Toro 132-5986 Installation Instructions

PowerDeckLiftKit

ZMaster3000,5000,and6000SeriesMowers

ModelNo.132-5986

WARNING

CALIFORNIA

Proposition65Warning

ThisproductcontainsachemicalorchemicalsknowntotheStateofCaliforniato

causecancer,birthdefects,orreproductiveharm.

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

Note:ThiskitisnotcompatiblewithmachinesthathavetheMyRide™suspensionsystem.

Safety

FormNo.3405-296RevA

InstallationInstructions

SafetyandInstructionalDecals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaofpotentialdanger.
Replaceanydecalthatisdamagedorlost.

119–6807

1.Warning—nostep

©2016—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

Registeratwww.T oro.com.

132-5992

1.Pressdownonthepedaltoliftthedeck.

OriginalInstructions(EN)

PrintedintheUSA

AllRightsReserved

*3405-296*A

Installation

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

ProcedureDescription

1
2

3

4

5

6

Nopartsrequired

Deckfootpedal

Switchtemplate
Momentaryswitch1
Powerliftfootpedal
Screw(1/4x3/4inch)
Flatwasher(1/4inch)
Whiz-locknut(1/4inch)
ZMaster6000seriestemplate1
ZMaster3000/5000seriestemplate
Actuatorbracket1
Screw(7/16x4–1/2inches)
Springdiscwasher(7/16inch)
Whiz-locknut(7/16inch)
Screw(3/8x3–1/2inches);forZMaster

6000seriesunitsonly
Conediscwasher
Whiz-locknut(3/8inch)
Screw(3/8x3–1/4inches);forZMaster

3000and5000seriesunitsonly
Nylocnut1
Frontdeckliftbracket
Screw(1/2x6–1/2inches)
Springdiscwasher(1/2inch)
Locknut(1/2inch)
Actuator1
Clevispin
Cotterpin
Actuatorsideplate2
Flatwasher(1/2inch)
Spacer
Screw(1/2x2–1/2inches)
Wireharness1
Cabletie
Fuse,25A1
Fuse,30A1

Qty.

Use

–

1

1

1
2
2
2

1

1
1
1

1

1
1

1

1
2
2
3

2
2

2
2
1

8

Preparethemachine.

Installthedeckfootpedal.

Installthepowerliftfootpedaland
switch.

Installtheactuatorbracket.

Installtheactuator.

Installthedeckliftharness.

7
8

Nopartsrequired

Nopartsrequired

2

–

–

Completetheinstallation.

Makethenaldeckliftadjustment.

1

2

PreparingtheMachine

NoPartsRequired

Procedure

1.Parkthemachineonalevelsurface,disengagethePTO ,
movethemotion-controlleverstotheNEUTRAL-LOCK
position,shutofftheengine,settheparkingbrake,and
removethekeyfromtheignitionswitch.

CAUTION

Ifyouleavethekeyintheignitionswitch,
someonecouldaccidentlystarttheengineand
seriouslyinjureyouorbystanders.

Removethekeyfromtheignitionswitch
beforeyouperformanymaintenance.

2.Disconnectthenegativecablefromthebatterypost;
refertotheOperator’ sManualforyourmachine.

InstallingtheDeckFootPedal

Partsneededforthisprocedure:

1

Deckfootpedal

Procedure

WARNING

InstallingthepowerliftfootpedalonZMaster3000,
5000,and6000seriesmowerswithoutreplacingthe
deckfootpedalcouldresultinseriousinjury.

Replacethedeckfootpedalonallunits.

Note:Usetheexistinghardware.

WARNING

Incorrectbatterycableroutingcoulddamage
themachineandcablescausingsparks.
Sparkscancausethebatterygassesto
explode,resultinginpersonalinjury.

•Alwaysdisconnectthenegative(black)
batterycablebeforedisconnectingthe
positive(red)cable.

•Alwaysconnectthepositive(red)battery
cablebeforeconnectingthenegative
(black)cable.

