Installation Instructions

ManualsBrandsToro ManualsAttachments, Parts & AccessoriesToro 78495

Printed in the USA

 2002 by The Toro Company

8111 Lyndale Avenue South

Bloomington, MN 55420-1196

Boot and Tube Kit

200 Series Z Master 62 Mowers

Model No. 78495

Form No. 3328–360 Rev A

Installation Instructions

Set Up

Loose Parts

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

Description Qty. Use

Rear baffle—right

Rear baffle—left

Rear baffle—center

Bolts, 5/16 x 5/8 in.

Flange nuts, 5/16 in.

Bolts, 1/4 x 5/8 in.

Flange nuts, 1/4 in.

Installing the rear baffles

Tunnel baffle—front

Tunnel baffle—rear

Tunnel baffle—center

Carriage Bolt, 5/16 x 5/8 in.

Flange nuts, 5/16 in.

Bolt, 5/16 x 3/4 in.

Installing the tunnel baffles

Lower bagger tube

Upper bagger tube

Tube clamp

Boot assembly

Installing the bagging tubes

Blade stiffener 3 Installing the blades

Checking for existing holes in

the Mower

If there are any existing holes in the mower, you can skip

the steps for drilling holes for that specific baffle

installation.

1. Before installing any baffle check for existing holes.

The holes must align with the baffle in it’s correct

position.

Note: Make sure the holes in the mower align with the

baffle in it’s correct position.

Removing the Grass Deflector

Bracket

Note: This section is only for mowers with grass deflector

bracket welded to the mower (Fig. 3).

1. Remove the grass deflector bracket from the mower as

shown in Figure 3. This will avoid any interference

with the rear tunnel baffle.

Summary of content (12 pages)

PAGE 1
Form No. 3328–360 Rev A Boot and Tube Kit 200 Series Z Master 62 Mowers Model No. 78495 Installation Instructions Set Up Loose Parts Note: Use the chart below to verify all parts have been shipped. Description Qty. Rear baffle—right 1 Rear baffle—left 1 Rear baffle—center 1 Bolts, 5/16 x 5/8 in. 5 Flange nuts, 5/16 in. 5 Bolts, 1/4 x 5/8 in. 6 Flange nuts, 1/4 in. 6 Tunnel baffle—front 1 Tunnel baffle—rear 1 Tunnel baffle—center 1 Carriage Bolt, 5/16 x 5/8 in.
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6 4 7 5 1 3 1 M–4450 Figure 2 2 1. 2. 3. 4. Mower Chain Chain Bolt Push Arm 5. Push Arm Bolt 6. Push Arm Nut 7. Push Arm Pin m–6169 Figure 1 1. Mower Before Installation 2. Remove grass deflector bracket 1. Tip mower upside down and block up ends to ease installation of components. Removing the Mower 2. Thoroughly clean the mower. All debris must be removed to ensure baffles will fit properly against mower.
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Removing the Cutting Chamber Brackets Note: This section is only for mowers with brackets welded to the cutting chamber (Fig. 3). 1. Remove the three cutting chamber brackets from the mower (Fig. 3). 2. Grind the welds flat on rear part of the cutting chambers. This will allow the correct fit for the cutting chamber baffles. 1 2 2 2 m–6159 Figure 3 1. Cutting chamber 2.
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Installing the Rear Mower Baffles Note: Use figure 4 for an over all view of where to install the baffles. 6 2 4 1 3 7 5 m–5884 Figure 4 1. Center rear baffle 2. Left rear baffle 3. Right rear baffle 4. Front tunnel baffle 5. Rear tunnel baffle 6. Front of mower 7. Center tunnel baffle Installing the Center Rear Baffle A right angle drill will be needed to perform this installation. Note: If present, use existing holes for installing this baffle.
PAGE 5
. Install the center baffle with 5 bolts (5/16 x 5/8 in.) and 5 flange nuts (5/16 in.) (Fig. 6). 1 5 Important Make sure the bolt heads are installed on the inside of the cutting chamber. See figure 6. 4 3 6 1 3 2 m–5874 2 4 Figure 7 5 1. Center Baffle 2. Left baffle 3. Flush with bottom of center baffle 4. Left cutting chamber m–5870 Figure 6 1. Center Baffle 2. Holes to drill 3. Center cutting blade chamber 4. Flange nuts, 5/16 in. 5. Bolts, 5/16 x 5/8 in. 5.
PAGE 6
2. Align the right baffle against and flush with the bottom of the center baffle (Fig. 9). 3. Position the left rear baffle so the baffle flange is 3–5/8 in. (92 mm) from the top of the cutting chamber (Fig. 5). Important Make sure the baffle flange is 3–5/8 in. (92 mm) from the top of the cutting chamber at all locations (Fig. 5). 5 Note: If 3–5/8 in. (92 mm) can not be achieved, the bottom welds have to be ground down. Refer to Grinding the Welds on page 6. 3 2 4. Clamp the baffle in place. 1 4 5.
PAGE 7
Installing the Front Tunnel Baffle 1. Place the rear tunnel baffle tight against the back wall of the discharge tunnel. (Fig. 12). Note: If present, use existing hole for installing this baffle. Make sure the existing hole matches the hole in the baffle. 2. Align tab with existing hole in the side of the mower (Fig. 12). 1. Remove the existing right front blowout baffle. Save baffle and hardware for use when bagging baffles are removed. 3. Clamp the baffle in place. 4.
PAGE 8
2 3 2 5 3 3 4 8 1 1 4 7 6 3 6 m–5868 Figure 15 3 5 4 1. Center tunnel baffle 2. Carriage Bolt, 5/16 x 5/8 in. 3. Nut, 5/16 in. 4. Flush edge with mounting bracket m–5871 Figure 14 1. Front tunnel baffle 2. Carriage Bolt, 5/16 x 5/8 in. 3. Nut, 5/16 in. 4. Hole to drill 5. Front wall 6. Mounting bracket 5. 6. 7. 8. Front tunnel baffle Bolt, 5/16 x 3/4 in.
PAGE 9
4. Rotate the blades to ensure there is a 1/2 in. ± 1/16 in. clearance between the blade tips and the baffles (Fig. 5). 1 3 2 5. If contact is made, do not use the mower. Check and make sure the baffles are installed properly. Important baffles. Do not use the mower if blades contact the 4 m–5960 Figure 17 1. Front tunnel baffle 2. Left–hand blowout baffle 3. Same height 1 Installing the Mower 2 1. Turn the mower over to upright position. 3 2.
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