Toro 78503 Operator's Manual
Form No. 3329–568
52 inch Twin Bagger and Finishing
Kit
200 Series Z Master
Model No. 78498—Serial No. 230000001 and Up
Model No. 78503
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 Mower 7. . . . . . . . . . . . . . . . . . . . . .
Preparing the Mower 8. . . . . . . . . . . . . . . . . . . . . .
Removing the Cutting Chamber Stiffeners 8. . . . . .
Installing the Front Tunnel Baffle 9. . . . . . . . . . . .
Installing the Rear Tunnel Baffle 10. . . . . . . . . . . . .
Installing the Center Rear Baffle 11. . . . . . . . . . . . .
Installing the Left Rear Baffle 12. . . . . . . . . . . . . . .
Installing the Right Rear Baffle 13. . . . . . . . . . . . . .
Removing the Existing Mower Pulley 14. . . . . . . . .
Installing the Pulley Assembly 14. . . . . . . . . . . . . . .
Installing the Belt Cover and Bagger Belt 14. . . . . .
Installing the Mounting Plates 15. . . . . . . . . . . . . . .
Installing the Mower and PTO Drive Belts 16. . . . .
Removing the Drive Wheels 17. . . . . . . . . . . . . . . .
Installing the Bagger Brackets 17. . . . . . . . . . . . . . .
Installing the Blower Assembly 19. . . . . . . . . . . . . .
Installing the Bagger Belt and Idler Spring 19. . . . .
Installing the Hood Assembly and Bags 21. . . . . . . .
Installing the Bagger Tube 23. . . . . . . . . . . . . . . . . .
Installing the Weights 24. . . . . . . . . . . . . . . . . . . . . .
Installing the Blades 25. . . . . . . . . . . . . . . . . . . . . . .
Using the Grass Deflector 25. . . . . . . . . . . . . . . . . .
Installing the Grass Deflector 26. . . . . . . . . . . . . . . .
Operation 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emptying the Grass Bags 27. . . . . . . . . . . . . . . . . . .
Clearing Obstructions From the Bagger System 27.
Removing the Bagger 28. . . . . . . . . . . . . . . . . . . . . .
Operating and Bagging Tips 29. . . . . . . . . . . . . . . . .
Maintenance 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Maintenance Schedule 30. . . . . . . . .
Cleaning the Hood Screen 30. . . . . . . . . . . . . . . . . .
Cleaning the Bagger 30. . . . . . . . . . . . . . . . . . . . . . .
Checking and Adjusting the Bagger Belt Tension 30
Checking and Adjusting the Blower Latch 32. . . . . .
Replacing the Blower Belt 33. . . . . . . . . . . . . . . . . .
Greasing the Blower 33. . . . . . . . . . . . . . . . . . . . . . .
Checking the Blower Liner 34. . . . . . . . . . . . . . . . .
Replacing the Blower Liner 34. . . . . . . . . . . . . . . . .
Inspecting the Bagger 35. . . . . . . . . . . . . . . . . . . . . .
Page
Inspecting the Mower Blades and Baffles 35. . . . . .
Storage 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
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.
Danger signals an extreme hazard that will cause serious
injury or death if you do not follow the recommended
precautions.
2003 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
All Rights Reserved
Printed in the USA
2
Warning signals a hazard that may cause serious injury or
death if you do not follow the recommended precautions.
• Do not leave grass in grass catcher for extended periods
of time.
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.
• 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.
• 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.
• 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, chock or block wheels, shut off engine before
leaving the operator’s position for any reason including
emptying the grass catcher or unclogging the chute.
• 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.
• 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.
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
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
6
7
8
9
10
Removing the mower existing pulley
assembly
Pulley assembly
Bagger Belt
Pulley cover
Mounting plate
Bolt, 3/8 x 1–1/4 inch
Flange nuts, 3/8 inch
No parts needed
No parts needed Removing the drive wheels
5
1
1
1
2
4
4
Installing the pulley assembly, belt and
cover
Installing the mounting plate
Installing the mower and PTO drive
belts
Step UseQty.Description
11
12
13
14
15
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
Idler spring
Hood assembly
Bag
Clevis pin
Hairpin cotter
Bagger tube
Clamp
Knob
Blower adapter
10
10
1
1
1
8
1
1
1
2
2
2
1
1
2
1
Installing the bagger brackets
Installing the bagger belt and idler
spring
Installing the hood assembly and bags
Installing the bagger tube
16
Caster weight
U–bolt
Nut, 1/2 inch
Lock washer, 1/2 inch
Plate
2
2
4
4
2
Installing the weights
6
Before Installation
3
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.
Removing the Mower
1. Remove the PTO drive belt from the rear idler arm
(Figures 2 and 4).
2
1
Figure 2
1. Center bolt, spring loaded
idler
2. Alignment hole
M–4417
5
1
m–6783
1. Center mower pulley
2. PTO Drive belt
3. Idler pulley
2
1
2
4
Figure 3
4. Mower belt
5. Right side pulley
3
2. Remove the PTO drive belt from the center mower
pulley (Fig. 3 and 4).
m–4451
Figure 4
1. Center mower pulley
2. PTO Drive belt
3. Rear idler pulley
3. Pull on the idler pulley to release tension on the mower
belt and remove the belt from the right side pulley
(Fig. 3).
