Toro CE Kit, 132cm Z Master 4000 Series Riding Mower Installation guide

FormNo.3445-540RevA

CEKit

122cm,132cm,or152cmZMaster

4000SeriesRidingMower

ModelNo.145-1261

ModelNo.145-1262

ModelNo.145-1263

InstallationInstructions

Note:TocreateaCEbagger,installthiskitontheBaggerKit(T oroModel78463).

Safety

SafetyandInstructional

Decals

Safetydecalsandinstructionsare

easilyvisibletotheoperatorandare

locatednearanyareaofpotential

danger.Replaceanydecalthatis

damagedormissing.

decal117-0923

117-0923

1.Warning—readthe

Operator’sManual;wear

hearingprotection.

4.Cutting/dismemberment

hazard,

impeller—disengage

thePTO,removethekey,

andwaitforallmoving

partstostop.

2.Thrownobject

hazard—keepbystanders

away.

5.Cutting/dismemberment

hazard,impeller—stay

awayfrommovingparts;

keepallguardsand

shieldsinplace.

3.Thrownobjecthazard,

deectorshield—do

notoperatewithoutthe

deector,dischargecover,

orgrasscollectionsystem

inplace

8111LyndaleAvenueSouth

Bloomington,MN55420

Registeratwww.Toro.com.

OriginalInstructions(EN)

PrintedintheUSA

AllRightsReserved

*3445-540*

Installation

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

ProcedureDescription

Qty.

Use

Nopartsrequired

–

Preparethemachine.

Nopartsrequired

–

Removetheexistingsidedischarge

chute.

Nopartsrequired

–

RemovetheOEMcoverandbrackets.

Nopartsrequired

–

Removethebeltcoverfortheblower(if

installed).

CEpulleyguard

CEbelt-coverbracket(ifnotpreviously

installed)

Hex-headbolt(1/4x1inch)

Carriagebolt(1/4x3/4inch)

Locknut(1/4inch)

Hex-headbolt(3/8x1inch)—122cm

mowerdecksonly

Flangenut(3/8inch)—122cmmower

decksonly

Clipnut

Rearguard(122cmmowerdecksonly)

InstalltheCEpulleyguards.

CEshaftguard

CEforwardguard

CEtensionerguard

InstalltheupperCEguards.

CElowerguard

Hex-headbolt(1/4x3/4inch)

Washer(1/4inch)

Locknut(1/4inch)

InstallthelowerCEguard.

Hex-headbolt(1/4x3/4inch)

Washer(5/16x3/4inch)

Washer(1/4x1/2inch)

Retainer1

InstalltheCEbeltcover.

Lowersupportrod1

Flange-headbolt(1/4x3/4inch)

Locknut(1/4inch)

Installthenewlowersupportrod.

Height-of-cutcoverplate(122cmdecks)

Height-of-cutcoverplate(132cmand

152cmdecks)

Locknut(1/4inch)

Carriagebolt(1/4x3/4inch)

Installtheheight-of-cutcoverplates.

PreparingtheMachine

NoPartsRequired

Procedure

1.Parkthemachineonalevelsurface.

2.Engagetheparkingbrake.

3.Shutofftheengineandremovethekey.

4.Thoroughlycleanthemowerdeck.

Note:Youmustremoveallthedebristoensure

thatthekitwilltproperly.

5.Repairallbentordamagedareasandreplace

anymissingparts.

6.Lowerthemowerdecktothelowestheight-of-cut

position;refertothemowerOperator’sManual.

RemovingtheExistingSide

DischargeChute

NoPartsRequired

Procedure

Removethebolt,spring,spacer,andlocknutsecuring

thedischargechuteandremovethedischargechute

(Figure1).

Note:Retainthesidedischargechute,bolt,spring,

spacer,andlocknutforinstallationifyouoperatethe

machinewiththebloweraccessoryremoved.

g348922

Figure1

1.Bolt

4.Spacer

2.Dischargechute5.Locknut

3.Spring

RemovingtheOEMCover

andBrackets

NoPartsRequired

RemovingtheBeltCover

IftheOEMbeltcoverisinstalled,removeitasfollows:

1.Rotatetheboltthatsecuresthebeltcovertothe

deckcounterclockwisetoloosenit(Figure2).

g203155

Figure2

1.Bolt(retainedtothebelt

cover)

4.Flangenut(3/8inch)

2.Beltcover

5.Carriagebolt(3/8x7/8

inch)

3.Cover-mountingbracket

2.RemovetheOEMbeltcoverandboltfromthe

mountingbracket(Figure2).

Note:RetaintheOEMbeltcoverandboltfor

installationwhenoperatingthemowerwiththeblower

accessoryremoved.

