Toro 100-2402, 100-2404 Installation Instructions

FORM NO. 3323-792

Heavy Duty Air Cleaner Kit

for Out Front Z

Part No. 100–2402 Part No. 100–2403 Part No. 100–2404

Loose

Note: Use the chart below to identify parts for assembly.

DESCRIPTION QTY. USE

Carburetor Adapter Plate Carburetor Gasket Air Cleaner Base Gasket Air Cleaner Adapter Gasket Adapter Air Cleaner Bracket Screws

Parts

1 1 1 1 1 1 1

Install New Carburetor

INSTALLATION

INSTRUCTIONS

Plug Screws Air Cleaner w/90º Inlet A/C Bracket Hood Nut

emplate #1

emplate #2

Rubber Grommet Air Intake Hose R–Clamp Screw

Flange Connector Radiator Clamp Screws

emplate #3

2 2 1 1 1 1

1 1

1 1 1 1

1 1 1

Cut Holes in Plastic T

Install Air Intake Hose

Install Flange Connector

Drill Holes in Bumper

ank

Printed in USA



The T

oro Company – 1999

Installation Instructions

DESCRIPTION USEQTY.

Air Cleaner Bracket Hex Head Screw Nuts

Air Cleaner Hex Head Screw Nuts

Radiator Clamp Filter Finder Kit Filter Guard

Cover Plate Screws Nuts Wing Nut Carriage bolts

This kit contains a heavy–duty air cleaner, carburetor, hose adapter

, hoses and mounting hardware. This creates a complete heavy–duty air cleaner system for Toro Out Front Z Mowers with Kohler Command Twin Cylinder Engines.

1 2 2

2 1 1

1 3 3 2 2

Install Air Cleaner Bracket

Install Air Cleaner

Install Hoses to Air Cleaner Install Filter Finder Kit

Install Guard and Cover

Pre–Installation

1. Disengage the power take off (PTO), set the

parking brake, and turn the ignition key to “OFF” to stop the engine. Remove spark plug wire(s) and remove the key.

POTENTIAL HAZARD

• If you leave the key in the ignition switch,

someone could start the engine.

WHAT CAN HAPPEN

• Accidental starting of the engine could

seriously injure you or other bystanders.

HOW TO AV

OID THE HAZARD

• Remove the key from the ignition switch

and pull the wire(s) off the spark plug(s) before you do any maintenance. Also push the wire(s) aside so it does not accidentally contact the spark plug(s).

2. Tilt hopper up remove all grass from hopper.

3. Thoroughly remove all grass and debris from

around the engine and plastic console on left side.

Installation Instructions

Removing

Hopper

1. Tilt hopper up.

2. Disconnect the wire harnesses along the rear left

side frame as shown in figure 1. Ensure that it is free of the frame.

3. Remove safety clip from end of gas spring to

hopper. Disconnect gas spring from ball stud attached to machine frame (Fig. 2). Support hopper to prevent falling.

4. Lower hopper. Remove both clevis pins from the

rear frame that the hopper pivots on. Remove hopper. (Fig. 2).

M-4582

Figure 1

1. Wire

Harness

Turning

Engine Lift Hook

Turning the engine lift hook will allow clearance for hose installed later in this instruction sheet. Keep the hook and hardware for future use if needed.

IMPORTANT: Return lift hook to original position before it is used for to remove engine.

1. Locate on engine the lift hook in figure 3.

2. Remove the lift hook from engine.

3. Rotate lift hook 180 degrees and reinstall.

M-4583

Figure 3

1. Engine

Lift Hook

2. Screws

1. Hopper

2. Safety

Gas Spring

Clip

Figure

Hair Pin Clevis pin

Removing

1. Remove all existing air cleaner components

Carburetor

attached to the carburetor. Save the three mounting screws from the air cleaner base plate and discard everything else.

2. Have an appropriate container ready to catch any

remaining fuel that might leak out and disconnect the fuel line from the carburetor.

3. Follow the red lead from the fuel shut–off

solenoid on the front of the carburetor and disconnect it from the harness plug.

M-4581

4. Remove and save the two carburetor mounting

screws.

Installation Instructions

5. Lift and pivot the carburetor to unhook the choke

link, throttle link, and throttle dampening spring attached to the carburetor. Discard the old carburetor.

6. Remove the carburetor gasket from the intake

manifold and clean off any remaining material using an aerosol gasket remover.

IMPORTANT: Do not nick or scratch manifold surface.

Installing

Carburetor

1. Install the two triangular plugs from the kit into

the air ducts on the top of the blower housing. Start the two thread–forming screws from the kit into the holes in the front of the air ducts. Tighten the screws until the plugs are locked into place (Fig. 5).

2. Install the new carburetor gasket onto the intake

manifold. Make sure all holes are aligned and open. A dab of gasket adhesive may be used to keep it in position (Fig. 5).

3. Reconnect the choke link, throttle link, and

throttle dampening spring into the corresponding levers of the new carburetor (Fig. 5).

6. Check the equipment throttle and choke controls

for proper operation. Be sure the plates in the carburetor are opening and closing fully with the movement of the control levers.

7. Connect the lead wire from the fuel shut–off

solenoid.

8. Reconnect the fuel line to the carburetor inlet

and secure with the clamp. Make sure the fuel line does not interfere with any of the linkages.

9. Place the new air cleaner base gasket from kit on

top of the carburetor (Fig. 5).

10. Position the new adapter plate over the

carburetor gasket and pull the breather tube through the corresponding hole until the plate is seated between the flanges. Assemble the new air cleaner bracket to the top of the new air cleaner base, inserting the breather tube through the hole in side of bracket. Make sure the end of the breather tube points toward the center of carburetor throat. Install the three mounting screws removed in step 1 of Removing Carburetor, page 3. Torque the screws to 88 in. lb (9.9 N•m). See figure 4.

4. Set the carburetor into position on the

gasket/intake manifold and install the two mounting screws saved in step 4 of Removing Carburetor. Lightly finger tighten the screws (Fig. 5).

5. Hold the governor lever toward the carburetor as

far as it will go. Check that the throttle plate is wide open in this position. If the throttle plate is not wide open, keep pressure against the governor lever and shift the carburetor until the plate is wide open. Torque the two mounting screws to 9.9 NSm (88 in.–lb.).

1. Air

Cleaner Bracket

Breather T

ube

Figure 4

Mounting Screw



Installation Instructions

11. Position the new adapter plate over the

carburetor gasket and pull the breather tube through the corresponding hole until the plate is seated between the flanges. The end of the breather hose must point into the carburetor throat. Install the three mounting screws removed in step 1 and torque them to 9.9 NSm (88 in. lb) (Fig. 5).

12. Position the adapter gasket and air intake adapter

onto the adapter plate, so the hose connection neck is facing straight back in the engine compartment. Secure with the seven M6 thread–forming screws. Torque the screws to

10.7 NSm (95 in.–lb.) (Fig. 5).

9 8

Cutting

Holes in Plastic

Console

A 3I and 3–1/2I diameter hole saw is needed to drill into the left side plastic console.

Note: Templates 1 and 2 must be used to

locate the correct location for holes. Templates are located in the back of this instruction sheet.

1. Locate and cut out templates 1 and 2 from the

back of this instruction sheet. Note: Do not cut out large circles in paper

templates.

2. Take template number one and fold it across the

fold line.

3. Place template number one onto the top of the

plastic console as shown in figure 6. Tape to plastic console.

5 4

3 1

1. Triangular

Plug Screws

Carburetor gasket

4. Carburetor

Air Cleaner Base Gasket

Plugs

Figure 5

Adapter Plate

Adapter Gasket

Air Intake Adapter

9. Screws

M-4571

13. Place rag or tape over air intake adapter opening

to prevent debris entering.

4. Using 3I diameter hole saw, cut a hole at the

specified area in template (Fig. 6).

m-4573

Diameter Hole to be cut

Leftside console

1. Template

2. T

emplate Position on

console

2 4

#1 (Folded)

Figure 6

3. 3”

5. Locate template number two and cut out small

hole. Fold template at the specified fold lines.

6. Place small cut out hole onto bolt head and place

the fold in the bend of metal support. (Fig. 7).

7. Align diagonal line on template with the edge of

metal support. Tape template to plastic console and metal support (Fig. 7).

Installation Instructions

8. Mark center of 3–1/2” hole. (Fig. 7).

9. Remove bolt that was used when locating

template position (Fig. 7).

10. Using 3–1/2I diameter hole saw, cut a hole at

the specified area in template (Fig. 7).

11. Reinstall bolt. (Fig. 7).

Note: Part of hole will be cut through metal

support. Remove any burrs from the metal support after hole is cut.

1. Template

2. T

console 3–1/2” Diameter Hole to

be cut

4. Bottom

#2 (Folded)

emplate Position on

of Leftside console

Figure 7

5. Bolt

Head (Remove bolt after 3–1/2” hole location is marked.)

Cut out circle (Align onto bolt head)

Edge of Metal Support

7 1 3

m-457

Drilling

Holes into Bumper

Note: Template 3 must be used to locate the

proper location for holes. Template 3 is located in the back of this instruction sheet.

1. Locate and cut out template three from the back

of this instruction sheet. Note: Do not cut out circles in paper

template.

2. Take template number three and fold it across

the fold line.

3. Place template number three onto the top of the

rear bumper as shown in figure 9. Tape to bumper.

4. Remove the three bolts as shown in figure 8.

Loosen the fourth bolt but do not remove.

Note: Figure 7 shows machine as if it were

tipped on its side. Do not tip machine on its side.

1. Bolts

2. Nuts

Figure 8

3. Bumper

4. Bolt

(Loosen)

m-4580

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