Toro 78496, 78497 Installation Instructions
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
3
3
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
7
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
1
Installing the pulley assembly, belt and
cover
Installing the mounting plate
All Rights Reserved
Printed in the USA
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
2
3
4
14
6
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.
3
5
Figure 2
Top View
5. Spring
6. 9–3/8 inch ± 1/8 inch
(238 mm ±3 mm)
7. Mower belt
2
7
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).
2
Removing the Cutting
3
2
Chamber Stiffener
Note: This section is only for mowers with a stiffener
welded to the cutting chamber (Fig. 4).
3
2
1
4
m–6265
m–6062
7
5
8
1
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).
6
2. Grind the welds flat on rear part of the chamber. This
will allow the correct fit for the cutting chamber
baffle.
1
2
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.
3
Step
1
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).
2
1
35
3
2
1
3
2
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
4
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).
4
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.
2
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.
2
4
4
1
6
5
4
3
2
1
3
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
5
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