4. Raise the height of cut lever.
5. Place wood blocks at the corners of the mower and
lower the mower onto the wood blocks.
7
Note: If the mower is removed from the bottom bolts,
attaching the chains to the mower, the mower may not need
to be leveled. Check the level of the mower after all
installation is complete.
6. Remove the four bolts at the bottom of the chains that
are attached to the mower (Fig. 5).
7. Remove the nuts and bolts holding the push arm pins
(Fig. 5).
Note: The gage wheels may need to be removed to allow
the push arm pins to be removed (Fig. 5).
8. Remove the push arm pins (Fig. 5).
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 Stiffeners
9. Raise the height of cut lever and slide the mower out
from under the machine (Fig. 5).
4
6
7
5
2
m–6062
1
Figure 5
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
Note: This section is only for mowers with stiffeners
welded to the cutting chamber (Fig. 6).
1. Remove the cutting chamber stiffeners from the mower
(Fig. 6).
2. Grind the welds flat on rear part of the chamber. This
will allow the correct fit for the cutting chamber baffle.
3
1
2
m–6081
Figure 6
1. Cutting chamber 2. Cutting chamber stiffener
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.
8
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
4. Clamp the baffle in place.
5. Using the baffle as a template, mark, center punch and
drill 1/8 inch pilot holes at the 4 locations (Fig. 8).
6. Remove the clamp.
7. Drill 11/32 inch dia. holes through the pilot holes
(Fig. 8).
8. 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. 8).
2
1
Installing the Front Tunnel
Baffle
Note: Blades and spindles are not shown in the graphics for
clarity.
1. Remove the existing right front blowout baffle. Save the
baffle and hardware for use when the bagging baffles
are removed.
2. Place the front tunnel baffle against the front wall of the
discharge tunnel (Fig. 7).
3. Align the front baffle, flush with the outside of the
mounting bracket (Fig. 7).
1
3
3
1. Front tunnel baffle
2. Carriage Bolt, 5/16 x
5/8 inch
34
2
m–6734
Figure 8
3. Flange nut, 5/16 inch
4. Front tunnel wall
2
1. Front tunnel baffle
2. Flush edge with outside of
mounting bracket
4
m–6733
Figure 7
3. Outside of mounting
bracket
4. Hole to drill
9
Step
6. Drill 11/32 inch dia. holes through the pilot holes
(Fig. 10).
7. Install the rear tunnel baffle with 3 carriage bolts
(5/16 x 5/8 inch) and 3 flange nuts (5/16 inch) (Fig. 10).
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. 9).
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. 9).
Important Make sure the bolt heads are installed on the
inside of the cutting chamber.
2
4
4
m–6736
1
6
5
4
3
1
3
2
Figure 9
1. Rear tunnel baffle
2. Mounting bracket
3. Clamp the baffle in place.
m–6735
3. Flush edge with outside of
mounting bracket
1. Rear tunnel baffle
2. Carriage Bolt, 5/16 x
5/8 inch
3. Flange nut, 5/16 inch
Figure 10
4. Hole to drill
5. Tunnel rear wall
6. Mounting bracket
4. Using the baffle as a template, mark, center punch and
drill 1/8 inch pilot holes at the 3 locations (Fig. 10).
5. Remove the clamp.
10
Step
3
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
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. 13).
2. Align the center rear baffle so the baffle ends are
touching the back mower flange (Fig. 11).
Note: The center baffle ends will rest on the mower flange
(Fig. 11).
3. Align the middle part, of the center rear baffle, 9/16 to
11/16 inch from the blade tip. Refer to Figures 11
and 12 for positions to measure.
4 32
Figure 12
1. Baffle flange
2. Blade
3. Spindle
4. Clamp the center baffle tightly against the cutting
chamber (Fig. 13).
5. Using the baffle as a template, mark, center punch and
drill 1/8 inch pilot holes at the 3 locations (Fig. 13).
6. Drill 11/32 inch dia. holes through the pilot holes
(Fig. 13).
7. Install the center baffle with 3 button head socket bolts
(5/16 x 3/4 inch) and 3 flange nuts (5/16 inch) (Fig. 13).
Important Make sure the bolt heads are installed on the
inside of the cutting chamber (Fig. 13).
1
4. Blade clearance,
9/16 to 11/16 inch
(14 mm to 17 mm)
53
m–62291
5
2
3
Figure 11
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 11 and 12).
4. Blade clearance,
9/16 to 11/16 inch
(14 mm to 17 mm)
5. Center blade
4
m–6256
4
5
1
1. Center Baffle
2. Hole to drill
3. Center cutting blade
2
2 m–6737
Figure 13
4. Flange nuts, 5/16 inch
5. Button head socket bolt,
5/16 x 3/4 inch
chamber
11
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