Toro 78492 Installation Instructions

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Boot and Tube Kit

100 Series Z Master 44 Mowers

Model No. 78492

Set Up

Loose Parts

Note: Use the chart below to verify all parts have been shipped.

Description Qty. Use

Form No. 3327–682

Installation Instructions

Tunnel baffle—rear Carriage Bolt, 5/16 x 5/8 in. Bolt—thread forming, 3/8 x 5/8 in. Flange nuts, 5/16 in.

Tunnel baffle—front Carriage Bolt, 5/16 x 5/8 in. Flange nuts, 5/16 in.

Tunnel baffle—center Carriage Bolt, 5/16 x 5/8 in. Bolt, 5/16 x 5/8 in. Flange nuts, 5/16 in.

Cutting chamber baffle Socket button head bolt, 1/4 x 5/8 in. Lock nuts, 1/4 in. Socket button head bolt, 5/16 x 3/4 in. Flange nuts, 5/16 in.

Lower bagger tube Upper bagger tube Boot assembly Tube clamp

1 3 1 3

1 2 2

1 2 1 3

1 2 2 3 3

1 1 1 1

Installing the rear tunnel baffle

Installing the front tunnel baffle

Installing the center tunnel baffle

Installing the cutting chamber baffle

Installing the discharge tubes

Note: If the mower is removed from the machine, it will need to be leveled when installed.

Removing the Mower

1. Lower the mower onto wood blocks.

 2002 by The Toro Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196

2. Remove the four bolts at the bottom of chains that

attached to mower (Fig. 1).

3. Remove the nuts and bolts holding pins in the push

arm (Fig. 1).

4. Remove the pins (Fig. 1).

5. Raise height of cut lever and slide mower out (Fig. 1).

Printed in the USA

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6. Remove the mower belt from the clutch.

1. Remove the four screws holding the right front

blowout baffle to the mower (Fig. 2).

2. Remove the baffle (Fig. 2). Save the baffle and screws

for use when not in bagging mode.

m–6062

Figure 1

1. Mower

2. Chain

3. Chain Bolt

4. Push Arm

5. Push Arm Bolt

6. Push Arm Nut

7. Push Arm Pin

Before Installation

1. Tip mower upside down and block up ends to ease

installation of components.

2. Thoroughly clean the mower. All debris must be

removed to ensure baffles will fit properly against the mower.

3. Repair all bent or damaged areas of mower and

replace any missing parts.

Warning

Contact with sharp blade can cause serious personal injury.

m–6069

Figure 2

1. Right front blowout baffle

2. Screw

3. Mower

Installing the Mower Baffles

Note: Use figure 3 for an overall view of where to install the baffles.

• Wear gloves or wrap sharp edges of the

blade with a rag.

Removing the Right Front Blowout Baffle

Note: Remember to install the right front blowout baffle to the mower if the bagger and bagger baffles are removed.

1. Front tunnel baffle

2. Rear tunnel baffle

3. Front of mower

m–6058

Figure 3

4. Center tunnel baffle

5. Cutting chamber baffle

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Installing the Front Tunnel Baffle

1. Place the front tunnel baffle against the front wall of

the discharge tunnel (Fig. 5).

2. Align the front tunnel baffle flush with the outside of

the mounting bracket (Fig. 4).

m–5930

Figure 4

1. Front tunnel baffle

2. Mounting bracket

3. Flush edge with outside of mounting bracket

4. Outside of mounting bracket

3. Clamp the baffle in place.

4. Using the baffle as a template, drill two, 11/32 in.

diameter, holes into the top of the discharge tunnel (Fig. 5).

5. Install the front tunnel baffle with 2 carriage bolts

(5/16 x 5/8 in.) and 2 flange nuts (5/16 in.) (Fig. 5).

m–6045

Figure 5

1. Front tunnel baffle

2. Carriage Bolt, 5/16 x 5/8 in.

3. Flange nut, 5/16 in.

4. Hole to drill

5. Mounting bracket

6. Front tunnel wall

Installing the Rear Tunnel Baffle

Note: There is an existing hole in the top of the mower for installing the rear tunnel baffle.

1. Place the rear tunnel baffle against the rear wall of the discharge tunnel. (Fig. 6).

2. Loosely, install the thread forming bolt (3/8 x 5/8 in.) into the existing hole in the top of the mower (Fig. 8).

Note: The rear tunnel baffle must not extend past the outside of the mounting bracket.

3. Slide the rear tunnel baffle along the rear wall until there is a 3/16 in. gap between the blade and the baffle tab (Fig. 7).

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m–6046

Figure 7

1. Rear tunnel baf fle

2. 3/16 in. gap

3. Blade

4. Baffle tab

5. Tunnel rear wall

4. Tighten the thread forming bolt (3/8 x 5/8 in.) into the

top of the mower (Fig. 8).

5. Clamp the baffle in place.

6. Using the baffle as a template, drill two, 11/32 in.

diameter, holes into the top of the discharge tunnel (Fig. 8).

7. Drill one, 11/32 in. diameter, hole into the rear wall of

the discharge tunnel (Fig. 8).

8. Remove the clamp.

9. Install the rear tunnel baffle with 3 carriage bolts

(5/16 x 5/8 in.) and 3 flange nuts (5/16 in.) (Fig. 8).