RemovingtheCoverMounting

Bracket

1.Removethe2boltsand2angenutsthat

securethecovermountingbrackettothedeck

(Figure2).

2.Removethebracket.

Note:RetaintheOEMcovermountingbracket,

bolts,andangenutforinstallationwhen

operatingthemowerwiththebloweraccessory

removed.

RemovingtheExistingLower

SupportRod

Removethelockingcotterpinfromtheexistinglower

supportrodandremoveit(Figure3).

Note:Retainthelockingcotterpinandlowersupport

rodforinstallationifyouoperatethemachinewiththe

bloweraccessoryremoved.

g350950

Figure3

1.Existinglowersupportrod2.Lockingcotterpin

RemovingtheBeltCover

fortheBlower(IfInstalled)

NoPartsRequired

RemovingtheBeltCoverforthe

Blower

Iftheblowerkitisinstalledonthemachine,remove

thebeltcoverinstalledfrombloweranddrivekitas

follows:

1.Removethethumbscrewthatsecuresthebelt

cover(Figure4).

g038117

Figure4

1.Thumbscrew2.Beltcover

2.Movethecoveroutwarduntiltheedgeofthe

coverclearsthehooksinthedeckanges

(Figure4).

3.Removethecoverfromthedeck.

Note:Discardthethumbscrew.

RemovingtheOEMShaftCover

andHardware

1.Removethe2nutsand2washersthatsecure

theOEMshaftcovertotheblowerassembly

(Figure5).

g203344

Figure5

122cmMowerDeckShown

1.Nut

3.OEMshaftcover

2.Washer4.Bolt

2.RemoveanddiscardtheOEMshaftcover

(Figure5).

InstallingtheCEPulley

Guards

Partsneededforthisprocedure:

CEpulleyguard

CEbelt-coverbracket(ifnotpreviouslyinstalled)

Hex-headbolt(1/4x1inch)

Carriagebolt(1/4x3/4inch)

Locknut(1/4inch)

Hex-headbolt(3/8x1inch)—122cmmowerdecks

only

Flangenut(3/8inch)—122cmmowerdecksonly

Clipnut

Rearguard(122cmmowerdecksonly)

122cmMowerDecks

1.AligntheholesoftheCEpulleyguardtothehole

intheforwarddeectorbracketandtheoutboard

holeintheforwarddeckange(Figure6).

Note:TheCEpulleybracketwrapsaroundthe

outboardedgeofthedeectorbracket

2.AligntheCEbelt-coverbracket(ifnotpreviously

installed)totheholesattherearsideofthe

forwarddeckange(Figure6).

3.SecuretheCEpulleyguardandthebeltcover

brackettotheforwarddeckangeatthe

outboardholeusing1hex-headbolt(1/4x1

inch)and1locknut(1/4inch)asshowninFigure

4.Securethebelt-coverbrackettotheforward

deckangeattheinboardholeusing1carriage

bolt(1/4x3/4inch)and1locknut(1/4inch)as

showninFigure6.

5.AligntheholeintherearangeoftheCE

belt-coverbracketwiththeholeinthedeck

whereyouremovedtheOEMbeltcoverbracket

instep1ofRemovingtheCoverMounting

Bracket(page4);refertoFigure6.

6.Aligntheclipnutwiththeholeinthetopofthe

CEbelt-coverbracket,andpushtheclipnut

ontothebracket(Figure6).

7.Looselyinstalltherearguardtothemowerdeck

using1hex-headbolt(3/8x1inch)and1ange

nut(3/8inch)asshowninFigure6.

Tightenthefastenersafteryouinstalltheblower;

refertoInstallingtheBlower(page10).

Important:Thisstepappliesto122cm

mowerdecksonly.

g351269

Figure6

1.CEpulleyguard6.Flangenut(3/8inch)

2.Belt-coverbracket

7.Locknut(1/4inch)

3.Rearguard(122cm

mowerdeckonly)

8.Deckange(forward)

4.Hex-headbolt(3/8x1

inch)

9.Carriagebolt(1/4x3/4

inch)

5.Clipnut10.Flange-headbolt(1/4x1

inch)

132cmand152cmMowerDecks

1.AligntheholesoftheCEpulleyguardtothehole

intheforwarddeectorbracketandtheoutboard

holeintheforwarddeckange(Figure7).

Note:TheCEpulleybracketwrapsaroundthe

outboardedgeofthedeectorbracket

2.AligntheCEbelt-coverbracket(ifnotpreviously

installed)totheholesattherearsideofthe

forwarddeckange(Figure7).

3.SecuretheCEpulleyguardandthebelt-cover

bracket(ifnotpreviouslyinstalled)tothe

forwarddeckangeattheoutboardholeusing1

hex-headbolt(1/4x1inch)and1locknut(1/4

inch)asshowninFigure7.

