Installation Instructions

ManualsBrandsToro ManualsAttachments, Parts & AccessoriesToro 107-7650

 2004 by The Toro Company

8111 Lyndale Avenue South

Bloomington, MN 55420-1196

Printed in the USA

Conversion Kit

Z200 to Z500 DFS Bagger

Part No. 107–7650

Form No. 3351–335

Installation Instructions

Loose Parts

Note: Use the chart below to identify parts for assembly.

Step Description Qty. Use

No parts needed – Removing the bagger arm

Stop plate 1 Installing the stop plate

Bagger arm 1 Installing the bagger arm

Foam grip 2 Installing the latch lever

Cable

Long clevis, liquid cooled machines only

Short clevis

Clevis pin

Cotter pin

Installing the new cable

No parts needed – Adjusting the bagger arm

Pulley

Plate

Bearing housing

Key

Bolt, 3/8 x 5/8 inch

Spring washer, 3/8 inch

Installing the drive pulley assembly

Tensioner bracket template

Eyebolt template

Drilling holes for the idler bracket and

the eyebolt

Tensioner bracket 1

Installing the tensioner bracket and the

eyebolt

No parts needed –

Installing the bagger tensioner

assembly and the belt

No parts needed – Adjusting the bagger belt

Summary of content (16 pages)

