Toro 78401 Installation Instructions

FormNo.3437-322RevA

48in,52in,or60inBlowerand
DriveKit

E-ZVac

™

StandardBaggerZero-Turn-Radius

RidingMower

ModelNo.78401—SerialNo.400000000andUp
ModelNo.78402—SerialNo.400000000andUp
ModelNo.78403—SerialNo.400000000andUp
ModelNo.78404—SerialNo.400000000andUp
ModelNo.78405—SerialNo.400000000andUp
ModelNo.78406—SerialNo.400000000andUp

Registeratwww.T oro.com.
OriginalInstructions(EN)

*3437-322*A

Introduction

Readthisinformationcarefullytolearnhowtooperate
andmaintainyourproductproperlyandtoavoid
injuryandproductdamage.Youareresponsiblefor
operatingtheproductproperlyandsafely .

Visitwww.T oro.comforproductsafetyandoperation
trainingmaterials,accessoryinformation,helpnding
adealer,ortoregisteryourproduct.

Wheneveryouneedservice,genuineToroparts,or
additionalinformation,contactanAuthorizedService
DealerorToroCustomerServiceandhavethemodel
andserialnumbersofyourproductready.Figure1
identiesthelocationofthemodelandserialnumbers
ontheproduct.Writethenumbersinthespace
provided.

Thismanualidentiespotentialhazardsandhas
safetymessagesidentiedbythesafety-alertsymbol
(Figure2),whichsignalsahazardthatmaycause
seriousinjuryordeathifyoudonotfollowthe
recommendedprecautions.

g000502

Figure2

Safety-alertsymbol

Thismanualuses2wordstohighlightinformation.
Importantcallsattentiontospecialmechanical
informationandNoteemphasizesgeneralinformation
worthyofspecialattention.

Contents

Safety.......................................................................3

SafetyandInstructionalDecals..........................3

Setup........................................................................5

1PreparingtheMachine.....................................6

2RemovingtheExistingBeltCover,Bracket,

andDischargeChute......................................6

3InstallingtheBlower-PulleyAssemblyand

Belt-CoverBracket..........................................7

4InstallingtheBafe..........................................11

5InstallingtheBlowerAssembly.......................12

6InstallingtheBlowerBeltandBlower-Belt

Coverl...........................................................14

Figure1

1.Blowermodelandserialnumberlocation

ModelNo.

SerialNo.

©2019—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

g309299

Contactusatwww.Toro.com.

2

PrintedintheUSA

AllRightsReserved

Safety

SafetyandInstructionalDecals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyarea
ofpotentialdanger.Replaceanydecalthatisdamagedormissing.

133-8061

decal133-8061

126-4662

1.Warning—readtheOperator’sManualforthecorrect
quantityofcounterbalanceweight(s).

2.Lossoftractionandsteeringorreducedstabilityhazard—Ez
Vaccounterbalanceweight(s)installedwithouttheEzV ac
maycauselossoftractionandsteeringcontrol.TheEzVac
installedwithouttheEzVaccounterbalanceweight(s)can
causereducedstability.Installweight(s)onlywhentheEz
Vacisinstalled.

decal126-4662

3

decal136-4164

136-4164

1.Warning—readtheOperator’sManual.4.Cutting/dismembermenthazard,impeller—keepawayfrom

movingparts;keepallguardsandcoversinplace.

2.Warning—hearingprotectionmustbeworn.

5.Cutting/dismembermenthazard,impeller—disengagethe
PTO,removethekey,andwaitforallmovingpartstostop.

3.Thrownobjecthazard—donotoperatetheblowerwithoutthe
entiresysteminstalledandlatched.

6.Warning;lossoftraction—donotoperatewithonly
counterbalanceweightsinstalled;donotoperatewithonly
E-ZV acinstalled;operateonlywithbothE-ZVacand
counterbalanceweightsinstalled.

4

Installation

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

ProcedureDescription

1

2

3

4

5

6

Nopartsrequired

Nopartsrequired

Blower-pulleyassembly1
Belt-coverbracket1
Speednut
Carriagebolt(1/4x3/4inch)
Locknut(1/4inch)
Locknut(3/8inch)
Blowerpulley1
Locknut(3/4inch)
Washer1
Pulleymount1
Bafe
Carriagebolt(5/16x7/8inch)
Flangenut(5/16inch)
Carriagebolt(3/8x7/8inch)
Flangenut(3/8inch)
Blowerassembly1
Blowerbelt1
Pivotpin1
Rollpin1
Blower-beltcover1
Knob1

Qty.

