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CE Kit, 122cm Z Master 4000 Series Riding Mower

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

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  • How do I prepare the machine for CE kit installation?
    How to remove the existing side discharge chute?
    How to remove the OEM cover and brackets?
    How to remove the OEM shaft cover and hardware?
    How to install the CE pulley guards?
    How to install the CE upper guards?
    How to install the CE lower guard?
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
©2021—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.Toro.com.
OriginalInstructions(EN)
PrintedintheUSA
AllRightsReserved
*3445-540*
Installation
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescription
Qty.
Use
1
Nopartsrequired
–
Preparethemachine.
2
Nopartsrequired
–
Removetheexistingsidedischarge
chute.
3
Nopartsrequired
–
RemovetheOEMcoverandbrackets.
4
Nopartsrequired
–
Removethebeltcoverfortheblower(if
installed).
CEpulleyguard
1
CEbelt-coverbracket(ifnotpreviously
installed)
1
Hex-headbolt(1/4x1inch)
1
Carriagebolt(1/4x3/4inch)
1
Locknut(1/4inch)
2
Hex-headbolt(3/8x1inch)—122cm
mowerdecksonly
1
Flangenut(3/8inch)—122cmmower
decksonly
1
Clipnut
1
5
Rearguard(122cmmowerdecksonly)
1
InstalltheCEpulleyguards.
CEshaftguard
1
CEforwardguard
1
6
CEtensionerguard
1
InstalltheupperCEguards.
CElowerguard
1
Hex-headbolt(1/4x3/4inch)
2
Washer(1/4inch)
2
7
Locknut(1/4inch)
2
InstallthelowerCEguard.
Hex-headbolt(1/4x3/4inch)
1
Washer(5/16x3/4inch)
1
Washer(1/4x1/2inch)
1
8
Retainer1
InstalltheCEbeltcover.
Lowersupportrod1
Flange-headbolt(1/4x3/4inch)
1
9
Locknut(1/4inch)
1
Installthenewlowersupportrod.
Height-of-cutcoverplate(122cmdecks)
2
Height-of-cutcoverplate(132cmand
152cmdecks)
2
Locknut(1/4inch)
2
10
Carriagebolt(1/4x3/4inch)
2
Installtheheight-of-cutcoverplates.
2
1
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.
2
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
3
3
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
4
4
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).
5
5
InstallingtheCEPulley
Guards
Partsneededforthisprocedure:
1
CEpulleyguard
1
CEbelt-coverbracket(ifnotpreviouslyinstalled)
1
Hex-headbolt(1/4x1inch)
1
Carriagebolt(1/4x3/4inch)
2
Locknut(1/4inch)
1
Hex-headbolt(3/8x1inch)—122cmmowerdecks
only
1
Flangenut(3/8inch)—122cmmowerdecksonly
1
Clipnut
1
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
6.
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)
6
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)
7
6
InstallingtheCEUpper
Guards
Partsneededforthisprocedure:
1
CEshaftguard
1
CEforwardguard
1
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)
8
7
InstallingtheCELower
Guard
Partsneededforthisprocedure:
1
CElowerguard
2
Hex-headbolt(1/4x3/4inch)
2
Washer(1/4inch)
2
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.
9
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).
10
8
InstallingtheCEBeltCover
Partsneededforthisprocedure:
1
Hex-headbolt(1/4x3/4inch)
1
Washer(5/16x3/4inch)
1
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.
11
9
InstallingtheNewLower
SupportRod
Partsneededforthisprocedure:
1Lowersupportrod
1
Flange-headbolt(1/4x3/4inch)
1
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)
12
10
InstallingtheHeight-of-Cut
CoverPlates
Partsneededforthisprocedure:
2
Height-of-cutcoverplate(122cmdecks)
2
Height-of-cutcoverplate(132cmand152cmdecks)
2
Locknut(1/4inch)
2
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
13
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
14
Notes:
/