar only when absolutely necessary; do not wear the seat belt when the roll bar is down.
3. Read the Operator’s Manual; drive slowly and carefully.

Installation

Loose Parts
Use the chart below to verify that all parts have been shipped.

Plate
Carriage bolt (3/8 x 2 inches) Nut (3/8 inch)| 5
1
2
2| Install the weights (machines with both 48in deck and bagger installed only).
3| Left lower roll bar
Right lower roll bar
Bolt (1/2 x 4 inches)
Washer
Locknut (1/2 inch)
Left support bracket
Right support bracket
Bolt (1/2 x 1-1/4 inches)
Bolt (1/2 x 1-3/4 inches)| 1
1
4
6
6
1
1
2
2| Install the lower tubes and seat belt.
4| Left seat-belt bracket—Machines without MyRide only
Right seat-belt bracket—Machines without MyRide only
Seat-belt assembly
Seat-belt buckle
Bolt (1/2 x 1-1/4 inches)
Locknut (1/2 inch)
Self-tapping screw (1/4 x 5/8 inch)
Bolt (7/16 x 1-1/4 inches)—Machines with MyRide only| 1
1
1
1
4
4
2
2| Install the seat belt.
5| Rollbar Side plate
Bolt (1/2 x 3 inches)
Flat spacer
Washer
Locknut (1/2 inch)
Bumper
Cylindrical spacer
Lanyard with pivot pin, washer, and hairpin cotter| 1
4
8
4
6
8
3
4
1| Install the roll bar.

Determine the left and right sides of the machine from the normal operating position.
1. Preparing the Machine
No Parts Required

Procedure

1. Park the machine on a level surface.
2. Disengage the PTO, engage the parking brake, and move the motion-control levers outward to the NEUTRAL-LOCK position.
3. Shut off the engine and remove the key.

2. Installing the Weights
Machines with Both 48in Deck and Bagger Installed
Parts needed for this procedure:

Procedure

1. Remove the retaining rod and suitcase weight (Figure 1).1. Retaining rod
   2. Suitcase weight

2. Install the 5 weights under the weight tray (Figure 2). 1. Nut (2)
   2. Weight tray
   3. Weight (5)
   4. Carriage bolt (2)

3. Install the plate at the front of the weight tray (Figure 3). 1. Plate

4. Install the suitcase weight behind the plate and install the retaining rod (Figure 1).

3. Installing the Lower Tubes and Seat Belt
Parts needed for this procedure:

Procedure

Note: The engine and left and right pods are not shown in the figures.

1. Raise and support the machine so that the rear wheels are off the ground.

2. Remove the rear wheels.

3. Loosely install the left and right lower roll bar tubes using 2 bolts (1/2 x 4 inches), 2 washers, and 2 locknuts (1/2 inch) for each tube (Figure 4).
   Note: Ensure that the battery cables route between the right pod and the right roll bar. 1. Bolt-1/2 x 4 inches (2)
   2. Washer (2)
   3. Left lower roll bar tubes
   4. Locknut (1/2 inch)
   5. Right lower roll bar (installed)

4. Loosely install the left and right support brackets using 1 bolt (1/2 x 1-1/4 inches), 1 locknut (1/2 inch), 1 bolt (1/2 x 1-3/4 inches), and 1 washer for each bracket (Figure 5).
   Note: Ensure that the battery ground cable routes under the right support bracket and other cables route above the right support bracket (Figure 6).

5. Right support bracket

6. Bolt (1/2 x 1-3/4 inches)

7. Washer (2)

8. Left support bracket (installed)

9. Locknut (1/2 inch)

10. Bolt (1/2 x 1-1/4 inches)

1. Right pod
2. Right support bracket
3. Battery ground cable
4. Cable

4. Installing the Seat Belt
Parts needed for this procedure:

Machines without MyRide

1. Install the left and right seat-belt brackets using 1 bolt (1/2 x 1-1/4 inches), 1 locknut (1/2 inch), and 1 self-tapping screw (1/4 x 5/8 inch) for each bracket (Figure 7).  Torque the bolts to 102 N.m (75 ft-lb). 1. Locknut (1/2 inch)
   2. Right seat-belt bracket
   3. Self-tapping screw (114 x 5/8 inch)
   4. Bolt (1/2 x 1-1/4 inches)

2. Install the seat-belt assembly and buckle to the brackets using 2 bo is (1/2 x 1-1/4 inches) and 2 locknuts (1/2 inch) as shown in Figure 8. Torque the bolts to 102 N.m (75 ft-lb).

