Toro 78499 Operator's Manual
Form No. 3329–570 Rev A
62 inch Triple Bagger and Finishing
Kit
200 Series Z Master
Model No. 78456—Serial No. 230000001 and Up
Model No. 78499
Operator ’s Manual
English (EN)
Contents
Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 4. . . . . . . . . . . . . . . .
Setup 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before Installation 7. . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Mower for Existing Holes 7. . . . . . .
Removing the Grass Deflector Bracket 7. . . . . . . .
Removing the Mower 8. . . . . . . . . . . . . . . . . . . . . .
Preparing the Mower 9. . . . . . . . . . . . . . . . . . . . . .
Removing the Existing Blades 9. . . . . . . . . . . . . . .
Removing the Cutting Chamber Brackets 9. . . . . .
Installing the Center Rear Baffle 10. . . . . . . . . . . . .
Grinding the Welds 11. . . . . . . . . . . . . . . . . . . . . . . .
Installing the Left Rear Baffle 11. . . . . . . . . . . . . . .
Installing the Rear Tunnel Baffle 12. . . . . . . . . . . . .
Installing the Right Rear Baffle 13. . . . . . . . . . . . . .
Installing the Front Tunnel Baffle 14. . . . . . . . . . . .
Installing the Blade Stiffener 16. . . . . . . . . . . . . . . .
Removing the Existing Mower Pulley and Right Rear
Gage Wheel 16. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Pulley Assembly 17. . . . . . . . . . . . . . .
Installing the Mounting Plates 17. . . . . . . . . . . . . . .
Installing the Gage Wheel 18. . . . . . . . . . . . . . . . . .
Installing the Mower and PTO Drive Belts 19. . . . .
Removing the Drive Wheels and Bumper Guard 20.
Installing the Bagger Brackets 21. . . . . . . . . . . . . . .
Installing the Blower Assembly 22. . . . . . . . . . . . . .
Installing the Bagger Belt and Idler Spring 23. . . . .
Installing the Bagger Tube Support and Elbow 25. .
Installing the Hood Assembly and Bags 25. . . . . . . .
Installing the Bagger Tube 27. . . . . . . . . . . . . . . . . .
Installing the Weights 28. . . . . . . . . . . . . . . . . . . . . .
Adjusting the Parking Brake 29. . . . . . . . . . . . . . . .
Using the Grass Deflector 30. . . . . . . . . . . . . . . . . .
Installing the Grass Deflector 30. . . . . . . . . . . . . . . .
Operation 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emptying the Grass Bags 31. . . . . . . . . . . . . . . . . . .
Clearing Obstructions From the Bagger System 32.
Operating and Bagging Tips 33. . . . . . . . . . . . . . . . .
Maintenance 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Maintenance Schedule 34. . . . . . . . .
Cleaning the Hood Screen 34. . . . . . . . . . . . . . . . . .
Cleaning the Bagger 34. . . . . . . . . . . . . . . . . . . . . . .
Checking and Adjusting the Bagger Belt Tension 35
Checking and Adjusting the Blower Latch 36. . . . . .
Page
Replacing the Blower Belt 37. . . . . . . . . . . . . . . . . .
Greasing the Blower 37. . . . . . . . . . . . . . . . . . . . . . .
Checking the Blower Liner 38. . . . . . . . . . . . . . . . .
Replacing the Blower Liner 38. . . . . . . . . . . . . . . . .
Inspecting the Bagger 39. . . . . . . . . . . . . . . . . . . . . .
Inspecting the Mower Blades and Baffles 39. . . . . .
Installing Mower Blades 39. . . . . . . . . . . . . . . . . . . .
Storage 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction
Read this manual carefully to learn how to operate and
maintain your product properly. The information in this
manual can help you and others avoid injury and product
damage. Although Toro designs and produces safe
products, you are responsible for operating the product
properly and safely.
Whenever you need service, genuine Toro parts, or
additional information, contact an Authorized Service
Dealer or Toro Customer Service and have the model and
serial numbers of your product ready. Figure 1 illustrates
the location of the model and serial numbers on the
product.
1
m–6231
Figure 1
1. Location of the model and serial numbers
Write the product model and serial numbers in the space
below:
Model No.
Serial No.
2003 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
All Rights Reserved
Printed in the USA
2
This manual identifies potential hazards and has special
safety messages that help you and others avoid personal
injury and even death. Danger, Warning, and Caution are
signal words used to identify the level of hazard. However,
regardless of the hazard, be extremely careful.