4.Securethebelt-coverbrackettotheforward

deckangeattheinboardholeusing1carriage

bolt(1/4x3/4inch)and1locknut(1/4inch)as

showninFigure7.

5.Aligntheclipnutwiththeholeinthetopofthe

CEbelt-coverbracket,andpushtheclipnut

ontothebracket(Figure7).

g351270

Figure7

1.CEpulleyguard5.Deckange(forward)

2.Belt-coverbracket(ifnot

previouslyinstalled)

6.Carriagebolt(1/4x3/4

inch)

3.Clipnut7.Flange-headbolt(1/4x1

inch)

4.Locknut(1/4inch)

InstallingtheCEUpper

Guards

Partsneededforthisprocedure:

CEshaftguard

CEforwardguard

CEtensionerguard

Procedure

1.Removethe3locknuts(1/4inch)fromthe

blowerassembly.

2.SecuretheCEtensionerguardtotheblower

usingthe2hex-headbolts(1/4x3/4inch)and

previouslyremoved2locknuts(1/4inch)as

showninFigure8.

3.SecuretheCEshaftguardusing2locknuts

(5/16inch)and2washers(Figure8).

4.SecuretheCEforwardguardusing1hex-head

bolt(1/4x3/4inch)andpreviouslyremoved

locknut(1/4inch)asshowninFigure8.

g351116

Figure8

122cmMowerDeckShown

1.Hex-headbolt(5/16x

1-3/4inches)

5.Locknut(1/4inch)

2.Washer(3/8inch)6.CEtensionerguard

3.Locknut(5/16inch)7.CEforwardguard

4.CEshaftguard8.Hex-headbolt(1/4x3/4

inch)

InstallingtheCELower

Guard

Partsneededforthisprocedure:

CElowerguard

Hex-headbolt(1/4x3/4inch)

Washer(1/4inch)

Locknut(1/4inch)

RemovingtheBlower

Iftheblowerassemblyisinstalled,removeitfromthe

mowerdeckasfollows:

1.Pullthespringloadedidlerpulleyawayfromthe

xedspringpost,andremovethebeltfromthe

idlerpulley(Figure9).

g203195

Figure9

1.Latchpin(lockingposition)6.Belt(alignedtotheidler

pulley)

2.Chutebracket

7.Idlerspringpost

3.Blowerassembly

8.Spring

4.Springhookends

9.Fixedspringpost

5.Idlerpivotbracket

2.Movetheidlerpivotbrackettowardthexed

springpostandremovethehookofthespring

fromtheidlerspringpost(Figure9).

3.Routethebeltbeneaththeidlerpulley(Figure

10).

g341600

Figure10

1.Blowerpulley4.Drivepulley

2.Idler/pulley5.Idler/tensionpulley

3.Blowerbelt

4.Removethebeltfromdrivepulley(Figure10).

5.Movetheblowerlatchpintotheopenposition

andswingthebloweroutward(Figure9).

6.Removetheblowerandbeltfromthemower

deck.

DrillingtheMountingHolesforthe

CELowerGuard

1.AlignthelowerCElowerguardtothe

blower-chutebracketasshowninFigure11.

g018859

Figure11

1.Hole1

7.Hex-headbolt(1/4x3/4

inch)

2.Hole2

8.Locknut(1/4inch)

3.Hole39.Rivettails

4.Hole410.Blower-chutebracket

5.CElowerguard11.Drillbit7mm(0.28inch)

6.Washer

2.Alignhole2andhole4ofthelowerCElower

guardtotherivettailsprotrudingthroughthe

blower-chutebracket(Figure11).

Note:EnsurethattheangeoftheCElower

guard(theangewiththeholes)isatagainst

theblower-chutebracket.

3.Marktheoutlineofhole1andhole3oftheCE

lowerguardontheblower-chutebracket,and

removetheCEguard(Figure11).

4.Locatethemarksontheblower-chutebracket,

andcenter-punchthelocations.

5.Drill7mm(0.28inch)holesintheblower-chute

bracketatthe2center-punchmarks(Figure11).

InstallingtheCELowerGuard

Note:InstalltheCElowerguardwiththeblower

assemblyremovedfromthemowerdeck;referto

theE-ZVac™BlowerandDriveKitInstallation

Instructions.

1.AligntheCElowerguardtotheblower-chute

bracket(Figure11).

2.Alignhole2andhole4oftheCElower

guardtotherivettailsprotrudingthroughthe

blower-chutebracket(Figure11).

3.SecuretheCElowerguardtotheblowerwith2

hex-headbolts(1/4x3/4inch),2washers,and

2locknuts(1/4inch)throughhole1andhole4

oftheCEguard(Figure11).

InstallingtheBlower

Ifyouremovedtheblower,installittothemowerdeck

asfollows:

Note:RefertotheBaggerKit(ToroModel78463)

manual.