1. Locknut (1/2 inch)
2. Seat-belt buckle
3. Right seat-belt bracket
4. Bolt (1/2 x 1-1/4 inches)
5. Left seat-belt bracket
6. Seat-belt assembly

Machines with MyRide
Install the seat-belt assembly and buckle to the seat as shown in Figure 9.

• For seats with a welded nut, use 2 bolts (7/16 x 1-1/4 inches). Torque the bolts to 68 NI-rn (50 ft-lb).
• For seats without a welded nut, use 2 bolts (1/2 x 1-1/4 inches) and 2 locknuts (1/2 inch). Torque the bolts to 102 N.m (75 ft-lb).

1. Seat-belt assembly
2. Bolt
3. Locknut (seats without welded nut only)
4. Seat-belt buckle

5. Installing the Roll Bar
Parts needed for this procedure:

Procedure
Note: Leave the bolts loose enough so that the parts are free to shift around.

1. Install 2 side plates to both sides of the roll bar using 3 bolts (1/2 x 3 inches), 2 flat spacers, 3 washers, 1 cylindrical spacer, and 3 locknuts (1/2 inch) on each side (Figure 10).
   1. Bolt-1/2 x 3 inches (3)
   2. Washer (3)
   3. Side plate (2)
   4. Flat spacer (2)| 5. Rollbar
   6. Bumper
   7. Locknut-1/2 inch (3)
   8. Cylindrical spacer
   ---|---

2. Install a bumper in the center of the roll bar (Figure 10).

3. Install a bumper and cylindrical spacer to both lower roll bar tubes (Figure 11). 1. Cylindrical spacer
   2. Bumper

4. With the assistance of a second person, attach the roll bar assembly and the lanyard washer to the lower roll bar tubes using a bolt (1/2 x 3 inches) and locknut (1/2 inch) on each tube (Figure 12). 1. Bolt (1/2 x 3 inches)
   2. Pivot pin
   3. Locknut (1/2 inch)

5. Raise the roll bar into the upright position and lock it into place using the pivot pin and hairpin cotter on both sides of the roll bar (Figure 13).

6. Torque all 1/2-inch bolts to 102 N.m (75 ft-lb).

7. Install the rear tires. Torque the lug nuts to 95 to 122 N.m (70 to 90 ft-lb).

8. Lower the machine to the ground.

Operation

Using the Rollover-Protection System
WARNING
To avoid injury or death from rollover: keep the roll bar in the fully raised, locked position and use the seat belt.
Ensure that the seat is secured to the machine.
WARNING
There is no rollover protection when the roll bar is in the down position.

• Lower the roll bar only when absolutely necessary.
• Do not wear the seat belt when the roll bar is in the down position.
• Drive slowly and carefully.
• Raise the roll bar as soon as clearance permits.
• Check carefully for overhead clearances (i.e., branches, doorways, electrical wires) before driving under any objects, and do not contact them.

Important: Ensure that the seat is secured to the machine.

Raising the Roll Bar

Lowering the Roll Bar

Maintenance

Checking the Seat Belt
Service Interval: Before each use or daily
Inspect the seat belt for wear, cuts, and proper operation of the retractor and buckle. Replace the seat belt if it is damaged.
Checking the Rollover Protection System (ROPS)
Service Interval: Before each use or daily
Visually inspect the ROPS for loose hardware or any other possible problem. Tighten the hardware or correct the problem before operating.
Notes:

Count on it.
Original Instructions
Printed In the USA
All Rights Reserved
© 2022—The Toro® Company 8111 Lyndale Avenue South Bloomington, MN 55420
Register at www.Toro.com.

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