Page 1
Two–Bearing Conversion Kit
DFS Bagger for 100 and 200 Series Z Master
Part No. 107–7651
Part No. 107–7652
Loose Parts
Note: Use the chart below to verify all parts have been shipped.
Step Description Qty. Use
Form No. 3350–856
Installation Instructions
1
2
3
4
5
6
No parts needed – Remove the bagger from the frame
No parts needed
Template 1 Drilling holes for the lower bearing
Shaft
Fan
Snap ring
Key (1/4 x 2 inch)
Set screw
Thread locker adhesive
Pillow block bearing
Locknut, 1/2 inch
Washer, 1/2 inch
Bolt, 1/2 x 1–3/4 inch (100 Series only)
Bolt, 1/2 x 2–1/2 inch (200 Series only)
Shim
Rectangular spacer (200 Series only)
Scroll top assembly
Bolt, 1/4 x 7/8 inch
Washer, 1/4 inch
Locknut, 1/4 inch
Jam nut, 3/4 inch
Washer, 3/4 inch
– Removing the fan and bearings
1
1
1
1
2
1
1
1
4
2
2
3
1
1
9
18
9
1
1
Assembling the fan
Installing the lower bearing
Install the fan and scroll top
Jam nut, 3/4 inch
Washer, 3/4 inch
7
8
9
2003 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
Pulley
Key (1/4 x 1 inch)
No parts needed –
No parts needed –
1
1
1
1
Install the bottom pulley and jam nut
Adjust the bagger belt for a 200 Series
Bagger
Adjust the bagger belt for a 100 Series
Bagger
Contact us at www.Toro.com
All Rights Reserved
Printed in the USA
Page 2
Step
Step
1
Removing the Bagger
No parts needed for this step.
Procedure
1. Disengage the PTO, set the parking brake, and chock or
block the drive wheels.
2. Turn off the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
3. Remove the discharge tubes.
4. Remove hairpin cotters and clevis pins from the bagger
and bagger bracket.
5. Remove the skid plate or pulley guard.
6. Remove the bagger belt and bagger tensioner pulley.
2
Removing the Fan and
Bearings
No parts needed for this step.
Procedure
1. If a heat shield is installed on your 200 Series bagger,
remove the heat shield from the bagger (Fig. 1).
2
7. Remove the bagger from the bagger mounting bracket.
1
m–7335
Figure 1
1. Bolts 2. Heat shield
2. Remove the bottom pulley, set screws and key at the
bottom of the shaft (Fig. 2).
3. Loosen the locking collar for the bottom bearing
(Fig. 2).
2
Page 3
5
1
2
3
1
4
2
m–7332
Figure 2
1. Bottom pulley
2. Set screw
3. Key
4. Locking collar
4. Take the bottom bearing off the bagger (Fig. 3).
Note: To make it easier to remove the fan and shaft, you
may have to cut the shaft at the bottom and top to remove
the shaft (Fig. 7).
3
4
3
m–7337
4
Figure 4
1. Middle bearing
2. Bolt
3. Washer
4. Nut
5. Locking collar
7. Remove the outside bolts, nuts and washers from the
scroll top (Fig. 5).
2
3
1
1
2
m–7333
Figure 3
1. Bearing
2. Bolts
3. Nuts
4. Washers
5. Loosen the locking collar for the middle bearing
(Fig. 4).
6. Remove the three bolts from the middle bearing bracket
(Fig. 4).
1. Scroll top and fan
2. Nut
3
m–7331
Figure 5
3. Washer
Page 4
8. Pull the whole fan, shaft and scroll top up and out of the
hopper (Fig. 6).
2
1
m–7351
Figure 6
1. Hopper 2. Fan, shaft and scroll top
Note: To make it easier to remove the fan and shaft, you
may have to cut the shaft at the bottom and top to remove
the shaft (Fig. 7).