1.Aligntheblowerbeltaroundthepulleyofthe

blower(Figure10).

2.Alignthepivotpinontheblowerwiththepivot

pinholeinthedeckandlowerthebloweronto

thedeck.

3.Opentheblowerlatchpin,closetheblowerto

thedeck,andsecurethelatchpintothechute

bracket(Figure9).

Note:Ensurethatthelatchpinextendsthrough

theholeinchutebracketandtheCEpulley

guard.

4.Temporarilyroutethebeltbeneaththeidler

pulley(Figure10).

5.Routethebeltaroundthedrivepulley(Figure

10).

6.Movetheidler/tensionpulleytowardthexed

springpost,andinstallthespringbyaligningthe

springhookontotheidlerspringpost(Figure9).

7.Pullthespringloadedidler/tensionpulleyaway

fromthexedspringpost,androutethebelt

aroundtheidlerpulley(Figure10).

InstallingtheCEBeltCover

Partsneededforthisprocedure:

Hex-headbolt(1/4x3/4inch)

Washer(5/16x3/4inch)

Washer(1/4x1/2inch)

1Retainer

InstallingtheCEBeltCoverBolt

1.Assemblethewasher(5/16x3/4inch)tothe

hex-headbolt(1/4x3/4inch)asshowninFigure

12.

g351271

Figure12

132cmMowerDeckShown

1.Washer(5/16x3/4inch)5.Washer(1/4x1/2inch)

2.Hex-headbolt(1/4x3/4

inch)

6.Retainer

3.Plasticplug

7.Clipnut

4.Beltcover

8.CEbelt-coverbracket

2.Inserttheboltandwasherthroughtheholein

thetopofthebeltcoverfromtheOEMblower

anddrivekit(Figure12).

3.Fromthebottomofthebeltcover,assemblethe

washer(1/4x1/2inch)andretaineroverthe

hex-headboltthreads(Figure12).

Ensurethattheboltheadandwasherare

positionedushwiththeuppersurfaceofthe

beltcoverandthewasherandretainerareush

withthebottomsurfaceofthecover.

InstallingtheBeltCover

1.Unlatchtheblowerandpullitoutpartially.

2.Alignthebeltcoverwithnotchesinthedeck

anges(Figure12).

3.Alignthehex-headboltinthecoverwiththeclip

nutonthebelt-coverbracket.

4.Securethebeltcovertothecoverbracketwith

thehex-headbolt(Figure12).

5.Installtheplasticplugintothecover(Figure12).

6.Opentheblowerlatchpin,closetheblowerto

thedeck,andsecurethelatchpintothechute

bracket.

InstallingtheNewLower

SupportRod

Partsneededforthisprocedure:

1Lowersupportrod

Flange-headbolt(1/4x3/4inch)

Locknut(1/4inch)

Procedure

1.Threadthenewlowersupportrodthroughthe

lowerskirtopening.

2.Securetherodusing1ange-headbolt(1/4x

3/4inch)and1locknut(1/4inch)asshownin

Figure13.

g351272

Figure13

1.Lowersupportrod

3.Flange-headbolt(1/4x

3/4inch)

2.Locknut(1/4inch)

InstallingtheHeight-of-Cut

CoverPlates

Partsneededforthisprocedure:

Height-of-cutcoverplate(122cmdecks)

Height-of-cutcoverplate(132cmand152cmdecks)

Locknut(1/4inch)

Carriagebolt(1/4x3/4inch)

122cmMowerDecks

Securethe2height-of-cutcoverplatestothe102to

140mmrangesoftheheight-of-cutbracketusing2

carriagebolts(1/4x3/4inch)and2locknuts(1/4inch)

asshowninFigure14andFigure15.

g351283

Figure14

1.Height-of-cutbracket3.Locknut(1/4inch)

2.Height-of-cutcoverplate

(122cmdecks)

4.Carriagebolt(1/4x3/4

inch)

g351823

Figure15

InstalledView

132cmand152cmMowerDecks

Securethe2height-of-cutcoverplatestothe133mm

and140mmrangesoftheheight-of-cutbracketusing

2carriagebolts(1/4x3/4inch)and2locknuts(1/4

inch)asshowninFigure16andFigure17.

g351284

Figure16

1.Height-of-cutbracket3.Height-of-cutcoverplate

(132cmand152cm

decks)

2.Locknut(1/4inch)4.Carriagebolt(1/4x3/4

inch)

g351824

Figure17

InstalledView

Notes:

Toro CE Kit, 132cm Z Master 4000 Series Riding Mower, CE Kit, 122cm Z Master 4000 Series Riding Mower, CE Kit, 152cm Z Master 4000 Series Riding Mower Installation guide

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