Use

–

–

1
2
2
3

1

1
1
1
2
2

Preparethemachine.

Removetheexistingbeltcover,bracket,
anddischargechute.

Installtheblower-pulleyassembly.

Installthebafe.

Installtheblowerassembly .

Installtheblowerbeltandbeltcover.

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

5

1

PreparingtheMachine

NoPartsRequired

Procedure

1.Parkthemachineonalevelsurface.

2.Movethemotion-controlleverstotheNEUTRAL-LOCKposition.

3.Engagetheparkingbrake.

4.Shutofftheengineandremovethekey.

g037289

Figure3

2

RemovingtheExisting
BeltCover,Bracket,and
DischargeChute

NoPartsRequired

Procedure

Note:Cleantheareaaroundthebeltcoverbefore

removingit.

1.Lowerthemowerdecktothelowestheight-of-cut
position.

2.Removetherightbeltcover(Figure4).

g027729

Figure4

6

3.Removetherightbelt-coverbracket,2washers
(60-inchmowerdeckonly),and2angenuts
fromthemowerdeck(Figure5).

Note:Retainthehardwarethatyouremoved

duringthisproceduresothatitisavailablefor
changeover.

Figure5

1.Rightbelt-coverbracket3.Flangenuts

2.Washers-onlyon152cm

(60inch)mowerdeck

4.Removethelocknut,bolt,spring,andspacer
securingthedeectortothepivotbrackets
(Figure6).

3

InstallingtheBlower-Pulley
AssemblyandBelt-Cover
Bracket

Partsneededforthisprocedure:

1Blower-pulleyassembly

1Belt-coverbracket

1

Speednut

2

Carriagebolt(1/4x3/4inch)

2

3

1Blowerpulley

1

1Washer

1Pulleymount

Locknut(1/4inch)

Locknut(3/8inch)

Locknut(3/4inch)

g038093

Procedure

Figure6

1.Bolt

2.Spacer6.Grassdeector

3.Locknut

4.Spring

5.Removethegrassdeector(Figure6).

5.Springinstalled

7.J-hookendofspring

1.Onthemachine,removethespringtensionfrom
thespring-loadedidlerpulley;refertoFigure7
orFigure9.

Note:ForblowerModels78401,78402,and

78403,usethespring-removaltool(ToroPart
No.92-5771)toremovethespringfromthe
mower-deckpost(Figure8).

Note:ForblowerModels78404,78405,and

78406,usearatchetinthesquareholeinthe
idlerarmtoremovetensionontheidlerspring
(Figure9).

g015594

7

Figure7

ForModels78401,78402,and78403

1.Clutchpulley3.Spring-loadedidlerpulley

2.Mowerbelt

4.Spring

g036865

g036861

1.Clutchpulley

2.Mowerbelt

3.Spring-loadedidlerpulley

ForModels78404,78405,and78406

Figure9

4.Ratchet

5.Squareholeintheidler
armfortheratchet

2.Removethebeltfromtherightmower-deck
pulley.

3.Useawrench(1-1/2inches)toholdthespindle
shaft,asyouremovethelocknut(3/4inch)and
washerfromthespindleshaft(Figure10).

Note:Setasidethelocknut(3/4inch)and

washerforblowerModels78404,78405,and

78406.

Figure8

ForModels78401,78402,and78403

1.Spring-removaltool(T oro
PartNo.92-5771)

2.Idlerspring5.Mowerbelt

3.Mower-deckpost

4.Idlerarm

g028279

g038095

Figure10

1.Locknut(3/4inch)3.Rightspindleshaft

2.Washer

8

4.Useawrench(1-1/2inches)toholdthespindle

shaft,asyouinstallthedoublepulleyontothe
rightspindleshaft.

•ForblowerModels78401,78402,and

78403,performthefollowingprocedure:

•ForblowerModels78404,78405,and

78406,performthefollowingprocedure:

A.Insertthethreadedstudsonpulley

mountthroughtheholesinthedeck
pulley(Figure12).

A.Usethelocknut(3/4inch)andwasherto

B.Torquethelocknut(3/4inch)to176to

1.Locknut(3/4inch)

2.Washer

securethenewdoublepulleyontothe
rightspindleshaft(Figure11).

217N∙m(130to160ft-lb).

Figure11

3.Doublepulley

4.Rightspindleshaft

B.Usethelocknut(3/4inch)andwasher

thatyousetasideearliertosecurethe
deckpulleytothespindleshaft(Figure

12).