1
2
1
2
Figure 7
1. Saw 2. Cut here if needed to
remove the shaft
m–7334
m–7349
4
Page 5
Step
3
Drilling the Holes for the Lower
Bearing
Parts needed for this step:
• 1 T emplate
Procedure
Note: Make sure to use the correct holes to line up the
template. See Figure 8 for the correct holes to use for a 100
or 200 Series bagger.
4
1
2
m–7352
1. 100 Series holes
2. 200 Series holes
Figure 8
3. Holes to drill
4. Template
3
1
2
3
1
Figure 9
1. Bagger
2. Template
3. Using the template, mark and center punch the holes.
4. Drill two 1/8 inch pilot holes into the frame (Fig. 10).
5. Remove the template and discard it.
6. Drill 2 holes, 1/2 inch diameter, into the 1/8 inch pilot
holes (Fig. 10).
1
3. Correct template position
1
m–7345
1. Position the template inside the frame where the
existing bearing was removed.
Note: Make sure the template is tight against the bagger
frame (Fig. 9).
2. Align the correct holes in the template with the holes
from the previously removed bearing (Fig. 9).
2
m–7346
Figure 10
1. Holes to drill 2. Bagger
5
Page 6
Step
4
7
4 2
8
7
3
4
Assembling the Fan
Parts needed for this step:
• 1 Shaft
• 1 Fan
• 1 Snap ring
• 1 Key, 1/4 x 2 inch
• 2 Set screws
• 1 Thread locker adhesive
Procedure
1. Install the snap ring onto the top of the new shaft and
into the groove (Fig. 11).
2. Install the key (1/4 x 2 inch) onto the shaft and install
the fan onto the shaft until it contacts the snap ring
(Fig. 11).
Note: Make sure the key is completely set in the key way
(Fig. 11).
3. Apply thread locker adhesive to the set screws and
install the set screws into the fan hub (Fig. 11).
1. Shaft
2. Fan
3. Snap ring
4. Set screw
1
5
6
m–7353
Figure 11
5. Key, 1/4 x 2 inch
6. Snap ring groove
7. Thread locker adhesive
8. Key way
4. Torque the set screws to 90 in–lb (10 Nm) (Fig. 11).
6
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Step
5
Installing the Lower Bearing
• 1 Pillow block bearing
• 2 Locknuts, 1/2 inch
• 4 Washers, 1/2 inch
• 3 Shims
• 2 Bolts, 1/2 x 2–1/2 inch (200 Series only)
• 2 Bolts, 1/2 x 1–3/4 inch (100 Series only)
• 1 Rectangular spacer (200 Series only)
Procedure
Note: Do not tighten the lower pillow block bearing to the
frame of the bagger at this time. It needs to be tightened
after the fan and shaft are assembled to the bagger.
Note: The shim for the 100 Series baggers may not be
needed. When the belt is installed check the tension and
add it if needed.
6
2
5
Figure 13
1. Bagger
2. Pillow block bearing
3. Bolt, 1/2 x 1–3/4 inch
4. Washer, 3/4 inch
3. For 200 Series baggers, loosely install the lower pillow
block bearing to the bagger with 2 bolts (1/2 x
1–3/4 inch), 4 washers (1/2 inch), shims as/if needed,
rectangular spacer and 2 locknuts (1/2 inch) (Fig. 14).
5. Nut, 3/4 inch
6. Shim (May not be
needed)
4 3
1
m–7347
Important The bearings are pre–greased and do not
require grease on installation.
Note: Make sure the bearing hub faces down when
installing the lower pillow block bearing. Refer to the side
view in Figure 12.
1
2
m–7350
Figure 12
Side View
1. Pillow block bearing, side
view
1. The set screws installed in the bearings are not needed.
Remove the set screws before installing the bearing.
