Toro 78496, 78497 Installation Instructions

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Page 1

Form No. 3329–234 Rev A

44 and 52 Finishing Kit

100 Series Z Master 44 Mowers 100 Series Z Master 52 Mowers

Model No. 78496 Model No. 78497

Installation Instructions

Important This kit will require significant time to install the first time. A right angle drill is recommended for

installation.

Loose Parts

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

Step Description Qty. Use

1 2 3 4

5 6

Tunnel baffle—front Carriage bolt, 5/16 x 5/8 inch Flange nut, 5/16 inch

Tunnel baffle—rear Carriage bolt, 5/16 x 5/8 inch Flange nut, 5/16 inch

Center rear baffle Button Head Socket Bolt, 5/16 x 3/4 inch Flange nut, 5/16 inch

Left rear baffle Button Head Socket Bolt, 5/16 x 3/4 inch Flange nut, 5/16 inch

Right rear baffle Button Head Socket Bolt, 5/16 x 3/4 inch Carriage bolt, 5/16 x 5/8 inch Flange nut, 5/16 inch

1 4 4

1 3 3

1 2 1 3

Installing the front tunnel baffle

Installing the rear tunnel baffle

Installing the center rear baffle

Installing the left rear baffle

Installing the right rear baffle

Removing the mower existing pulley assembly

Pulley assembly

8 9

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

Bagger Belt Pulley cover

Mounting plate Bolt, 3/8 x 1–1/4 inch Flange nuts, 3/8 inch

Modifying a 44 inch Mower for Belt Clearance

1 1 1

2 4 4

Installing the pulley assembly, belt and cover

Installing the mounting plate

Page 2

Before Installation

Checking the Mower for Existing Holes

Check for existing holes. Use existing holes in the mower that align the baffles in their correct positions.

Checking the Spindle for 1999 Models

For mowers built in 1999, the right hand blade spindle may need to be replaced (Fig. 1). Check the right blade spindle for splines. The splines are needed to install the pulley assembly shown in Figure 17.

Order a new, year 2000 model, splined spindle from an Authorized Service Dealer (Fig. 1).

1. Outer nut

2. Idler pulley

3. Idler arm

4. Spring eye bolt

2. Remove the mower belt from the right outside pulley. Note: Do not remove the spring.

Figure 2

Top View

5. Spring

6. 9–3/8 inch ± 1/8 inch (238 mm ±3 mm)

7. Mower belt

M–4197

m–6381

Figure 1

Top View

1. Blade spindle—without splines

2. No splines

3. Year 2000 blade spindle—with splines

4. Splines

Removing the Mower

Note: If the mower is removed from the top bolts, the mower will not need to be leveled.

1. Loosen the outer nut on the spring eye bolt (Fig. 2).

Caution

Spring is under tension when installed and can cause personal injury.

Do not remove spring from spring eye bolt.

3. Lower the mower onto wood blocks.

4. Remove the four bolts at the top of chains that

attached to mower (Fig. 3).

5. Remove the nuts and bolts holding the push arm pins

(Fig. 3).

Note: The gage wheels may need to be removed to allow the push arm pins to be removed (Fig. 3).

6. Remove the push arm pins (Fig. 3).

7. Raise height of cut lever and slide mower out (Fig. 3).

Page 3

Removing the Cutting

Chamber Stiffener

Note: This section is only for mowers with a stiffener welded to the cutting chamber (Fig. 4).

m–6265

m–6062

Figure 3

1. Mower

2. Chain

3. Chain Bolt

4. Push Arm

5. Push Arm Bolt

6. Push Arm Nut

7. Push Arm Pin

8. Gage wheel

Preparing the Mower

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

installation of components.

1. Remove the cutting chamber stiffener from the mower

(Fig. 4).

2. Grind the welds flat on rear part of the chamber. This

will allow the correct fit for the cutting chamber baffle.

m–6081

Figure 4

1. Cutting chamber 2. Cutting chamber stiffener

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 the mower and

replace any missing parts.

Warning

Contact with sharp blade can cause serious personal injury.

• Wear gloves or wrap sharp edges of the blade

with a rag.

Page 4

Step

Parts needed for this step:

• 1 Tunnel baffle—front

• 4 Carriage bolts, 5/16 x 5/8 inch

• 4 Flange nuts, 5/16 inch

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 baffle, flush with the outside of the

mounting bracket (Fig. 5).