3.Disconnectthepositivecablefromthebatterypost;
refertotheOperator’ sManualforyourmachine.

4.Removethespark-plugwirefromtheterminalofthe
sparkplug.

Figure1

3

4.Insertthebottomhalfoftheswitchthroughthe
undersideofthetoeboard,makingsurethecontacts

3

pointdownward(Figure2).Screwonthetophalfof
theswitchhand-tight.Donotovertighten.

InstallingthePowerLiftFoot
PedalandMomentarySwitch

Partsneededforthisprocedure:

1

Switchtemplate

1Momentaryswitch

1

Powerliftfootpedal

2

Screw(1/4x3/4inch)

2

Flatwasher(1/4inch)

2

Whiz-locknut(1/4inch)

Procedure

1.Raiseandlockthedeckinthe14cm(5–1/2inch)
transportposition.

2.Cutouttheswitchtemplate,alignthetemplateas
showninFigure2,centerpunchtheholes,anddrill
theholesasfollows:

•Fortheswitch-mountinghole,drillahole(5/8inch

diameter)throughthetoeboard.

5.Handtightenthenutonthebottomhalfoftheswitch
untilitrestsagainsttheundersideofthetoeboard.Do
notovertighten.

6.Installthepowerliftfootpedalusing2screws(1/4x
3/4inch),2atwashers(1/4inch),and2whiz-lock
nuts(1/4inch)asshowninFigure2.

•Forthepowerliftfootpedalmountingholes,drill2

holes(11/32inchdiameter)throughthetoeboard.

Figure2

1.Whiz-locknut(1/4inch)6.Washer(1/4inch)

2.Switch—bottomhalf7.Screw(1/4x3/4inch)

3.Deckfootpedal8.Switchtemplate

4.Switch—tophalf

5.Powerliftfootpedal

9.Toeboard

3.Unscrewthetophalfoftheswitchfromthebottom
halfandunscrewthenutfromthebottomhalfuntilit
stops.

4

Note:Ifthehardwareisdifculttoremove,cutoff
thebolthead.

4

InstallingtheActuatorBracket

Partsneededforthisprocedure:

1ZMaster6000seriestemplate

1

ZMaster3000/5000seriestemplate

1Actuatorbracket

1

Screw(7/16x4–1/2inches)

1

Springdiscwasher(7/16inch)

1

Whiz-locknut(7/16inch)

Screw(3/8x3–1/2inches);forZMaster6000series

1

unitsonly

1

Conediscwasher

1

Whiz-locknut(3/8inch)

Screw(3/8x3–1/4inches);forZMaster3000and

1

5000seriesunitsonly

1Nylocnut

Procedure

1.Raiseandlockthedeckinthe14cm(5–1/2inch)
transportposition.

2.Inserttheheight-adjustmentpinintothe14cm(5–1/2
inch)holetoassurethedeckislockedinthefull-up
(transport)position.

3.Ontheleftsideoftheunit,measurethedistance
betweenthenutontheendofthespringandthe
bracket(Figure3).Notethismeasurement.

5.Removeandretainthefrontspringhardwareandthe
sidespring.

6.Cutouttheappropriatereardeckliftarmtemplate,
alignthetemplateasshowninFigure4,centerpunch
thehole,anddrilltheholeasfollows:

•ForZMaster6000seriesunits,drillahole(25/64

or13/32inchdiameter).

•ForZMaster3000and5000seriesunits,drillapilot

hole(5/16inchdiameter)andtap3/8-16UNC.

Note:Aat-bottomtapisnecessarytofullythread
thehole.

Figure4

1.ZMaster3000/5000series
reardeckliftarm

2.Template4.Bottomhole

7.Installtheactuatorbrackettothereardeckliftarmby
performingthefollowing:

A.Alignthetopholeoftheactuatorbracketandrear

deckliftarm.