C.Torquethelocknut(3/4inch)to176to

217N∙m(130to160ft-lb).

D.Arrangetheblowerpulleyontothe

threadedstudsandlooselyinstallthe
locknut(Figure12).

E.Rotatetheblowerpulleyclockwiseuntil

itstops.

F.Torquethe3locknutsto18N∙m(13

ft-lb).

g038253

9

6.Installthemowerbeltaroundthelowerpulleyof
thedoublepulley(Figure13).

Figure13

1.Lowerpulley2.Mowerbelt

7.Installthebelt-coverbrackettothemowerdeck
using2carriagebolts(1/4x3/4inch)and2
locknuts(1/4inch)asshowninFigure14.

8.Installthespeednutontothebelt-coverbracket
(Figure14).

g038097

Figure12

1.Locknut(3/8inch)

2.Blowerpulley6.Pulleymount

3.Locknut(3/4inch)7.Rightspindleshaft

4.Washer

5.Existingdeckpulley

5.Ensurethatthebladeboltistorquedto115to
149N∙m(85to1 10ft-lb).

g188637

g038112

Figure14

1.Carriagebolt(1/4x3/4
inch)

2.Belt-coverbracket

3.Speednut

4.Locknut(1/4inch)

9.Installthemowerdeckbeltaroundthe

spring-loadedidlerpulley(Figure7orFigure9).

10.Usethespring-removaltool(ToroPart
No.92-5771)toattachthespringtothe
spring-loadedidlerpulley.

10

4

InstallingtheBafe

Partsneededforthisprocedure:

1

Bafe

1

Carriagebolt(5/16x7/8inch)

1

Flangenut(5/16inch)

2

Carriagebolt(3/8x7/8inch)

2

Flangenut(3/8inch)

Procedure

1.Removethe2existingangenuts(3/8inch)and
2carriagebolts(3/8x7/8inch)fromthemower
deck(Figure15).

Figure15

1.Flangenut(3/8inch)2.Carriagebolt(3/8x7/8

inch)

2.Installthebafeusingthecarriagebolt(5/16x
7/8inch),angenut(5/16inch),2carriagebolts
(3/8x7/8inch),and2angenuts(3/8inch)as
showninFigure16.

g038289

Figure16

1.Flangenut(3/8inch)4.Flangenut(5/16inch)

2.Carriagebolt(3/8x7/8
inch)

3.Bafe

g038113

5.Carriagebolt(5/16x7/8
inch)

11

5

InstallingtheBlower
Assembly

Partsneededforthisprocedure:

1Blowerassembly

1Blowerbelt

1Pivotpin

1Rollpin

Procedure

Verifythatthepivotpinissecuredontheblower
assemblyinthecorrectlocation(Figure17).

•Ifyouhavea48-inchor52-inchmowerdeck,

installthepivotpininthefronthole(Figure17).

•Ifyouhavea60-inchmowerdeck,installthepivot

pinintherearhole(Figure17).

1.Alignthepivotpinontheblowerwiththe
pivot-pinholeinthemowerdeck(Figure18).

Figure17

Blowerfor48-inchand52-inchmowerdeckshown

g309295

Figure18

1.Blowerassembly3.Pivothole

2.Blower-pivotpin4.Deck

2.Installthebeltaroundthepulleysinsidethe
blower(Figure19).

g309297

1.Blowerassembly4.Pivotpin

2.Fronthole(48-inchand
52-inchmowerdeck)

3.Rearhole(60-inchmower
deck)

5.Rollpin

g309298

Figure19

12

3.Lowertheblowerandslidethepivotpinintothe

pivothole(Figure18).

Note:Ensurethatthebeltremainspositioned

intheblowerpulley.

4.Movethelatchpinfromthelockingpositionto

theopenposition(Figure20).

Figure20

g309296

1.Latchpin4.Idlerpulley

2.Chutebracket5.Belt(beneaththeidler

3.Idler-pivotbracket6.Blowerassembly

pulley)

5.Closetheblowerassemblyandalignthelatch

pinwiththeholeinthechutebracket(Figure20).

6.Movethelatchpintothelockingposition.

Note:Ensurethatthelatchpinextendsthrough

theholeinthechutebracket.

Note:Ensurethatthelatchrmlyholdsthe

blowerassemblyagainstthemowerdeck,but
youcanreleaseitbyhand.