5. Install the front tunnel baffle to the mower with

4 carriage bolts (5/16 x 5/8 inch) and 4 flange nuts (5/16 inch) (Fig. 6).

Figure 5

1. Front tunnel baffle

2. Flush edge with outside of mounting bracket

3. Clamp the baffle in place.

3. Outside of mounting bracket

m–6223

1. Front tunnel baffle

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

m–6172

Figure 6

3. Flange nut, 5/16 inch

4. Hole to drill

5. Front tunnel wall

4. Using the baffle as a template, center punch and drill

4 holes (11/32 inch dia.) into the mower (Fig. 6).

Page 5

Step

4. Using the baffle as a template, center punch and drill

3 holes (11/32 inch dia.) into the top of the mower (Fig. 6).

5. Remove the clamp.

Parts needed for this step:

• 1 Tunnel baffle—rear

• 3 Carriage bolt, 5/16 x 5/8 inch

• 3 Flange nut, 5/16 inch

Installing the Rear Tunnel Baffle

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

discharge tunnel (Fig. 7).

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

2. Align the rear tunnel baffle, flush with the outside of

the mounting bracket (Fig. 7).

6. Install the rear tunnel baffle with 3 carriage bolts

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

Important Make sure the bolt heads are installed on

the inside of the cutting chamber.

5 4

m–6224

Figure 7

1. Rear tunnel baffle

2. Mounting bracket

3. Flush edge with outside of mounting bracket

3. Clamp the baffle in place.

4. Outside of mounting bracket

1. Rear tunnel baffle

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

3. Flange nut, 5/16 inch

m–6173

Figure 8

4. Hole to drill

5. Tunnel rear wall

6. Mounting bracket

Page 6

Step

Parts needed for this step:

• 1 Center cutting chamber baffle

• 3 Button Head Socket Bolts, 5/16 x 3/4 inch

• 3 Flange nuts, 5/16 inch

4 32

Figure 10

1. Baffle flange

2. Blade

3. Spindle

4. Clamp the center baffle tightly against the cutting

chamber (Fig. 11).

4. Blade clearance, 9/16 to 11/16 inch (14 mm to 17 mm)

m–62291

Installing the Center Rear Baffle

A right angle drill is recommended to install this baffle.

1. Place the center rear baffle behind the center cutting

blade chamber (Fig. 11).

2. Align the center rear baffle so the baffle ends are

touching the back mower flange (Fig. 9).

Note: The center baffle ends will rest on the mower flange (Fig. 9).

3. Align the middle part, of the center rear baffle, 9/16 to 11/16 inch from the blade tip. See Figures 9 and 10

on where to measure.

5. Using the baffle as a template, mark, center punch and

drill 1/8 inch pilot holes at the 3 locations (Fig. 11).

6. Drill 11/32 inch dia. holes through the pilot holes

(Fig. 11).

7. Install the center baffle with 3 button head socket bolts

(5/16 x 5/8 inch) and 3 flange nuts (5/16 inch) (Fig. 11).

Important Make sure the bolt heads are installed on

the inside of the cutting chamber (Fig. 11).

1 4

Figure 9

1. Mower flange

2. Center baffle

3. Center baffle end touching mower

Important Make sure the baffle flange is

9/16 to 11/16 inch (14 mm to 17 mm) from the mower blade (Figures 9 and 10).

4. Blade clearance, 9/16 to 11/16 inch (14 mm to 17 mm)

5. Center blade

m–6256

m–6176

Figure 11

1. Center Baffle

2. Hole to drill

3. Center cutting blade chamber

4. Flange nuts, 5/16 inch

5. Button head socket bolt, 5/16 x 5/8 inch

Page 7

Step

Important Make sure the bolt heads are installed on

the inside of the cutting chamber. See figure 13.

Parts needed for this step:

• 1 Left rear baffle

• 3 Button Head Socket Bolts, 5/16 x 3/4 inch

• 3 Flange nuts, 5/16 inch

Installing the Left Rear Baffle

1. Place the left rear baffle behind the left cutting

chamber (Fig. 12). The tabs will mount on the outside of the mower.

2. Align the left rear baffle tight against and flush with

the bottom of the center baffle and against the mower flange (Figures 12 and 13).

