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  3. Metal Plate Kit, Z Master Commercial 2000 Series Riding Mower

Toro Metal Plate Kit, Z Master Commercial 2000 Series Riding Mower Installation guide

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FormNo.3378-515RevA
MetalPlateKit
ZMaster
®
Commercial2000SeriesRidingMower
ModelNo.125-4790
InstallationInstructions
Note:Keepthemowerdeckbeltinstalledduringthe
installationofthiskit.Thereisnointerferencewiththe
mowerdeckbelt.
WARNING
CALIFORNIA
Proposition65Warning
Thisproductcontainsachemicalorchemicals
knowntotheStateofCaliforniatocausecancer,
birthdefects,orreproductiveharm.
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
Description
Qty.
Use
Nopartsrequired
–
Checkthefueltank.
Nopartsrequired
–
Installthefueltank.
Nopartsrequired
–
Removethepulleys.
Nopartsrequired
–
Inspecttheidler-armpulley.
Plate1
Starwasher
1
Thinatwasher
1
Flangenut(3/8inch)
2
Thickatwasher
1
Installtheplate.
CAUTION
Ifthemachinehasbeenrunning,themuferand
exhaustsystemwillbeveryhotandcancause
seriousburnsifyoutouchthem.
Allowthemachinetocoolcompletelybefore
performingthisprocedure.
CheckingtheFuelTank
Note:Ensureanewfueltankandidlerpulleyareorderedif
thereisanywearontheexistingfueltank.
Checkthefueltankforanywearundertheidlerpulley(Figure
1).
•Ifyouseeorfeelwithyourngernail,agrooveinthefuel
tankfromtheidlerpulley,replacethefueltankandidler
pulley(Figure1).Orderanewfueltankandanewidler
pulley.ProceedtoReplacingtheFuelTank(page2).
•Ifthefueltankdoesnothaveanywearfromtheidler
pulley,proceedtoRemovingthePulleys(page4).
©2013—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.T oro.com.
OriginalInstructions(EN)
PrintedintheUSA.
AllRightsReserved
*3378-515*A
g021893
1 2
Figure1
1.Wearareaonfueltank
2.Idlerpulley
ReplacingtheFuelTank
Note:Onlyreplacethefueltankwhenthereiswearonthe
existingfueltankfromtheidlerpulley.
1.Drivethemachinetoalevelsurface.
2.DisengagethePTO,movethemotioncontrolleversto
theneutrallockedposition,andsettheparkingbrake.
3.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.
4.Movetheseatthefurthestrearpositiontoexposethe
frontnuts.
5.Loosenthefrontnuts.Thenutsdonotneedtobe
removed.
6.Movetheseatthefurthestforwardpositiontoexpose
therearnuts.
7.Loosentherearnuts.Thenutsdonotneedtobe
removed.
8.Slidetheseatandseatplateforwardtoallowthefront
nutstogothroughthekeyhole(
Figure2).
g018378
1
2
Figure2
1.Seat
2.Frontnutswithkeyhole
9.Removetheseatandbasefromthemachine.
10.Unplugtheharnessconnectorfromtheseatswitch
locatedundertheseat(Figure3).
g018380
1
Figure3
1.Harnessconnector
11.Removethetwoboltsholdingtheleftsidemotion
controlleverbracket.
12.Rotatethemotioncontrolleverbrackettoallowthe
frontpaneltoberemoved(
Figure4).
2
g019593
3
1
2
Figure4
1.Motioncontrollever
bracket
3.Rotatethemotioncontrol
leverbracket
2.Removethetwobolts
13.Removethefourboltsholdingthefrontpanelinplace
andremovethefrontpanel(Figure5).
g019590
1 2
1
3
1
Figure5
1.Removethesebolts3.Motioncontrollever
bracket
2.Frontpanel
14.Usingapliers,loosenthefuelhoseclampandslideit
downthefuelhose.
15.Removethefuelventhoseandfuelhosefromthefuel
tank(
Figure6).
2
g019591
1
3
4
2
1
Figure6
1.Fuelhose3.Fueltank
2.Venthose4.Hoseclamp
16.Removeanyfuelfromthetankbypumpingitoutinto
afuelcan.
17.Removethetankfromthemachine.
18.Installthenewfueltankbyreversingsteps4through
17.
19.Destroytheoldfueltankbyoneofthefollowing
processes:
•Drilla1/4inchholeinthebottomofthefueltank
(
Figure7).
•Cutthellerneckoffofthefueltank(Figure7).