• If you remove the grass catcher, be sure to install any
discharge deflector or guard that might have been
removed to install the grass catcher. Do not operate the
mower without either the entire grass catcher or the
grass deflector in place.
Danger signals an extreme hazard that will cause serious
injury or death if you do not follow the recommended
precautions.
Warning signals a hazard that may cause serious injury or
death if you do not follow the recommended precautions.
Caution signals a hazard that may cause minor or moderate
injury if you do not follow the recommended precautions.
This manual uses two other words to highlight information.
Important calls attention to special mechanical
information and Note: emphasizes general information
worthy of special attention.
Safety
The following list contains safety information specific to
Toro products and other safety information you must know.
• Become familiar with the safe operation of the
equipment, with the operator controls, and safety signs.
• Use extra care with grass catchers or other attachments.
These can change the operating characteristics and the
stability of the machine.
• Turn off the engine and wait for all moving parts to
stop before removing the grass catcher or
unclogging the chute.
• Do not use your hands to unclog the chute, blower or
bagger.
• Do not leave grass in grass catcher for extended periods
of time.
• Grass catcher components are subject to wear, damage
and deterioration, which could expose moving parts or
allow objects to be thrown. Frequently check
components and replace with manufacturer’s
recommended parts, when necessary.
• Do not use a grass catcher on steep slopes. A heavy
grass catcher could cause loss of control or overturn the
machine.
• Slow down and use extra care on hillsides. Be sure to
travel in the recommended direction on hillsides. Turf
conditions can affect the machine’s stability. Use
extreme caution while operating near drop–offs.
• Keep all movement on slopes slow and gradual. Do not
make sudden changes in speed, directions or turning.
• The grass catcher can obstruct the view to the rear. Use
extra care when operating in reverse.
• Use care when loading or unloading the machine into a
trailer or truck
• Never operate with the discharge deflector raised or
removed and never altered, unless using a grass catcher
or mulching baffles.
• Keep hands and feet away from moving parts. Do not
make adjustments with the engine running.
• Stop on level ground, disengage drives, set the parking
brake, shut off the engine before leaving the operator’s
position for any reason including emptying the grass
catcher or unclogging the chute.
3
Safety and Instruction Decals
Safety decals and instructions are easily visible to the operator and are located near any area
of potential danger. Replace any decal that is damaged or lost.
79-0350
79-0360
1-653554
80-8040
88-8950
106-0871
98-4387
1. Warning—wear hearing protection.
93-1122
4
Setup
Note: Determine the left and right sides of the machine from the normal operating position.
Loose Parts
Note: Use the chart below to verify all parts have been shipped.
Important This kit and bagger will require significant time to install the first time. A right angle drill is recommended for
installation.
Step Description Qty. Use
1
2
3
4
5
Center rear baffle
Bolt, 5/16 x 5/8 inch
Flange nut, 5/16 inch
Left rear baffle
Bolt, 1/4 x 5/8 inch
Flange nut, 1/4 inch
Tunnel baffle—rear
Bolt, 5/16 x 5/8 inch
Flange nut, 5/16 inch
Bolt, 1/4 x 5/8 inch
Lock nut, 1/4 inch
Right rear baffle
Bolt, 1/4 x 5/8 inch
Flange nut, 1/4 inch
Tunnel baffle—front
Carriage bolt, 5/16 x 5/8 inch
Flange nut, 5/16 inch
1
5
5
1
3
3
1
2
2
1
1
1
2
2
1
3
3
Installing the center rear baffle
Installing the left rear baffle
Installing the rear tunnel baffle
Installing the right rear baffle
Installing the front tunnel baffle
6
7
8
9
10
Blade stiffener 3 Installing the blade stiffeners
No parts needed
Pulley assembly 1
Mounting plate
Bolt, 3/8 x 1–1/4 inch
Flange nuts, 3/8 inch
Template
Roller bushing
Bolt, 3/8 x 4–1/4 inch
5
2
4
4
1
1
1
Removing the existing mower pulley
assembly and the right rear gage wheel
Installing the pulley assembly, belt and
cover
Installing the mounting plates
Installing the gage wheel
Step UseQty.Description
11
12
13
14
15
No parts needed
No parts needed
Bagger mounting bracket
Left side bagger bracket
Right side bagger bracket
Bolt, 3/8 x 1 inch
Flange nut, 3/8 inch
Belleville washer, 3/8 inch
Blower assembly 1 Installing the blower assembly
Blower belt cover
Bagger Belt
Idler spring
Pulley cover
1
1
1
10
10
8
1
1
1
1
Installing the mower and PTO drive
belts
Removing the drive wheels and rear
bumper guard
Installing the bagger brackets
Installing the bagger belt and idler
spring
16
17
18
Hood assembly
Bag
Clevis pin
Hairpin cotter
Bagger tube support
Elbow
Bolt, 1/4 x 1–1/2 inch
Nut, 1/4 inch
Flat washer, 1/4 inch
Bagger tube
Clamp
Knob
Blower adapter
1
3
2
2
1
1
4
4
4
1
1
2
1
Installing the hood assembly and bags
Installing the bagger tube support and
elbow
Installing the bagger tube
6
Step UseQty.Description
Caster weight
U–bolt
Nut, 1/2 inch
Lock washer, 1/2 inch
19
20
Plate
Top weight
Bolt, 1/2 x 3 inch
Plate
No parts needed Adjusting the parking brake
Before Installation
Checking the Mower for
Existing Holes
Check for existing holes. Use any existing holes in the
mower that align the baffles in their correct positions.