3. Clamp the baffle in place.

1. Left rear baffle

2. Left side of mower

3. Button head socket bolt, 5/16 x 3/4 inch

4. Flange nut, 5/16 inch

m–6179

Figure 13

5. Hole to drill

6. Rear center baffle

7. Mower flange

8. Tab

Figure 12

1. Center Baffle

2. Left rear baffle against mower flange

3. Flush with bottom of center baffle

4. Using the baffle as a template, mark, center punch and drill 1/8 inch pilot holes at the 3 locations (Fig. 13).

5. Drill 11/32 inch dia. holes through the pilot holes (Fig. 13).

6. Install the left rear baffle with 3 button head socket bolts (5/16 x 3/4 inch) and 3 flange nuts (5/16 inch) (Fig. 13).

4. Left cutting chamber

5. Tab

m–6178

Page 8

Step

Parts needed for this step:

5. Drill 11/32 inch dia. holes through the pilot holes

(Fig. 15).

6. Remove the clamp.

7. Install the right rear baffle to the mower with 2 button

head socket bolts (5/16 x 3/4 inch) and 2 flange nuts (5/16 inch) (Fig. 15).

8. Install the right rear baffle to the rear tunnel baffle

with a carriage bolt (5/16 x 5/8 inch) and a flange nut (5/16 inch) (Fig. 15).

• 1 Right rear baffle

• 2 Button Head Socket Bolts, 5/16 x 3/4 inch

• 1 Carriage bolts, 5/16 x 5/8 inch

• 4 Flange nuts, 5/16 inch

Installing the Right Rear Baffle

1. Place the right rear baffle behind the left cutting

chamber (Fig. 14). The tabs will mount on the outside of the mower.

2. Align the right rear baffle tight against and flush with

the bottom of the center baffle and against the mower flange (Fig. 14 and 15).

Important Make sure the bolt heads are installed on

the inside of the cutting chamber. See figure 15.

m–6177

1. Rightrear b a ffle

2. Right side of mower

3. Carriage Bolt, 5/16 x 5/8 inch

4. Button head socket bolt, 5/16 x 5/8 inch

Figure 15

5. Flange nut, 5/16 inch

6. Holes to drill

7. Mower flange

Figure 14

1. Center Baffle

2. Right rear baffle against mower flange

3. Clamp the baffle in place.

4. Using the baffle as a template, mark, center punch and

drill 1/8 inch pilot holes at the 2 locations (Fig. 15).

3. Flush with bottom of

4. Right cutting chamber

center baffle

m–6175

9. Rotate the blades and check if the blades make contact with the baffles.

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

Page 9

Step

2 3

No Parts needed for this step.

Removing the Existing Mower Pulley

Note: Clean the area around pulley before removing pulley assembly. Hold spindle up from underneath the deck. It can fall when nut and washer are removed.

1. Turn the mower over.

2. Remove the right belt cover from the mower and

discard.

3. Remove the nut and washer on top of the spindle

(Fig. 17). Save the nut and washer.

4. Remove the existing pulley assembly.

Step

1. 44 inch mower

2. Remove this corner

3. 3–1/4 inches

m–6227

Figure 16

4. 1 inch

5. Pulley cover stud

No Parts needed for this step.

Modifying a 44 inch Mower for Belt Clearance

Note: This section is only for 44 inch mowers.

1. Remove the right rear corner of the pulley cover plate

(Fig. 16). This will give clearance for the blower belt.

2. Refer to Figure 16 for the correct dimensions of the

cutout.

Note: Do not cut out the stud in the back of the pulley cover plate. The stud is needed for the pulley cover.

Page 10

Step

Parts needed for this step:

• 1 Pulley assembly

• 1 Bagger Belt

• 1 Pulley cover

Installing the Pulley Assembly

Note: For mowers built in 1999, check the right blade spindle for splines. Refer to Checking the Spindle for 1999 Models on Page 2.

1. Install new pulley assembly onto the spindle. Install it

so the large pulley is on the bottom (Fig. 17).

2. Install the washer and nut (Fig. 17).

Important Tighten the nut to 115 ft–lb ± 15 ft–lb

torque.

3. Grease the spindle to fill bearings with grease.

1 2

Parts needed for this step:

• 2 Mounting plates

• 1 Template

• 4 Bolts, 3/8 x 1–1/4 inch

• 4 Flange nuts, 3/8 inch

Installing the Mounting Plates

Drilling the Holes into the Mounting Bracket

This kit contains a metal template for locating the mounting bracket holes to drill.

1. Remove the grass deflector from the mower (Fig. 22).

2. Position the template onto the the mounting bracket

and align with the top and sides of the mounting bracket. (Fig. 18).

