Installation Instructions

ManualsBrandsToro ManualsAttachments, Parts & AccessoriesToro 107-7652

 2003 by The Toro Company

8111 Lyndale Avenue South

Bloomington, MN 55420-1196

Printed in the USA

Two–Bearing Conversion Kit

DFS Bagger for 100 and 200 Series Z Master



Part No. 107–7651

Part No. 107–7652

Form No. 3350–856

Installation Instructions

Loose Parts

Note: Use the chart below to verify all parts have been shipped.

Step Description Qty. Use

No parts needed – Remove the bagger from the frame

No parts needed

– Removing the fan and bearings

Template 1 Drilling holes for the lower bearing

Shaft

Fan

Snap ring

Key (1/4 x 2 inch)

Set screw

Thread locker adhesive

Assembling the fan

Pillow block bearing

Locknut, 1/2 inch

Washer, 1/2 inch

Bolt, 1/2 x 1–3/4 inch (100 Series only)

Bolt, 1/2 x 2–1/2 inch (200 Series only)

Shim

Rectangular spacer (200 Series only)

Installing the lower bearing

Scroll top assembly

Bolt, 1/4 x 7/8 inch

Washer, 1/4 inch

Locknut, 1/4 inch

Jam nut, 3/4 inch

Washer, 3/4 inch

Install the fan and scroll top

Jam nut, 3/4 inch

Washer, 3/4 inch

Pulley

Key (1/4 x 1 inch)

Install the bottom pulley and jam nut

No parts needed –

Adjust the bagger belt for a 200 Series

Bagger

No parts needed –

Adjust the bagger belt for a 100 Series

Bagger

Summary of content (16 pages)