2
2
4
4
Installing the weights
2
2
2
2
1
Removing the Grass Deflector
Bracket
Note: This section is only for mowers with grass deflector
bracket welded to the mower (Fig. 2).
1. Remove the grass deflector bracket from the mower as
shown in Figure 2. This will avoid any interference with
the rear tunnel baffle.
2. If you have a mower like the one shown in Figure 2,
contact an Authorized Service Dealer for a discharge
chute kit. This kit will allow you to install the bagger
and blower.
2
m–6169
Figure 2
1. Mower 2. Remove grass deflector
bracket
7
Removing the Mower
Note: If the mower is removed from the bottom bolts
attaching the chains to the mower, the mower will not need
to be leveled.
1. Remove the PTO drive belt from the rear idler arm
(Figures 3 and 5).
4
2
1
3
2
1
M–4417
Figure 3
1. Center bolt, spring loaded
idler
2. Alignment hole
2. Remove the PTO drive belt from the center mower
pulley (Fig. 5).
3. Remove PTO drive belt from the front fixed idler pulley
assembly (Figures 4 and 5).
3
2
1
m–6763
Figure 4
1. Center mower pulley
2. PTO Drive belt
3. Fixed idler pulley
assembly
m–4451
Figure 5
Top View
1. Center mower pulley
2. PTO Drive belt
3. Fixed idler pulley
assembly
4. Rear idler pulley
4. Loosen two nuts securing idler plate and move the idler
arm to relieve belt tension on the idler pulley (Fig. 29).
5. Remove the mower belt from the right side pulley.
5
4
6
6
2
1
M–4312
3
Figure 6
Top View
1. Mower Belt
2. Idler Arm
3. Idler nuts
4. Idler adjusting nut
5. Right side pulley
6. Idler pulley
6. Raise the mower with the height–of–cut lever.
7. Place wood blocks under the mower and lower the
mower onto the wood blocks.
Note: If the mower is removed from the bottom bolts
attaching the chains to the mower, the mower will not need
to be leveled.
8. Remove the four bolts at the bottom of the chains that
are attached to the mower (Fig. 7).
8
9. Remove the nuts and bolts holding the push arm pins
(Fig. 7).
Note: The gage wheels may need to be removed to allow
the push arm pins to be removed (Fig. 7).
10.Remove the push arm pins (Fig. 7).
Removing the Existing Blades
Note: In most mowing conditions, improved bagging
performance can be achieved by using bagging blades
(high lift). Contact an Authorized Service Dealer for the
proper blades for different mowing conditions.
11. Raise the height of cut lever and slide the mower out
from under the machine (Fig. 7).
2
6
4
7
5
3
1
M–4450
Figure 7
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
9. Nut
1. Remove the existing blades from the spindles. Keep the
blade bolts for installing blades.
Warning
Contact with sharp blade can cause serious
personal injury.
• Wear gloves or wrap sharp edges of the
blade with a rag.
Removing the Cutting
Chamber Brackets
Note: This section is only for mowers with brackets welded
to the cutting chamber (Fig. 8).
1. Remove the three cutting chamber brackets from the
mower (Fig. 8).
2. Grind the welds flat on rear part of the cutting
chambers. This will allow the correct fit for the cutting
chamber baffles.
Preparing the Mower
1. Tip the 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 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.
1
2
2
2
m–6159
Figure 8
1. Cutting chamber 2. Cutting chamber stiffener
9
Step
1
Parts needed for this step:
• 1 Center cutting chamber baffle
1
2
• 5 Bolts, 5/16 x 5/8 inch
• 5 Flange nuts, 5/16 inch
Installing the Center Rear
Baffle
A right angle drill will be needed to perform this
installation.