2. Bearing hub down
7
6
2
5
1. Bagger
2. Pillow block bearing
3. Bolt, 1/2 x 1–3/4 inch
4. Washer, 3/4 inch
Figure 14
5. Nut, 3/4 inch
6. Shim
7. Rectangular spacer
3
4
1
m–7348
2. For 100 Series baggers, loosely install the lower pillow
block bearing to the bagger with 2 bolts (1/2 x
1–3/4 inch), 4 washers (1/2 inch) and 2 locknuts
(1/2 inch) (Fig. 13).
7
Page 8
Step
6
Installing the Fan and Scroll
Top
• 1 Scroll Assembly
1
2
• 9 Bolt, 1/4 x 7/8 inch
• 18 Washer, 1/4 inch
• 9 Lock nut, 1/4 inch
• 1 Jam nut, 3/4 inch
• 1 Washer, 3/4 inch
Procedure
1. Install the scroll top to the fan with a jam nut (3/4 inch)
and a washer (3/4 inch). Torque the jam nut to 115 ft–lb
(155 Nm) (Fig. 15).
3
2
1
4
m–7339
3
Figure 16
1. Shaft and fan assembly
2. Hopper
3. Assemble the scroll top to the lower scroll with 9 bolts
(1/4 x 7/8 inch), 18 washers (1/4 inch) and 9 locknuts
(1/4 inch) (Fig. 17).
3. Lower bearing
m–7342
4
3
1
Figure 15
1. Scroll top
2. Jam nut, 3/4 inch
2. Install the shaft, fan assembly and scroll top into the
plastic hopper and the lower pillow block bearing
(Fig. 16).
3. Washer, 3/4 inch
4. Fan
m–7341
1. Scroll
2. Bolt, 1/4 x 7/8 inch
8
3
2
Figure 17
3. Washer, 1/4 inch
4. Nut, 1/4 inch
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4. Install the metal cap over the jam nut and the rubber cap
over the grease zerk (Fig. 18).
2
Step
1. Scroll
2. Rubber cap
Figure 18
3. Metal cap
4. Grease zerk
3
1
4
m–7340
Installing the Bottom Pulley
7
and Jam Nut
Parts needed for this step:
• 1 Pulley
• 1 Key, 1/4 x 1 inch
• 1 Spacer (100 Series only)
• 1 Washer, 3/4 inch
• 1 Jam nut, 3/4 inch
Procedure
1. For the 100 Series baggers, install a spacer onto the
shaft before the short key and the pulley (Fig. 19).
2. Install the short key and pulley onto the shaft (Fig. 19).
Note: Make sure the long pulley hub is installed upward
(Fig. 19).
4
3
2
1
Figure 19
1. Pulley
2. Long pulley hub
3. Install the washer (3/4 inch) and jam nut (3/4 inch) onto
the shaft (Fig 20).
4. Torque the jam nut to 115 ft–lb (155 Nm) (Fig 20).
3. Key, 1/4 x 1 inch
4. Spacer, 100 Series only
m–7343
9
Page 10
2
1
Figure 20
1. Jam nut, 3/4 inch 2. Washer, 3/4 inch
m–7344
7
6
2
5
1. Bagger
2. Pillow block bearing
3. Bolt, 1/2 x 1–3/4 inch
4. Washer, 3/4 inch
Figure 22
5. Nut, 3/4 inch
6. Shim
7. Rectangular spacer
3
4
1
m–7348
5. Tighten the lower pillow block bearing to the frame.
See Figures 21 or 22.
6
2
5
4 3
1
m–7347
Figure 21
1. Bagger
2. Pillow block bearing
3. Bolt, 1/2 x 1–3/4 inch
4. Washer, 3/4 inch
5. Nut, 3/4 inch
6. Shim (May not be
needed)
6. If a heat shield was removed earlier for your 200 Series
bagger, install the heat shield to the bagger (Fig. 23).
2
1
m–7336
Figure 23
1. Bolts 2. Heat shield
7. Install the bagger belt onto the bagger and the machine.
Refer to the bagger Operators Manual for the correct
procedure.
8. Check the belt tension.
9. Install the skid plate or pulley guard previously
removed.