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Form No. 3350–856 Two–Bearing Conversion Kit DFS Bagger for 100 and 200 Series Z Master Part No. 107–7651 Part No. 107–7652 Installation Instructions Loose Parts Note: Use the chart below to verify all parts have been shipped.
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Step 1 Step Removing the Bagger 2 Removing the Fan and Bearings No parts needed for this step. No parts needed for this step. Procedure Procedure 1. Disengage the PTO, set the parking brake, and chock or block the drive wheels. 1. If a heat shield is installed on your 200 Series bagger, remove the heat shield from the bagger (Fig. 1). 2. Turn off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the discharge tubes. 2 4.
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5 1 2 3 4 1 3 2 4 m–7337 m–7332 Figure 4 Figure 2 1. Bottom pulley 2. Set screw 1. Middle bearing 2. Bolt 3. Washer 3. Key 4. Locking collar 4. Take the bottom bearing off the bagger (Fig. 3). 4. Nut 5. Locking collar 7. Remove the outside bolts, nuts and washers from the scroll top (Fig. 5). Note: To make it easier to remove the fan and shaft, you may have to cut the shaft at the bottom and top to remove the shaft (Fig. 7). 2 3 1 3 4 1 2 m–7333 m–7331 Figure 3 1. Bearing 2.
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8. Pull the whole fan, shaft and scroll top up and out of the hopper (Fig. 6). 2 1 m–7351 Figure 6 1. Hopper 2. Fan, shaft and scroll top Note: To make it easier to remove the fan and shaft, you may have to cut the shaft at the bottom and top to remove the shaft (Fig. 7). 1 2 m–7334 1 2 m–7349 Figure 7 1. Saw 2.
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Step 3 3 1 1 Drilling the Holes for the Lower Bearing m–7345 Figure 9 Parts needed for this step: 1. Bagger 2. Template • 1 Template 3. Correct template position 3. Using the template, mark and center punch the holes. Procedure 4. Drill two 1/8 inch pilot holes into the frame (Fig. 10). Note: Make sure to use the correct holes to line up the template. See Figure 8 for the correct holes to use for a 100 or 200 Series bagger. 5. Remove the template and discard it. 6.
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Step 4 7 7 4 4 2 3 8 Assembling the Fan 1 Parts needed for this step: 5 • 1 Shaft 6 • 1 Fan • 1 Snap ring m–7353 • 1 Key, 1/4 x 2 inch Figure 11 • 2 Set screws 1. 2. 3. 4. • 1 Thread locker adhesive Procedure 1. Install the snap ring onto the top of the new shaft and into the groove (Fig. 11). 2. Install the key (1/4 x 2 inch) onto the shaft and install the fan onto the shaft until it contacts the snap ring (Fig. 11). Note: Make sure the key is completely set in the key way (Fig. 11). 3.
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Step 5 Note: The shim for the 100 Series baggers may not be needed. When the belt is installed check the tension and add it if needed. 6 Installing the Lower Bearing 2 4 5 • 1 Pillow block bearing 3 1 • 2 Locknuts, 1/2 inch m–7347 • 4 Washers, 1/2 inch Figure 13 • 3 Shims 1. 2. 3. 4. • 2 Bolts, 1/2 x 2–1/2 inch (200 Series only) • 2 Bolts, 1/2 x 1–3/4 inch (100 Series only) Bagger Pillow block bearing Bolt, 1/2 x 1–3/4 inch Washer, 3/4 inch 5. Nut, 3/4 inch 6.
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Step 6 1 2 Installing the Fan and Scroll Top • 1 Scroll Assembly • 9 Bolt, 1/4 x 7/8 inch 3 • 18 Washer, 1/4 inch m–7342 • 9 Lock nut, 1/4 inch Figure 16 1. Shaft and fan assembly 2. Hopper • 1 Jam nut, 3/4 inch 3. Lower bearing • 1 Washer, 3/4 inch 3. Assemble the scroll top to the lower scroll with 9 bolts (1/4 x 7/8 inch), 18 washers (1/4 inch) and 9 locknuts (1/4 inch) (Fig. 17). Procedure 1. Install the scroll top to the fan with a jam nut (3/4 inch) and a washer (3/4 inch).
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4. Install the metal cap over the jam nut and the rubber cap over the grease zerk (Fig. 18). Step 2 3 1 7 4 Installing the Bottom Pulley and Jam Nut m–7340 Figure 18 1. Scroll 2. Rubber cap Parts needed for this step: 3. Metal cap 4. Grease zerk • 1 Pulley • 1 Key, 1/4 x 1 inch • 1 Spacer (100 Series only) • 1 Washer, 3/4 inch • 1 Jam nut, 3/4 inch Procedure 1. For the 100 Series baggers, install a spacer onto the shaft before the short key and the pulley (Fig. 19). 2.
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6 7 2 4 5 3 1 m–7348 2 Figure 22 1 1. 2. 3. 4. m–7344 Figure 20 1. Jam nut, 3/4 inch 2. Washer, 3/4 inch 5. Tighten the lower pillow block bearing to the frame. See Figures 21 or 22. Bagger Pillow block bearing Bolt, 1/2 x 1–3/4 inch Washer, 3/4 inch 5. Nut, 3/4 inch 6. Shim 7. Rectangular spacer 6. If a heat shield was removed earlier for your 200 Series bagger, install the heat shield to the bagger (Fig. 23). 2 6 2 4 5 3 1 1 m–7347 Figure 21 1. 2. 3. 4.
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Step 8 C. Tighten the 4 mounting bolts holding the drive pulley assembly to the machine frame (Fig. 25). 3 1 5 Adjusting the Bagger Belt for a 200 Series Bagger 4 2 No parts needed for this step. m–5892 Figure 25 Procedure 1. Drive pulley assembly 2. Mower belt 3. Bagger belt 1. Check the belt tension (Fig 24). 2. Measure the gap, at the bagger tensioner pulley, between the tight and slack side of the belt when the bagger tensioner pulley and spring are installed (Fig. 24). 4. Mounting bolts 5.
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9 Step 2. To adjust the belt tension: A. Remove the tensioner spring (Fig. 27). B. Loosen the 2 nuts on the lower fan shaft pillow block bearing (Fig. 28). C. Insert a spacer between the pillow block and the frame (Fig. 28). D. Tighten the nuts. E. Install the tensioner spring (Fig. 27). Adjusting the Bagger Belt for a 100 Series Bagger F. Check the belt gap and repeat procedure as required. No parts needed for this step. Procedure If the bagger belt is too loose, proceed to the following steps.
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Maintenance Greasing the Fan Shaft Bearings Grease the upper and lower bagger fan shaft bearings (Fig. 29 & 30) every 100 hours. 1. Grease the lower bearing (Fig. 29). 2 1 Figure 29 1. Lower bearing 2. Grease zerk 2. Remove the rubber plug to expose the grease fitting (Fig. 30). 2 1 Figure 30 1. Plug 2.
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