B.Attachtheactuatorbrackettothereardecklift

armwithascrew(7/16x4–1/2inches),spring
discwasher(7/16inch),andwhiz-locknut(7/16
inch)asshowninFigure5.Handtightenagainst
thebracket.

3.Zmaster6000seriesrear
deckliftarm

Figure3

1.Measuredistance

2.Bracket5.Fronthardware

3.Nut6.Rearhardware

4.Sidespring

4.Removeandretaintherearhardwareholdingthe
spring.

Figure5

1.Whiz-locknut(7/16inch)3.Springdiscwasher(7/16

2.Actuatorbracket

5

inch);conetowardsbolt
head

4.Screw(7/16x4–1/2
inches)

C.Installhardwareintobottomholeoftheactuator

bracketbyperformingthefollowing:

•ForZMaster6000seriesunits,installascrew

(3/8x3–1/2inches),conediscwasher,
andwhiz-locknut(3/8inch)andtighten
hand-tight.

•ForZMaster3000and5000seriesunits,

installascrew(3/8x3–1/4inches)andcone
discwasher.

8.Torquethescrewsfromstep7accordingtothe
followingtable.

ScrewSizeTorqueSpecication

7/16inch61to75N∙m(45to55ft-lb)

3/8inch37to45N∙m(27to33ft-lb)

9.Installthesidespringbyplacingtherearhookonto
thescrew .Installthenylocnutandleavea9mm(0.35
inch)gapbetweenthenylocnutandwhiz-locknut
(7/16inch)asshowninFigure6.

5

InstallingtheActuator

Partsneededforthisprocedure:

1

Frontdeckliftbracket

2

Screw(1/2x6–1/2inches)

2

Springdiscwasher(1/2inch)

3

Locknut(1/2inch)

1Actuator

2

Clevispin

2

Cotterpin

2Actuatorsideplate

2

Flatwasher(1/2inch)

2

Spacer

1

Screw(1/2x2–1/2inches)

Procedure

Figure6

1.Nylocnut

2.Screw(7/16x4–1/2
inches)

10.Haveahelperpressdownonthedeckpedalandhold
thedecktothefull-up(transport)position.

11.Installthefrontboltofthesidespring,usethe
measurementrecordedinstep3tosetthegapbetween
thenutontheendofthespringandthebracket(see

Figure3),andtightenorloosenthespringboltuntil

theappropriategapisreached.

12.Yourhelpercannowreleasethedeckandallowitto
returntotheTRANSPORT-LOCKposition.

3.Whiz-locknut(7/16inch)

4.9mm(0.35inch)gap

1.Raisetheleftsideofthedeckandsupportitwithjack
stands.Makesurethatthereisnoweightontheleft
frontdeckliftlinkadjuster.

WARNING

Raisingthemowerforserviceormaintenance
relyingsolelyonmechanicalorhydraulic
jackscouldbedangerous.Themechanicalor
hydraulicjacksmaynotbeenoughsupport
ormaymalfunctionallowingtheunittofall,
whichcouldcauseinjury.

Donotrelysolelyonmechanicalorhydraulic
jacksforsupport.Useadequatejackstands
orequivalentsupport.

2.Raiseandlockthedeckinthe14cm(5–1/2inch)
transportposition.

3.Inserttheheight-adjustmentpinintothe14cm(5–1/2
inch)holetoassurethedeckislockedinthefull-up
(transport)position.

4.Removethehardwarefromtheleft,frontcross-shaft
support.

6

5.Installthefrontdeckliftbracketusing2screws(1/2x
6–1/2inches),2springdiscwashers(1/2inch),and2
locknuts(1/2inch)asshowninFigure7.Torquethe
screwsto91to113N∙m(67to83ft-lb).

7.InstalltherearactuatorsideplatesasshowninFigure9.

Figure9

Figure7

1.Screw(1/2x6–1/2inches)4.Left,frontcross-shaft

2.Springdiscwasher(1/2
inch);conetowardsbolt
head

3.Frontdeckliftbracket

support

5.Locknut(1/2inch)

6.Installtheactuatoronthefront,deck-liftbracketusing
theclevispinandhairpincotter(Figure8).

