Toro 107-7650 Installation Instructions
Conversion Kit
Z200 to Z500 DFS Bagger
Part No. 107–7650
Loose Parts
Note: Use the chart below to identify parts for assembly.
Step Description Qty. Use
Form No. 3351–335
Installation Instructions
1
2
3
4
5
6
7
No parts needed – Removing the bagger arm
Stop plate 1 Installing the stop plate
Bagger arm 1 Installing the bagger arm
Foam grip 2 Installing the latch lever
Cable
Long clevis, liquid cooled machines only
Short clevis
Clevis pin
Cotter pin
No parts needed – Adjusting the bagger arm
Pulley
Plate
Bearing housing
Key
Bolt, 3/8 x 5/8 inch
Spring washer, 3/8 inch
1
1
1
1
1
2
1
1
2
2
2
Installing the new cable
Installing the drive pulley assembly
Tensioner bracket template
8
9
10
11
2004 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
Eyebolt template
Tensioner bracket 1
No parts needed –
No parts needed – Adjusting the bagger belt
1
1
1
Drilling holes for the idler bracket and
the eyebolt
Installing the tensioner bracket and the
eyebolt
Installing the bagger tensioner
assembly and the belt
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Printed in the USA
Step UseQty.Description
12
13
14
15
16
Step
No parts needed – Installing and adjusting the mower belt
Middle tube 1
Mounting plate 1
Boot
Middle tube
Flexible tube
Clamp
Weight
U–Bolt, 3/8 X 6 inch
Lock nut, 3/8 inch
Washer, 3/8 inch
Spacer
1
1
1
1
1
2
4
4
4
Installing hardware onto a new middle
tube
Installing the existing boot and brackets
to the new mounting plate
Installing the boot and discharge tubes
Installing the weight
5
2
4
7
8
1
Removing the Existing Bagger
Arm
Parts needed for this step:
None
Procedure
1. Remove the shoulder bolt and cable from the bagger
arm (Fig. 1).
2. Loosen the nut and pulley on the bagger and remove the
cable from the pulley (Fig. 1).
3. Remove the cable from the bagger door hinge (Fig. 1).
Save all the hardware.
1
m–6136
Figure 1
1. Bagger arm
2. Cable
3. Shoulder bolt
4. Pulley and nut
4. Loosen the setscrew holding the latch lever (Fig. 6).
5. Remove the plastic cable ties on the handle and slide
the latch lever down the handle (Fig. 1).
5. Bagger door hinge
6. Cable tie
7. Latch lever
8. Grip
36
6. Remove the grip from the bagger arm (Fig. 3).
2
7. Remove the cotter pin and washer from the bagger arm
(Fig. 2). Save the washer and cotter pin.
8. Slide the bagger arm and washer out from the bagger
frame (Fig. 2). Save the washer.
3
Step
2
Installing the Stop Plate
Parts needed for this step:
Qty. Part
1
Stop plate
2
m–6206
1. Bagger arm
2. Bagger
9. Remove the latch lever off of the bagger arm and
discard the the bagger arm (Fig. 3).
4
1
Figure 2
3. Cotter pin
4. Washer
2
1
4
Procedure
1. Remove the existing stop bolt and jam nuts from the
bagger frame (Fig. 4).
2. Install the stop plate to the stop bracket using the bolt
and jam nut previously removed (Fig. 4). Do not
tighten.
2
3
1
3
5
Figure 4
1. Bagger dump lever
2. Bagger cable
3. Bagger cable clevis
4. Bolt, 1/2 x 1–3/4 inch
5. Jam nut, 1/2 inch
6. Stop bracket
7. Stop plate
6
7
5
4
m–7513
1. Bagger Arm
2. Latch lever
m–7173
Figure 3
3. Foam grip
3
Step
Step
3
Installing the Bagger Arm
Parts needed for this step:
Qty. Part
1
Bagger arm
Procedure
1. Install the latch lever onto the bagger arm.
2. Install 1 washer previously removed onto the bagger
arm pivot and install the bagger dump handle into the
bagger frame (Fig. 5).
3. Secure the bagger handle with the previously removed
washer and cotter pin (Fig. 5).
4
Installing the Latch Lever
Parts needed for this step:
Qty. Part
1
Foam grip
Procedure
1. Position the latch lever 6 inches (15.2 cm) down from
the end of the bagger arm. See Figure 6.
5
214
1. Bagger arm pivot
2. Washer
Figure 5
3. Cotter pin
4. Bagger frame
m–7515
3
2
1. Bagger arm end
2. Latch lever position
3. Latch lever cable
2. Position the latch lever at the 10 o’clock position when
1
2
3
Figure 6
looking at the end of the handle (Fig. 7).
6
4
4. Set screw
5. Foam grip
6. 6 inches (15.2 cm)
m–7175
4
2
1
4
3
1
2
m–7176
Figure 7
End view of handle
1. Latch lever
2. End of handle
3. 10 o’clock position
4. 12 o’clock position
3. Tighten the setscrew that holds the latch lever (Fig. 6).
4. Install the cable ties (Fig. 9).
5. Install the foam grip onto the bagger arm (Fig. 6).
Step
7
8
5
3
4
m–7178
Figure 8
1. Bagger arm
2. Cable
3. Shoulder bolt
4. Pulley and nut
5. Bagger door hinge
6. Cable tie
7. Nut
8. Washer
Note: Install the long cable clevis onto the bagger dump
handle if it is for a liquid cooled machine (Fig. 9).
3. Secure the bagger cable clevis to the bagger arm with
the clevis pin and cotter pin (Fig. 9).
4. Install the cable into the cable clevis installed on the
bagger handle (Fig. 9).
6
5
Installing the New Cable
Parts needed for this step:
Qty. Part
1
Cable
1 Long clevis, liquid cooled machines only
1 Short clevis
1 Clevis pin
1 Cotter pin
Procedure
1. Install the new cable to the top of the bagger with the
previously removed shoulder bolt, washer and nut
(Fig. 8).
2. Install the cable into the pulley and tighten the nut
(Fig. 8).
2
1
3
8
7
6
9
5 4
m–7520
5
Figure 9
1. Bagger dump lever
2. Bagger cable
3. Long cable clevis—liquid
cooled machines only
4. Bolt, 1/2 x 1–3/4 inch
5. Jam nut, 1/2 inch
6. Stop bracket
7. Clevis pin
8. Cotter pin
9. Stop plate
5. Adjust the handle stop, refer to Adjusting the Bagger
Arm, page 6.
5
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