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Form No. 3351–335 Conversion Kit Z200 to Z500 DFS Bagger Part No. 107–7650 Installation Instructions Loose Parts Note: Use the chart below to identify parts for assembly. Step 1 2 3 4 5 6 7 8 9 10 11 Description Qty.
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Step 12 13 14 15 16 Description Qty.
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7. Remove the cotter pin and washer from the bagger arm (Fig. 2). Save the washer and cotter pin. Step 2 8. Slide the bagger arm and washer out from the bagger frame (Fig. 2). Save the washer. Installing the Stop Plate 3 Parts needed for this step: Qty. 1 4 Stop plate Procedure 1. Remove the existing stop bolt and jam nuts from the bagger frame (Fig. 4). 2 4 1 2. Install the stop plate to the stop bracket using the bolt and jam nut previously removed (Fig. 4). Do not tighten. m–6206 Figure 2 1.
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Step Step 3 4 Installing the Bagger Arm Installing the Latch Lever Parts needed for this step: Parts needed for this step: Qty. 1 Part Qty. 1 Bagger arm Part Foam grip Procedure Procedure 1. Install the latch lever onto the bagger arm. 1. Position the latch lever 6 inches (15.2 cm) down from the end of the bagger arm. See Figure 6. 2. Install 1 washer previously removed onto the bagger arm pivot and install the bagger dump handle into the bagger frame (Fig. 5). 5 3.
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2 1 4 3 7 8 5 3 1 4 2 6 m–7178 m–7176 Figure 8 Figure 7 1. 2. 3. 4. End view of handle 1. Latch lever 2. End of handle 3. 10 o’clock position 4. 12 o’clock position 3. Tighten the setscrew that holds the latch lever (Fig. 6). Bagger arm Cable Shoulder bolt Pulley and nut 5. 6. 7. 8. Bagger door hinge Cable tie Nut Washer Note: Install the long cable clevis onto the bagger dump handle if it is for a liquid cooled machine (Fig. 9). 4. Install the cable ties (Fig. 9). 3.
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Step Step 6 7 Adjusting the Bagger Arm Installing the Drive Pulley Assembly Parts needed for this step: Parts needed for this step: None Qty. Procedure Part 2 Pulley The bagger arm needs to be adjusted to remove slack in the bagger cable with the bagger door closed. 1 Plate 1 Bearing housing 1. Loosen the nuts on both sides of the stop bracket (Fig. 10). 2 Bolt, 3/8 x 5/8 inch 2 Spring washer, 3/8 inch 2. Adjust the stop bolt until there is no slack in the bagger cable (Fig. 10).
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5 1 7 8 9 8 7 4 9 2 10 6 3 2 7 1 11 5 6 4 3 m–7495 m–6001 Figure 12 Figure 11 1. 2. 3. 4. Rear frame Drive pulley assembly Bolt, 1/2 x 1–1/4 inch Nut, 1/2 inch 1. 2. 3. 4. 5. 6. 5. Washer, 1/2 inch 6. Cut–out 7. Pulley plate New small pulley New bearing housing New plate Bolt Nut Spacer 7. 8. 9. 10. 11. Bolt, 3/8 x 5/8 inch Spring washer, 3/8 inch Key New large pulley Cut–out 3. Remove the pulleys from the existing assembly. 4. Remove the plate from the existing bearing housing. 7.
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Important A final adjustment may be needed when installing the bagger belt. Step 8 Positioning the Drive Pulley Assembly on a Liquid Cooled Machine 1. Pull the drive pulley assembly all the way rearward and then forward a 1/4 inch (6 mm) (Fig. 11). Drilling Holes for the Tensioner Bracket and Eyebolt Note: The bolt head on the drive pulley assembly, should be approximately a 1/4 inch (6mm) rearward of the center in the frame slot (Fig. 13). View this from the right–hand side of the machine.
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6. Align the eyebolt template with the existing hole in the bagger frame (Fig. 15). 5 Note: Make sure the templates are tight against the bagger frame (Fig. 15). 3 1 4 2 4 3 2 5 1 1 m–7492 2 Figure 16 m–7491 1. 9/32 inch hole to drill 2. 11/32 inch holes to drill 3. Bagger frame Figure 15 1. Tensioner bracket template 2. Eyebolt template 3. Bagger frame 4. Correct template position 5. Bagger wall 7. Using the templates, mark and center punch the holes. 8.
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Step Step 9 10 Installing the Tensioner Bracket and Eyebolt Installing the Bagger Tensioner Assembly and Belt Parts needed for this step: Qty. Parts needed for this step: Part 1 None Tensioner bracket Procedure Procedure 1. Install the bagger tensioner assembly to the tensioner bracket with with the previously removed bolt, washers and lock nut (Fig. 18). 1. Install the tensioner bracket to the bagger frame with the previously removed nuts (Fig. 14). 2.
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3 2 1 5 1 4 2 m–5892 6 3 5 Figure 21 4 m–5887 1. Drive pulley assembly 2. Mower belt 3. Bagger belt Figure 19 1. 2. 3. 4. Tensioner spring Eye bolt Bagger tensioner pulley Bagger pulley 5. Belt 6. Shortest space between belt strands, 1 inch ±1/8 inch 4. Mounting bolts 5. Back of machine Step Note: There should be a 1/4 twist in the belt when it is installed onto the bagger tensioner pulley 11 4. Install the spring onto the idler arm (Fig. 19). 5.
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7. If the gap measurement is too large, pull the pulley assembly rearward slightly [1/8–3/16 inch (3–5 mm)] from the original set–up position (Fig 21). Step 12 8. Tighten the 4 mounting bolts holding the drive pulley assembly to the machine frame (Fig 21). 9. Install the tensioner spring to the eyebolt to apply tension on the PTO spring loaded idler. 10. Measure the bagger belt spacing. There must be a gap of 1 inch ± 1/8 inch (26mm ± 3 mm) between the belt strands (Fig 22).
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Step 13 1 2 Installing Hardware onto the New Middle Tube 3 M–4417 1 Figure 24 1. Center bolt 2. Alignment hole Parts needed for this step: 3. Left support plate 4. Spring loaded idler Qty. Part 1 Middle tube 6. If adjustment is required, loosen the mower idler plate to adjust it (Fig. 25). Procedure 7. Insert a ratchet or breaker bar into the square hole in the mower idler plate to adjust the tension (Fig. 25). 1.
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4. Install the boot to the new mounting plate with exiting hardware (Fig. 28). Step 14 3 4 Installing the Existing Boot and Brackets to the New Mounting Plate 2 1 m–7499 Figure 28 Parts needed for this step: Qty. 1 1. Boot 2. New mounting plate Part 3. Existing bolt 4. Existing nut Mounting plate Procedure Step 1. Remove the existing mounting plate from the boot. Save the hardware. 15 2. Remove the existing mounting bracket and bracket clamp from the existing mounting plate.
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3. To relieve the spring tension on the grass deflector, place the L or the straight end of the spring in front of the mounting bracket (Fig. 29). 9 4. Lift the grass deflector all the way back. 5. Position the boot’s front hook into the front slot on the mounting bracket (Fig. 30). 2 4 2 1 3 7 1 8 6 m–7056 5 Figure 29 1. Grass deflector frame 2. Grind this part off m–7498 Figure 30 1. 2. 3. 4. 5. 6. Place the rear hook over the rear of the mounting bracket (Fig. 30). 7.
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Step 2 16 1 4 Installing the Weight 5 Parts needed for this step: Qty. m–7501 Part Figure 32 1 Weight 2 U–Bolt, 3/8 X 6 inch 4 Lock nut, 3/8 inch 4 Washer, 3/8 inch 4 Spacer 1. U–bolt 2. Single weight plate 3. Lock nut, 3/8 inch Procedure 1. Raise the foot pan and then remove the footrest from the machine (Fig. 31). 2 1 4 3 M–6961 Figure 31 1. Footrest 2. Bolt 3 6 3. Nut 4. Machine frame 2.