Note:Makesurethatthemotorispointingdown.

1.Clevispin

2.Flatwasher(1/2inch)

3.Actuatorsideplates

4.Spacer8.Locknut(1/2inch)

5.Actuatorbracket

6.Hairpincotter

7.Screw(1/2x2–1/2inches)

8.Iftheactuatorholedoesnotalignwiththe
actuator-side-platehole,turntheendoftheactuator
clockwiseorcounterclockwiseuntilitalignsasshown
inFigure10.

Figure10

1.Actuatorend3.Turntoshorten

2.Turntolengthen

Figure8

1.Front,deck-liftbracket3.Clevispin

2.Actuator4.Hairpincotter

9.Installtheactuatorsideplatestotheactuatorbracket
asshowninFigure9.

Note:Usethetopcenterholeposition.

10.Carefullyremovethejackstand.

7

6

12

3

4

5

7

5

8

9

10

6

5

G012951

InstallingtheDeckLiftHarness

Partsneededforthisprocedure:

1Wireharness

8

Cabletie

1Fuse,25A

1Fuse,30A

Procedure

2.Connecttheotherendtotheactuatorharness.Push
thedeckliftandactuatorharnessconnectioninside
thetoeboard(Figure12).

Harnessroutingoverview:

Figure11

1.Actuator6.Floorpan

2.Connectactuatorand
deckliftharness

3.Deckliftharness8.Controlpanelfront

4.Connectswitchtodecklift
harness

5.Cabletie10.Connectdeckliftharness

7.Rightmotioncontrolpanel

opening

9.Controlpanelrearopening

toaccessory

Figure12

1.Toeboard3.Actuatorharness

2.Deckliftharness

3.Removethe15Aaccessoryfusefromthefuseboxand
replaceitwiththe25Afuse.

4.Removethe25Amainfusefromthefuseboxand
replaceitwiththe30Afuse.

5.Removeandretainthehardwarefromthecontrol
panel,carefullyremovethecontrolpanel,andremove
thecapfromtheaccessoryplug.

6.Routethedeckliftharnessundertherightsideofthe
oorpanelalongthesideoftheframesothatitjoins
withthemainsystemwireharness.

Note:Usecabletiestosecurethewireharnesstothe
machineasshowninFigure11.

7.Insertthedeckliftharnessthroughthefrontopening
ofthecontrolpanel,routeitthroughtherearopening
ofthecontrolpanel,andconnectittotheaccessory
harnessplug.

8.Ifmultipleaccessoriesarebeingused,anadd-on
accessoryharnesskitisrequired(PartNo.109-9798).

9.Installthepreviouslyremovedcontrolpanelwiththe
correspondinghardware.

4.Actuator

1.Plugthedeckliftharnessintotheswitchandroute
theharnessaroundthecross-shaftusingcabletiesto
securetheharnessasnecessary.

8

7

CompletingtheInstallation

NoPartsRequired

Procedure

1.Connectthepositivebatterycabletothepositivepost
ofthebattery;refertotheOperator’sManualforyour
machine.

2.Iftheactuatordoesnotraisethedeckhighenoughto
getoutoftheTRANSPORT-LOCKposition,movethe
rearclevispinbackaholeasshowninFigure13.

WARNING

Incorrectbatterycableroutingcoulddamage
themachineandcablescausingsparks.
Sparkscancausethebatterygassesto
explode,resultinginpersonalinjury.

•Alwaysdisconnectthenegative(black)
batterycablebeforedisconnectingthe
positive(red)cable.

•Alwaysconnectthepositive(red)battery
cablebeforeconnectingthenegative
(black)cable.

2.Connectthenegativecablefromthebatterypost;refer
totheOperator’sManualforyourmachine.

3.Connectthespark-plugwiretotheterminalofthe
sparkplug.