3
g019797
1
2
Figure7
1.Cutthellerneckoff2.Drilla1/4inchhole
RemovingthePulleys
WARNING
Mechanicalorhydraulicjacksmayfailtosupport
machineandcauseaseriousinjury.
Usejackstandswhensupportingmachine.
1.Drivethemachinetoalevelsurface.
2.DisengagethePTO,movethemotioncontrolleversto
theneutrallockedposition,andsettheparkingbrake.
3.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.
4.Raisetherearofmachineupandsupportitwithjack
stands.
5.Removethespringfromtheidler-springpost(
Figure
8).Thiswillreleasethetensiononthehydraulic-pump
belt.
Note:Donotremovethehydraulic-pumpbeltfrom
themachine;allowthehydraulic-pumpbelttolayloose
inthemachinewhileinstallingthiskit.
g021894
1
2
3
Figure8
1.Idler-springpost
3.Clutchpulley
2.Spring
6.Removetheidlerarmbolt,washer,rubberwashers,
innerspacer,idlerarm,largespacerandtheangenut
abovetheenginedeck(Figure12andFigure13).
7.Removethexedidlerpulleyandwasherfromthe
machine(Figure11).Discardthewasher.
Note:Donotremovethexed-idlercarriagebolt.
4
InspectingtheIdler-ArmPulley
1.Inspecttheidler-armpulleytoensureitfreelyrotates
andhasnowobble.Replacethepulleyifnecessary.
2.Iftheidler-armpulleydoesnotneedtobereplaced,
torquetheidler-pulleyboltbetween27and33ft-lbs.
3.Ifthepulleyneedstobereplaced,removethepulley
fromtheidlerarm(Figure9).Makenoteofhowitis
installed.
4.Installthenewidler-armpulleywithanewangenut
(3/8inch)asshowninFigure9.
Note:Ensurethebushingisinstalledtowardsthe
idlerarm(Figure9).
5.Torquetheidler-pulleyboltbetween27and33ft-lbs.
1
2
3
4
g021906
5 6 7
8
Figure9
1.Idler-pulleybolt
5.Newangenut(3/8inch)
2.Idler-armpulley
6.Bottomoftheidlerarm
pulley
3.Spacer
7.Ensurethebushingis
installedtowardstheidler
arm
4.Idlerarm
8.Topoftheidlerarmpulley
InstallingthePlate
1.Installthethinatwasherandstarwasherontothe
xed-idlercarriagebolt(Figure10).
g021896
1
2
Figure10
1.Thinatwasher2.Starwasher
2.Positiontheplateintothemachine,ushagainstthe
bottomoftheenginedeck(Figure11).
3.Installthenewthickatwasher,xed-idlerpulley
(correctorientation)andthenewlocknut(Figure11).
Note:Ensurethatthebushingisinstalledtowards
theplate(Figure11).
5
g021897
1
2
3
4
8
5
6 7
Figure11
1.Plate
5.Bottomofthexed-idler
pulley
2.Newthickwasher6.Ensurethebushingis
installedtowardstheplate
3.Fixed-idlerpulley
7.Topofthexed-idler
pulley,installtowardsthe
plate
4.Newangenut(3/8inch)8.Carriageboltwithat
washerandstarwasher
4.Installthelargespacer,rubberwashers,idlerarm,inner
spacer,andwashertotheenginedeckwiththeidler
armboltandnewlocknut(Figure12andFigure13).
Note:Thisrequirestwopeopletocomplete;the
angenutislocatedontopoftheenginedeckandin
frontoftheengine(Figure13).
g021903
1
2
3
4
2
5
6
7
Figure12
1.Largespacer5.Washer
2.Rubberwasher6.Idler-armpivotbolt
3.Idlerarm7.Plateinstalled
4.Innerspacer
6
g021877
1
2
3
Figure13
Topviewofthemachine
1.Engine
3.Newangenut(3/8inch)
2.Rollbar
5.Torquethenewangenutandcarriageboltatthe
xed-idlerpulleybetween27and33ft-lbs(Figure11).
6.Torquetheidler-armpivotboltbetween27and33
ft-lbs(Figure12).
7.Routethebeltaroundthepulleys(Figure14).
Note:Ensurethatthebeltisroutedaroundallpulleys.
g021895
1
6
2
3
4
5
Figure14
1.Idlerpulley4.Pumpdrivebelt
2.Idlerspringpost5.Right-handhydraulic
pumppulley
3.Enginepulley
6.Left-handhydraulicpump
pulley
8.Attachthespringtotheidler-springpost(Figure8).
9.Raisetherearofmachineup,removethejackstands,
andlowerthemachine.
7
/