10
Page 11
Step
C. Tighten the 4 mounting bolts holding the drive
pulley assembly to the machine frame (Fig. 25).
3
8
Adjusting the Bagger Belt for a
200 Series Bagger
No parts needed for this step.
Procedure
1. Check the belt tension (Fig 24).
2. Measure the gap, at the bagger tensioner pulley,
between the tight and slack side of the belt when the
bagger tensioner pulley and spring are installed
(Fig. 24).
2
1
6
1
2
Figure 25
1. Drive pulley assembly
2. Mower belt
3. Bagger belt
6. If the gap measurement is too small:
A. Loosen the 2 nuts on the lower fan shaft pillow
block bearing (Fig. 26).
B. Insert a shim behind the pillow block bearing
(Fig. 26).
C. Tighten the nuts.
4. Mounting bolts
5. Back of machine
5
4
m–5892
5
3
Figure 24
1. Tensioner spring
2. Eye bolt
3. Bagger tensioner pulley
4. Bagger pulley
3. There must be a gap of 1 inch ± 1/8 inch
(26mm ± 3 mm) between the belt strands (Fig. 24).
4. If the gap is not correct, remove the tensioner spring
from the eyebolt and remove the tension on the mower
spring loaded idler (Fig. 24).
5. If the gap measurement is too large:
A. Loosen the 4 mounting bolts holding the drive
pulley assembly (Fig. 25).
B. Pull the pulley assembly rearward slightly
[1/8–3/16 inch (3–5 mm)] from the original set–up
position (Fig. 25).
5. Belt
6. Shortest space between
belt strands, 1 inch
±1/8 inch
m–5887
D. Check the belt gap and repeat procedure as required.
4
2
1
Figure 26
1. Pillow block bearing
2. Fan shaft
7. Install the tensioner spring to the eyebolt and apply the
tension on the mower spring loaded idler.
8. Measure the bagger belt tension. There must be a gap of
1 inch ± 1/8 inch (26mm ± 3 mm) between the belt
strands (Fig. 24).
9. Repeat this procedure if a gap of 1 inch ± 1/8 inch
(26mm ± 3 mm) was not achieved (Fig. 24).
3. Shim
3
11
Page 12
Step
9
Adjusting the Bagger Belt for a
100 Series Bagger
No parts needed for this step.
Procedure
If the bagger belt is too loose, proceed to the following
steps. When a new belt is installed or when the belt is tight
do not use any shims.
2. To adjust the belt tension:
A. Remove the tensioner spring (Fig. 27).
B. Loosen the 2 nuts on the lower fan shaft pillow
block bearing (Fig. 28).
C. Insert a spacer between the pillow block and the
frame (Fig. 28).
D. Tighten the nuts.
E. Install the tensioner spring (Fig. 27).
F. Check the belt gap and repeat procedure as required.
1. With the bagger belt tensioned, measure the gap
between the insides of the belt at the tensioner pulley
(Fig. 27). The gap must be 1–1/2 to 1–3/4 inches. If the
gap is not between 1–1/2 and 1–3/4 inches, proceed to
the next step.
7
6
4
3
2
1
Figure 28
1. Pillow block
2. Fan shaft
2
1
5
8
1
3. Spacer
3
6
1. Tensioner spring
2. Bolt for spring
3. Bagger tensioner pulley
4. Bagger pulley
m–6004
Figure 27
5. Bagger belt
6. Clutch drive pulley
7. Clutch
8. 1–1/2 to 1–3/4 inch gap
12
Page 13
Maintenance
Greasing the Fan Shaft
Bearings
Grease the upper and lower bagger fan shaft bearings
(Fig. 29 & 30) every 100 hours.
1. Grease the lower bearing (Fig. 29).
2
Figure 29
1. Lower bearing 2. Grease zerk
2. Remove the rubber plug to expose the grease fitting
(Fig. 30).
1
2
1
Figure 30
1. Plug 2. Grease zerk
13
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