3. Clamp the template to the mounting bracket (Fig. 18).

4. Mark and center punch the 4 holes and remove the

template (Fig. 18).

1. Nut

2. Washer

3. Pulley Assembly

Figure 17

4. Blade spindle

5. Mower

m–6228

5. Drill 1/8 inch pilot holes at the 4 marked locations and then drill 7/16 inch dia. holes.

6. File the metal burrs from the drilled holes.

1. Template

2. Mounting bracket

Figure 18

3. Mark and center punch holes

m–6225

Page 11

Installing the Mounting Plates

1. Install the mounting plates to the inside of the

mounting bracket with 4 bolts (3/8 x 1–1/4 inch) and 4 flange nuts (3/8 inch) (Fig. 19).

Figure 19

1. Mounting plate

2. Bolt, 3/8 x 1–1/4 inch

3. Flange nut, 3/8 inch

4. Mounting bracket

5. 7/16 inch holes to drill

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.

m–6226

1. Install the blade onto the spindle shaft (Fig. 20).

Important The curved part of the blade must be

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

2. Install the spring disk and blade bolt (Fig. 20). 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.

3 5

M–4226

Figure 20

1. Sail Area of Blade

2. Blade

3. Spring Disk

4. Blade Bolt

5. Cone T owards Bolt Head

Page 12

Installing the Mower and

Using the Grass Deflector

Mower Belt

1. Install the mower to the machine. Reverse the

instructions in Removing the Mower on page 2.

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

2. Route the mower belt onto the lower pulley and idler

pulley.

3. Tighten the outer nut on spring eye bolt (Fig. 21). Note: Check the spring length. The spring should measure

9–3/8 inch ± 1/8 inch (238 mm ± 3 mm) when installed. Adjust if it does not (Fig. 21).

4. Tighten the inner nut on spring eye bolt (Fig. 21).

Note: Make sure the grass deflector is installed when the bagger and tubes are removed.

Warning

Without the grass deflector, bagger tubes or complete bagger assembly mounted in place, you and others are exposed to blade contact and thrown debris. Contact with the rotating mower blade(s) and thrown debris will cause injury or death.

• Always install the grass deflector when

removing the bagger and changing to side discharge mode.

• If the grass deflector is ever damaged, replace

it immediately. The grass deflector routes material down toward the turf.

• Never put your hands or feet under the mower.

• Never try to clear the discharge area or mower

blades unless you move the power take off (PTO) to off and rotate the ignition key to off. Also remove the key and pull the wire off of the spark plug(s).

1. Outer nut

2. Idler pulley

3. Idler arm

4. Spring eye bolt

Figure 21

Top View

5. Spring

6. 9–3/8 inch ± 1/8 inch (238 mm ±3 mm)

7. Mower belt

M–4197

Installing the Belt Cover and Bagger Belt

Refer to the bagger operators manual for installing the belt cover and bagger belt.

1. When the bagger is to be used for dedicated bagging,

leave the grass deflector off the machine.

• Remember to install the grass deflector when

changing to side discharge mode.

2. When the mower is switched between bagging and

side discharge frequently, leave the grass deflector on the machine. The grass deflector will rest against the blower belt cover.

Page 13

Installing the Grass Deflector

Note: Make sure the grass deflector is installed when the bagger and tubes are removed.

The grass deflector spring will have either an L end or a straight end (Fig. 22).

Warning

An uncovered discharge opening could allow the lawn mower to throw objects in the operator’s or bystander’s direction and result in serious injury. Also, contact with the blade could occur.

Never operate the lawn mower unless you install a cover plate, a mulch plate, grass deflector or a grass chute and catcher.

1. Place spacer and spring onto grass deflector. Place the L or the straight end of spring behind deck edge.

Note: Make sure the L or the straight end of spring is

installed behind deck edge before installing the bolt as shown in figure 22.

2. Install bolt and nut. Place J hook end of spring around grass deflector (Fig. 22).

Important The grass deflector must be lowered down

into position. Lift the deflector up to test that it lowers into the full down position.

m–6085

Figure 22

1. Bolt

2. Spacer

3. Locknut

4. Spring

5. Spring installed

6. Grass Deflector

7. L end of spring, place behind mounting bracket before installing bolt

8. J hook end of spring

9. Mounting bracket

10. Straight end—possible style of spring

Page 14

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Toro 78496, 78497 Installation Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual