Toro 125-4790 Installation Instructions

MetalPlateKit

ZMaster

ModelNo.125-4790

®

FormNo.3378-515RevA

Commercial2000SeriesRidingMower

InstallationInstructions

Note:Keepthemowerdeckbeltinstalledduringthe

installationofthiskit.Thereisnointerferencewiththe
mowerdeckbelt.

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

Description

Nopartsrequired

Nopartsrequired

Nopartsrequired

Nopartsrequired

Plate1
Starwasher
Thinatwasher
Flangenut(3/8inch)
Thickatwasher

Qty.

WARNING

CALIFORNIA

Proposition65Warning

Thisproductcontainsachemicalorchemicals

knowntotheStateofCaliforniatocausecancer,

birthdefects,orreproductiveharm.

Use

–

–

–

–

1
1
2
1

Checkthefueltank.

Installthefueltank.

Removethepulleys.

Inspecttheidler-armpulley .

Installtheplate.

CAUTION

Ifthemachinehasbeenrunning,themuferand
exhaustsystemwillbeveryhotandcancause
seriousburnsifyoutouchthem.

Allowthemachinetocoolcompletelybefore
performingthisprocedure.

CheckingtheFuelTank

Note:Ensureanewfueltankandidlerpulleyareorderedif

thereisanywearontheexistingfueltank.

Checkthefueltankforanywearundertheidlerpulley(Figure

1).

•Ifyouseeorfeelwithyourngernail,agrooveinthefuel

tankfromtheidlerpulley,replacethefueltankandidler

©2013—TheT oro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

Registeratwww.T oro.com.

pulley(Figure1).Orderanewfueltankandanewidler
pulley.ProceedtoReplacingtheFuelTank(page2).

•Ifthefueltankdoesnothaveanywearfromtheidler

pulley,proceedtoRemovingthePulleys(page4).

OriginalInstructions(EN)

PrintedintheUSA.

AllRightsReserved

*3378-515*A

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Figure2

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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.

1.Seat

2.Frontnutswithkeyhole

9.Removetheseatandbasefromthemachine.

10.Unplugtheharnessconnectorfromtheseatswitch
locatedundertheseat(Figure3).

6.Movetheseatthefurthestforwardpositiontoexpose
therearnuts.

1.Harnessconnector

Figure3

7.Loosentherearnuts.Thenutsdonotneedtobe
removed.

8.Slidetheseatandseatplateforwardtoallowthefront
nutstogothroughthekeyhole(

Figure2).

11.Removethetwoboltsholdingtheleftsidemotion
controlleverbracket.

12.Rotatethemotioncontrolleverbrackettoallowthe
frontpaneltoberemoved(

Figure4).

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Figure4

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1.Motioncontrollever
bracket

2.Removethetwobolts

3.Rotatethemotioncontrol
leverbracket

13.Removethefourboltsholdingthefrontpanelinplace
andremovethefrontpanel(Figure5).

1.Fuelhose3.Fueltank

2.Venthose4.Hoseclamp

Figure6

16.Removeanyfuelfromthetankbypumpingitoutinto
afuelcan.

17.Removethetankfromthemachine.

18.Installthenewfueltankbyreversingsteps4through

17.

19.Destroytheoldfueltankbyoneofthefollowing
processes:

•Drilla1/4inchholeinthebottomofthefueltank

Figure7).

(

•Cutthellerneckoffofthefueltank(Figure7).

1.Removethesebolts3.Motioncontrollever

2.Frontpanel

14.Usingapliers,loosenthefuelhoseclampandslideit
downthefuelhose.

15.Removethefuelventhoseandfuelhosefromthefuel
tank(

Figure6).

Figure5

bracket

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Figure7

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1.Cutthellerneckoff2.Drilla1/4inchhole

RemovingthePulleys

Figure8

1.Idler-springpost

2.Spring

3.Clutchpulley

6.Removetheidlerarmbolt,washer,rubberwashers,
innerspacer,idlerarm,largespacerandtheangenut
abovetheenginedeck(Figure12andFigure13).

WARNING

Mechanicalorhydraulicjacksmayfailtosupport
machineandcauseaseriousinjury.

Usejackstandswhensupportingmachine.

1.Drivethemachinetoalevelsurface.

2.DisengagethePTO ,movethemotioncontrolleversto
theneutrallockedposition,andsettheparkingbrake.

3.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

4.Raisetherearofmachineupandsupportitwithjack
stands.

5.Removethespringfromtheidler-springpost(

8).Thiswillreleasethetensiononthehydraulic-pump
belt.

Note:Donotremovethehydraulic-pumpbeltfrom
themachine;allowthehydraulic-pumpbelttolayloose
inthemachinewhileinstallingthiskit.

Figure

7.Removethexedidlerpulleyandwasherfromthe
machine(Figure11).Discardthewasher.

Note:Donotremovethexed-idlercarriagebolt.

4

InspectingtheIdler-ArmPulley

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InstallingthePlate

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.Installthethinatwasherandstarwasherontothe
xed-idlercarriagebolt(Figure10).

Figure10

1.Thinatwasher2.Starwasher

2.Positiontheplateintothemachine,ushagainstthe
bottomoftheenginedeck(Figure11).

3.Installthenewthickatwasher,xed-idlerpulley
(correctorientation)andthenewlocknut(Figure11).

Note:Ensurethatthebushingisinstalledtowards
theplate(Figure11).

1.Idler-pulleybolt

2.Idler-armpulley

3.Spacer

4.Idlerarm

Figure9

5.Newangenut(3/8inch)

6.Bottomoftheidlerarm
pulley

7.Ensurethebushingis
installedtowardstheidler
arm

8.Topoftheidlerarmpulley

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Figure11

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1.Plate

2.Newthickwasher6.Ensurethebushingis

3.Fixed-idlerpulley

4.Newangenut(3/8inch)8.Carriageboltwithat

5.Bottomofthexed-idler
pulley

installedtowardstheplate

7.Topofthexed-idler
pulley,installtowardsthe
plate

washerandstarwasher

4.Installthelargespacer,rubberwashers,idlerarm,inner
spacer,andwashertotheenginedeckwiththeidler
armboltandnewlocknut(Figure12andFigure13).

Note:Thisrequirestwopeopletocomplete;the
angenutislocatedontopoftheenginedeckandin
frontoftheengine(Figure13).

Figure12

1.Largespacer5.Washer

2.Rubberwasher6.Idler-armpivotbolt

3.Idlerarm7.Plateinstalled

4.Innerspacer

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Topviewofthemachine

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5

9.Raisetherearofmachineup,removethejackstands,
andlowerthemachine.

Figure13

1.Engine

2.Rollbar

3.Newangenut(3/8inch)

5.Torquethenewangenutandcarriageboltatthe
xed-idlerpulleybetween27and33ft-lbs(Figure11).

6.Torquetheidler-armpivotboltbetween27and33
ft-lbs(Figure12).

7.Routethebeltaroundthepulleys(Figure14).

Note:Ensurethatthebeltisroutedaroundallpulleys.

Figure14

1.Idlerpulley4.Pumpdrivebelt

2.Idlerspringpost5.Right-handhydraulic

3.Enginepulley

8.Attachthespringtotheidler-springpost(Figure8).

pumppulley

6.Left-handhydraulicpump
pulley

7