Note: If present, use existing holes for installing this baffle.
Make sure the existing holes match the holes in the baffle.
1. Place the center rear baffle behind the rear cutting blade
chamber (Fig. 11).
2. Align the center rear baffle so the baffle flange is
3–5/8 in. (92 mm) from the top of the cutting chamber
(Figures 9 and 11).
Important Make sure the baffle flange is 3–5/8 inch
(92 mm) from the top of the cutting chamber at all
locations (Figures 9 and 13).
m–6774
Figure 10
1. Baffle flange 2. Baffle to top of cutting
chamber, 3–5/8 in.
3. Clamp the center baffle in place, tightly against the
cutting chamber.
4. Using the baffle as a template, mark, center punch and
drill 1/8 inch pilot holes at the 5 locations (Fig. 11).
5. Drill 11/32 inch dia. holes through the pilot holes
(Fig. 11).
Install the center baffle with 5 bolts (5/16 x 5/8 inch) and 5
flange nuts (5/16 inch) (Fig. 11).
Important Make sure the bolt heads are installed on the
inside of the cutting chamber. See figure 11.
5
3
1
154 32
1. Baffle flange
2. Blade
3. Spindle
Figure 9
4. Blade clearance,
1/2 ±1/16 in.
5. Baffle to top of cutting
chamber, 3–5/8 in.
m–5942
2
1. Center Baffle
2. Hole to drill
3. Center cutting blade
chamber
10
4
Figure 11
2
4. Flange nuts, 5/16 inch
5. Bolt, 5/16 x 5/8 inch
m–6775
Step
2
Parts needed for this step:
• 1 Left rear baffle
• 3 Bolts, 1/4 x 5/8 inch
• 3 Flange nuts, 1/4 inch
2. Align the left rear baffle within 3/16 inch and flush with
the bottom of the center baffle (Fig. 13).
3. Position the left rear baffle so the baffle flange is
3–5/8 in. (92 mm) from the top of the cutting chamber
(Fig. 9).
Important Make sure the baffle flange is 3–5/8 inch
(92 mm) from the top of the cutting chamber at all
locations (Fig. 9).
Note: If 3–5/8 inch (92 mm) can not be achieved, the
bottom welds have to be ground down. Refer to Grinding
the Welds on page 11.
4. Clamp the baffle in place.
5. Using the baffle as a template, drill three, 9/32 inch
diameter, holes into the left cutting chamber (Fig. 14).
Grinding the Welds
Note: If 3–5/8 inch (92 mm) can not be achieved when
installing the left and right rear baffles, the bottom welds
need to be ground down.
1. Grind the welds flat on rear part of the mower. This will
allow the correct fit for the left and right rear baffles
(Fig. 12).
1
m–5877
Figure 12
1. Grind welds flat
Installing the Left Rear Baffle
1. Place the left rear baffle behind the left cutting chamber
(Fig. 13). The tabs will mount on the outside of the
mower.
6. Install the left baffle with 3 bolts (1/4 x 5/8 inch) and 3
flange nuts (1/4 inch) (Fig. 14).
Important Make sure the bolt heads are installed on the
inside of the cutting chamber. See figure 14.
1
5
4
6
3
2
1. Center Baffle
2. Left baffle
3. Flush with bottom of
center baffle
4. Left cutting chamber
Figure 13
5. Baffle flange to top of
cutting chamber, 3–5/8 in.
(92 mm)
6. 0 to 3/16 inch gap
m–5874
11
m–6773
3
1
8
Step
6
4
5
1. Left rear baffle
2. Left side of mower
3. Bolt, 1/4 x 5/8 inch
4. Flange nut, 1/4 inch
4
Figure 14
5. Hole to drill
6. Rear center baffle
7. Cutting chamber
8. Tab
7
3
Parts needed for this step:
• 1 Tunnel baffle—rear
• 2 Bolts, 5/16 x 5/8 inch
4
2
5
• 2 Flange nuts, 5/16 inch
Installing the Rear Tunnel
Baffle
1. Place the rear tunnel baffle against the rear wall of the
discharge tunnel (Fig. 16).
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. 16).
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 3 locations in Figures 15,
16, and 17.
5. Remove the clamp.
6. Drill two, 11/32 inch diameter, holes through the pilot
holes along the tunnel (Figures 15 and 16).
m–6768
4
Figure 15
1. Rear tunnel baffle
2. Mounting bracket
3. Flush edge with outside of
mounting bracket
4. Drill an 11/32 inch hole
here
2
1
3
12
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