Toro 78508, 78509 Installation Instructions

Form No. 3329–565

44 and 52 Finishing Kit

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

Model No. 78508 Model No. 78509

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

 2003 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

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 Shaft for 1999 Models

For mowers built in 1999, the right hand blade spindle shaft 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 shaft 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, starting at 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 spi n d l e shaft—without splines

2. No splines

3. Year 2000 blade spindle shaft—with splines

4. Splines

Removing the Mower

Note: If the mower is already level and 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. Note: If the mower is removed from the top bolts, the

mower will not need to be leveled.

4. Remove the four bolts and nuts 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 the height of cut lever and slide the mower out

(Fig. 3).

Removing the Cutting Chamber Stiffener

m–6062

1. Mower

2. Chain

3. Chain Bolt

4. Push Arm

5. Push Arm Bolt

welded to the cutting chamber (Fig. 4).

1. Remove the cutting chamber stiffener from the mower

(Fig. 4).

Note: This section is only for mowers with a stiffener

m–6265

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

will allow the correct fit for the cutting chamber baffle.

Figure 3

6. Push Arm Nut

7. Push Arm Pin

8. Gage wheel

9. Nut

m–6684

Figure 4

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.

Warning

Contact with sharp blade can cause serious personal injury.

• Wear gloves or wrap sharp edges of the blade

with a rag.

Step

5. Remove the clamp.

6. 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).

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

Note: Blades and spindles are not shown in the graphics for clarity.

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).

m–6708

1. Front tunnel baffle

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

Figure 6

3. Flange nut, 5/16 inch

4. Front tunnel wall

m–6707

Figure 5

1. Front tunnel baffle

2. Flush edge with outside of mounting bracket

3. Clamp the baffle in place.

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

4 holes (11/32 inch dia.) into the mower (Fig. 5).

3. Outside of mounting bracket

4. Hole to drill

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

Note: Blades and spindles are not shown in the graphics for clarity.

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–6709

1. Rear tunnel baffle

2. Mounting bracket

3. Flush edge with outside of mounting bracket

Figure 7

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–6710

Figure 8

4. Hole to drill

5. Tunnel rear wall

6. Mounting bracket

3. Clamp the baffle in place.

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