Toro 78496 Manual de usuario

Printed in the USA

2002 by The Toro Company

8111 Lyndale Avenue South

Bloomington, MN 55420-1196

44and 52Finishing Kit

100 Series Z Master 44Mowers

100 Series Z Master 52Mowers

Model No. 78496

Model No. 78497

Form No. 3329–234 Rev A

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

1Tunnel baffle—front

Carriage bolt, 5/16 x 5/8 inch

Flange nut, 5/16 inch

4Installing the front tunnel baffle

2Tunnel baffle—rear

Carriage bolt, 5/16 x 5/8 inch

Flange nut, 5/16 inch

3Installing the rear tunnel baffle

3Center rear baffle

Button Head Socket Bolt, 5/16 x 3/4 inch

Flange nut, 5/16 inch

3Installing the center rear baffle

4Left rear baffle

Button Head Socket Bolt, 5/16 x 3/4 inch

Flange nut, 5/16 inch

3Installing the left rear baffle

5Right 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

Installing the right rear baffle

6Removing the mower existing pulley

assembly

7Modifying a 44 inch Mower for Belt

Clearance

8Pulley assembly

Bagger Belt

Pulley cover

Installing the pulley assembly, belt and

cover

9Mounting plate

Bolt, 3/8 x 1–1/4 inch

Flange nuts, 3/8 inch

4Installing 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 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).

m–6381

Figure 1

Top View

1. Bladespindle—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).

M–4197

14 3

Figure 2

Top View

1. Outer nut

2. Idler pulley

3. Idler arm

4. Spring eye bolt

5. Spring

6. 9–3/8 inch ±1/8 inch

(238 mm ±3 mm)

7. Mower belt

2. Remove the mower belt from the right outside pulley.

Note: Do not remove the spring.

Spring is under tension when installed and can

cause personal injury.

Do not remove spring from spring eye bolt.

Caution

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).

m–6062

m–6265

Figure 3

1. Mower

2. Chain

3. ChainBolt

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.

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.

Contact with sharp blade can cause serious

personal injury.

•Wear gloves or wrap sharp edges of the blade

with a rag.

Warning

Removing the Cutting

Chamber Stiffener

Note: This section is only for mowers with a stiffener

welded to the cutting chamber (Fig. 4).

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.

2m–6081

Figure 4

1. Cuttingchamber 2. Cutting chamber stiffener

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).

m–6223

Figure 5

1. Fronttunnel baffle

2. Flush edge with outside of

mounting bracket

3. 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. 6).

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).

m–6172

Figure 6

1. Fronttunnel baffle

2. Carriage Bolt, 5/16 x

5/8 inch

3. Flange nut, 5/16 inch

4. Hole to drill

5. Front tunnel wall

Step

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).

m–6224

Figure 7

1. Rear tunnel baffle

2. Mounting bracket

3. Flush edge with outside of

mounting bracket

4. Outside of mounting

bracket

3. Clamp the baffle in place.

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.

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.

m–6173

Figure 8

1. Rear tunnel baffle

2. Carriage Bolt, 5/16 x

5/8 inch

3. Flange nut, 5/16 inch

4. Hole to drill

5. Tunnel rear wall

6. Mounting bracket

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

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.

m–6256

Figure 9

1. Mowerflange

2. Center baffle

3. Center baffle end touching

mower

4. Blade clearance,

9/16 to 11/16 inch

(14 mm to 17 mm)

5. Center blade

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).

m–622914 32

Figure 10

1. Baffle flange

2. Blade

3. Spindle

4. Blade clearance,

9/16 to 11/16 inch

(14 mm to 17 mm)

4. Clamp the center baffle tightly against the cutting

chamber (Fig. 11).

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).

m–6176

Figure 11

1. CenterBaffle

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

Step

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.

m–6178

Figure 12

1. CenterBaffle

2. Left rear baffle against

mower flange

3. Flush with bottom of

center baffle

4. Left cutting chamber

5. Tab

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).

Important Make sure the bolt heads are installed on

the inside of the cutting chamber. See figure 13.

m–6179

Figure 13

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

5. Hole to drill

6. Rear center baffle

7. Mower flange

8. Tab

Step

Parts needed for this step:

•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).

m–6175

Figure 14

1. CenterBaffle

2. Right rear baffle against

mower flange

3. Flush with bottom of

center baffle

4. Right cutting chamber

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).

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).

Important Make sure the bolt heads are installed on

the inside of the cutting chamber. See figure 15.

m–6177

Figure 15

1. Rightrear baffle

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

5. Flange nut, 5/16 inch

6. Holes to drill

7. Mower flange

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.

Step

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

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.

m–6227

Figure 16

1. 44 inch mower

2. Remove this corner

3. 3–1/4 inches

4. 1 inch

5. Pulley cover stud

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.

m–6228

Figure 17

1. Nut

2. Washer

3. Pulley Assembly

4. Blade spindle

5. Mower

Step

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).

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.

m–6225

Figure 18

1. Template

2. Mountingbracket 3. Mark and center punch

holes

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