13

6

InstallingtheBlowerBelt
andBlower-BeltCoverl

Partsneededforthisprocedure:

1Blower-beltcover

1Knob

Procedure

1.Pullbackthespring-loadedidlerpulleyand

routetheblowerbeltaroundthedrivepulley
(Figure21).

2.Installtheblower-beltcoverovertheblowerbelt
andsecuretheblower-beltcoverwiththeknob
(Figure22).

g309587

Figure22

1.Knob2.Beltcover

Figure21

1.Blowerbelt2.Drivepulley

g309586

14

CaliforniaProposition65WarningInformation

Whatisthiswarning?

Youmayseeaproductforsalethathasawarninglabellikethefollowing:

WARNING:CancerandReproductiveHarm—www.p65Warnings.ca.gov.

WhatisProp65?

Prop65appliestoanycompanyoperatinginCalifornia,sellingproductsinCalifornia,ormanufacturingproductsthatmaybesoldinorbroughtinto
California.ItmandatesthattheGovernorofCaliforniamaintainandpublishalistofchemicalsknowntocausecancer,birthdefects,and/orother
reproductiveharm.Thelist,whichisupdatedannually,includeshundredsofchemicalsfoundinmanyeverydayitems.ThepurposeofProp65isto
informthepublicaboutexposuretothesechemicals.

Prop65doesnotbanthesaleofproductscontainingthesechemicalsbutinsteadrequireswarningsonanyproduct,productpackaging,orliteraturewith
theproduct.Moreover,aProp65warningdoesnotmeanthataproductisinviolationofanyproductsafetystandardsorrequirements.Infact,the
CaliforniagovernmenthasclariedthataProp65warning“isnotthesameasaregulatorydecisionthataproductis‘safe’or‘unsafe.’”Manyofthese
chemicalshavebeenusedineverydayproductsforyearswithoutdocumentedharm.Formoreinformation,gotohttps://oag.ca.gov/prop65/faqs-view-all

AProp65warningmeansthatacompanyhaseither(1)evaluatedtheexposureandhasconcludedthatitexceedsthe“nosignicantrisklevel”;or(2)
haschosentoprovideawarningbasedonitsunderstandingaboutthepresenceofalistedchemicalwithoutattemptingtoevaluatetheexposure.

Doesthislawapplyeverywhere?

Prop65warningsarerequiredunderCalifornialawonly.ThesewarningsareseenthroughoutCaliforniainawiderangeofsettings,includingbutnot
limitedtorestaurants,grocerystores,hotels,schools,andhospitals,andonawidevarietyofproducts.Additionally ,someonlineandmailorder
retailersprovideProp65warningsontheirwebsitesorincatalogs.

.

HowdotheCaliforniawarningscomparetofederallimits?

Prop65standardsareoftenmorestringentthanfederalandinternationalstandards.TherearevarioussubstancesthatrequireaProp65warning
atlevelsthatarefarlowerthanfederalactionlimits.Forexample,theProp65standardforwarningsforleadis0.5μg/day,whichiswellbelow
thefederalandinternationalstandards.

Whydon’tallsimilarproductscarrythewarning?

•ProductssoldinCaliforniarequireProp65labellingwhilesimilarproductssoldelsewheredonot.

•AcompanyinvolvedinaProp65lawsuitreachingasettlementmayberequiredtouseProp65warningsforitsproducts,butothercompanies

makingsimilarproductsmayhavenosuchrequirement.

•TheenforcementofProp65isinconsistent.

•CompaniesmayelectnottoprovidewarningsbecausetheyconcludethattheyarenotrequiredtodosounderProp65;alackofwarningsfora

productdoesnotmeanthattheproductisfreeoflistedchemicalsatsimilarlevels.

WhydoesToroincludethiswarning?

Torohaschosentoprovideconsumerswithasmuchinformationaspossiblesothattheycanmakeinformeddecisionsabouttheproductstheybuyand
use.T oroprovideswarningsincertaincasesbasedonitsknowledgeofthepresenceofoneormorelistedchemicalswithoutevaluatingthelevelof
exposure,asnotallthelistedchemicalsprovideexposurelimitrequirements.WhiletheexposurefromT oroproductsmaybenegligibleorwellwithinthe
“nosignicantrisk”range,outofanabundanceofcaution,TorohaselectedtoprovidetheProp65warnings.Moreover,ifT orodoesnotprovidethese
warnings,itcouldbesuedbytheStateofCaliforniaorbyprivatepartiesseekingtoenforceProp65andsubjecttosubstantialpenalties.

RevA