8

Figure13

1.Moveforwardifdeckhits
framestops

2.Initialposition

3.Iftheactuatorraisesthedecktoofarandthedeckhits
theframe(Figure14)priortotheactuatorbeingfully
retracted,anoticeableloudbangingsoundoccursas
theclutchslipserratically.Ifthishappens,movethe
rearclevispinforwardahole;refertoFigure13.

3.Movebackwardif
unabletogetin/outof
TRANSPORT-LOCK

MakingtheFinalDeckLift Adjustment

NoPartsRequired

Procedure

1.Afterthedeckliftkitiscompletelyinstalled,turnonthe
keyandactivatethepowerliftfootpedal.Theactuator
retractsandliftsthedecktothehighestposition.

Note:Theactuatorhasaratchetingslipclutchyou
cannoticeablyhearwhentheactuatorisbeingfully
retracted.Ifthedeckliftisadjustedproperly ,thedeck
liftsoutoftheTRANSPORT-LOCKpositionandthere
isarapidclickingsoundwhentheactuatorisfully
retracted.

Figure14

1.Deckstop3.Actuatorbracket

2.Framestop

4.Ifthedeckdoesnotfallunderitsownweight,lengthen
thedistancebetweenthedeckbracketandsidespring
nutby1/8inch(3mm);refertoFigure3.Testthe
actuatoragain.Repeatthisstepuntilthedeckfalls
underitsownweight.

9

Operation

Thepowerdeckliftkitisdesignedtoworkinconjunction
withtheoriginaldeck-lift,height-of-cut,andtransport-lock
mechanismsalreadyonthemower.Whenthepowerdeck
liftkitisproperlyinstalled,anelectricactuatorprovides
apoweredliftingfeaturethatreducestheneedtopush
onthemanualfootleverwhenraisingthedecktothe
TRANSPORT-LOCKposition.However,themanualfootlever
maystillbeusedformanualoverrideofthepoweredsystem,
intheeventitisconvenientornecessarytodoso.

RaisingtheDeckUsingthe PoweredDeckLift

Pressthepowerliftfootpedaltoraisethedecktothe
TRANSPORT-LOCKposition.Theelectricactuatorhasaslip
clutchthatratchetswhenthedeckisfullyraised,andthere
isarapidclickingsoundwhentheclutchisslipping.This
ratchetingsoundisnormalastheactuatorisdesignedto
ratchettoalimiteddegree.

Note:Holdingthepowerliftfootpedalagainsttheswitch
formorethan2seconds,afteritisfullyraised,causesthe
actuatortooverheatandreducesthelifeoftheactuator.It
isrecommendedtolimittheactuatorratchetingtonolonger
than2secondsatatime,witharestingperiodofatleast30
seconds,orexcessiveheatingandactuatordamagemayoccur.
PutthedeckinTRANSPORT-LOCK,orusethemanualfoot
lever,toholdthedeckinplaceforlongerperiodsoftime.

LoweringtheDeckUsingthe PoweredDeckLift

1.Stopthemachineandmovethemotioncontrollevers
outwardtotheNEUTRAL-LOCKposition.

2.DisengagethePTO.

3.WiththedeckintheTRANSPORT-LOCKposition,insert
theheight-adjustmentpinintothedesiredheight-of-cut
setting.

4.Releasepressurefromthetransportlockbypushing
eitherthepowerliftfootpedal,orthemanualdeckfoot
lever,andsimultaneouslypullingonthetransport-lock
rod.

5.Slowlyreleasethepowerliftfootpedalorthemanual
deckliftfootpedal.Whenreleased,thedeckisfree
tofallunderitsownweight,whichback-drivesthe
actuator,untilthedeckstopsontheheight-adjustment
pin.

Note:Ifthedeckdoesnotfallunderitsownweight
orifthedeckhitstheframewhenthedeckisinthe
full-upposition;referto8MakingtheFinalDeckLift

Adjustment(page9).

10

Notes:

11