Important Make sure the bolt heads are installed on

the inside of the cutting chamber.

m–5925

Figure 8

1. Rear tunnel baffle

2. Carriage Bolt, 5/16 x 5/8 in.

3. Flange nut, 5/16 in.

4. Hole to drill

5. Existing hole

6. Baffle tab

7. Rear wall of the discharge tunnel

8. Outside of mounting bracket

9. Thread forming bolt, 3/8 x 5/8 in.

Installing the Center Tunnel Baffle

Important Do not install this baffle when bagging

grass unless blowout is a problem. This baffle is highly recommended when bagging leaves.

Note: Remove this baffle once the cutting chamber baffle is installed.

1. Place the center tunnel baffle between the front and

rear tunnel baffles (Fig. 9).

2. Install the center tunnel baffle to the front tunnel

baffle. The flange on the center baffle goes over and behind the front baffle (Fig. 9).

3. Secure the center tunnel baffle with two carriage bolts

(5/16 x 5/8 in.) and flange nuts (5/16 in.) (Fig. 9).

Note: There is an existing hole for installing the center baffle to the rear wall.

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4. Install the center tunnel baffle to the rear wall of the

discharge tunnel. Use a bolt (5/16 x 5/8 in.) and flange nut (5/16 in.) (Fig. 9).

m–5930

Figure 9

1. Center tunnel baffle

2. Bolt, 5/16 x 5/8 in.

3. Flange nut, 5/16 in.

4. Flush edge

5. Front tunnel baffle

6. Existing hole

1. Baffle flange

2. Blade

3. Spindle

Figure 10

54 32

4. Blade clearance, 5/8 in. ±1/16 in.

5. Baffle to top of cutting chamber, 4–1/8 in.

m–608

Installing the Cutting Chamber Baffle

Note: There are two existing holes in the mower flange for installing the cutting chamber baffle.

1. Place the cutting chamber baffle behind the right

cutting blade chamber and against the mower flange (Fig. 12).

2. Install the cutting chamber baffle to the mower flange

with 2 socket button head bolts (1/4 x 5/8 in.) and 2 locknuts (1/4 in.) (Fig. 12).

3. Align the cutting chamber baffle so the baffle flange is

4–1/8 in. (92 mm) from the top of the cutting chamber (Figures 10 and 11).

Important Make sure the baffle flange is 4–1/8 in.

(92 mm) from the top of the cutting chamber and there is blade clearance of 5/8 in. ±1/16 in. (Figures 10 and 11).

m–606

Figure 11

1. Baffle flange

2. Blade

3. Spindle

4. Baffle to top of cutting chamber, 4–1/8 in.

4. Clamp the cutting chamber baffle in place (Fig. 11).

5. Using the baffle as a template, drill two 11/32 in.

diameter, holes into the side of the cutting chamber (Fig. 12).

6. Drill one, 11/32 in. diameter, hole into the back of the

mower (Fig. 13).

7. Remove the clamp.

8. Install the cutting chamber baffle to the back side of

the cutting chamber with 2 socket button head bolts (5/16 x 3/4 in.) and 2 flange nuts (5/16 in.) (Fig. 12).

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1 4

9 6

Figure 12

1. Cutting chamber baffle

2. Holes to drill

3. Flange nuts, 5/16 in.

4. Socket button head bolt, 5/16 x 3/4 in.

5. Socket button head bolt, 1/4 x 5/8 in.

6. Lock nut, 1/4 in.

7. Baffle flange

8. Mower flange

9. Existing hole

9. Install the cutting chamber baffle to the back of the mower with a socket button head bolt (5/16 x 3/4 in.) and a flange nut (5/16 in.) (Fig. 13).

m–6055

m–6083

Figure 13

1. Cutting chamber baffle

2. Hole to drill

3. Right–hand cutting blade chamber

4. Flange nut, 5/16 in.

5. Socket button head bolt, 5/16 x 3/4 in.

6. Mower flange

7. Back of mower

Important Make sure the bolt heads are installed on

the inside of the cutting chamber.

10.Rotate the blades to ensure there is clearance between the blade tips and the baffles, as specified in figure 10.

11. If contact is made, do not use the mower. Check and make sure all baffles are installed properly.

Installing the Discharge Tubes

Refer to the bagger operator ’s manual for installing the discharge tubes.

Installing the Blades

Note: In certain mowing conditions, improved bagging performance can be achieved by using bagging blades. Contact an Authorized Service Dealer for the proper blades for different mowing conditions.

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Warning

Contact with sharp blade can cause serious personal injury.

• Wear gloves or wrap sharp edges of the

blade with a rag.

1. Install the bagging blade onto the spindle shaft

(Fig. 14).

Important The curved part of the blade must be

pointing upward toward the inside of the mower to ensure proper cutting.

2. Install the flat washer, lock washer and blade bolt (Fig. 14). Torque the blade bolt to 85–110 ft.-lb.

(115–150 Nm).

3. Rotate the blades to ensure there is clearance between the blade tips and the baffles.

4. If contact is made, do not use the mower. Check and make sure the baffles are installed properly.

Important Do not use the mower if blades contact the

baffles.

m–4318

Figure 14

1. Sail area of blade

2. Blade

3. Flat washer

4. Blade bolt

5. Split lockwasher

Installing the Mower

1. Install the mower to the machine. Reverse the instructions in Removing the Mower on page 1.

Note: The mower will need to be leveled when installed. Refer to your operator’s manual.

2. Install the mower belt after the bagger is installed.

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