Installation Instructions

ManualsBrandsToro ManualsAttachments, Parts & AccessoriesToro 78509

Printed in the USA

 2003 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. 78508

Model No. 78509

Form No. 3329–565

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

Tunnel baffle—front

Carriage bolt, 5/16 x 5/8 inch

Flange nut, 5/16 inch

Installing the front tunnel baffle

Tunnel baffle—rear

Carriage bolt, 5/16 x 5/8 inch

Flange nut, 5/16 inch

Installing the rear tunnel baffle

Center rear baffle

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

Flange nut, 5/16 inch

Installing the center rear baffle

Left rear baffle

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

Flange nut, 5/16 inch

Installing the left rear baffle

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

Installing the right rear baffle

Removing the mower existing pulley

assembly

Modifying a 44 inch Mower for Belt

Clearance

Pulley assembly

Bagger Belt

Pulley cover

Installing the pulley assembly, belt and

cover

Mounting plate

Bolt, 3/8 x 1–1/4 inch

Flange nuts, 3/8 inch

Installing the mounting plate

Summary of content (16 pages)

PAGE 1
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 installation. This kit will require significant time to install the first time. A right angle drill is recommended for Loose Parts Note: Use the chart below to verify all parts have been shipped.
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Before Installation Checking the Mower for Existing Holes 1 4 5 3 2 Check for existing holes. Use existing holes in the mower that align the baffles in their correct positions. 7 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.
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Removing the Cutting Chamber Stiffener 7. Raise the height of cut lever and slide the mower out (Fig. 3). 2 Note: This section is only for mowers with a stiffener welded to the cutting chamber (Fig. 4). 3 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. 3 2 6 9 5 7 1 4 8 m–6265 m–6062 Figure 3 1. 2. 3. 4. 5. Mower Chain Chain Bolt Push Arm Push Arm Bolt 6. 7.
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Step 1 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). 2 1 Parts needed for this step: 4 • 1 Tunnel baffle—front 3 2 3 • 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.
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Step 2 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.
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Step 3 4 1 2 3 m–6229 Figure 10 1. Baffle flange 2. Blade 3. Spindle Parts needed for this step: • 1 Center cutting chamber baffle 4. Blade clearance, 9/16 to 11/16 inch (14 mm to 17 mm) • 3 Button Head Socket Bolts, 5/16 x 3/4 inch • 3 Flange nuts, 5/16 inch 4. Clamp the center baffle tightly against the cutting chamber (Fig. 11). Installing the Center Rear Baffle 5. Using the baffle as a template, mark, center punch and drill 1/8 inch pilot holes at the 3 locations (Fig. 11). 6.
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Step 4 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. 6 2 Parts needed for this step: • 1 Left rear baffle 3 • 3 Button Head Socket Bolts, 5/16 x 3/4 inch • 3 Flange nuts, 5/16 inch 7 Installing the Left Rear Baffle 5 Note: Blades and spindles are not shown in the graphics for clarity. 5 1.
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Step 5 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). Parts needed for this step: • 1 Right rear baffle 8.
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Step 6 2 3 5 No Parts needed for this step. 1 4 4 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. m–6713 3. Remove the nut and washer on top of the spindle (Fig. 17). Save the nut and washer. Figure 16 1. 44 inch mower 2. Remove this corner 3. 3–1/4 inches 4.
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Step 8 Installing the Belt Cover and Bagger Belt Refer to the bagger Operator’s Manual for installing the belt cover and bagger belt. 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.
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Step 9 Installing the Mounting Plates 1. Install the mounting plates to the inside of the mounting bracket with 4 bolts (3/8 x 1–1/4 inch) and 4 flange nuts (3/8 inch) (Fig. 19). 1 1 3 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 5 This kit contains a metal template for locating the mounting bracket holes to drill. 2 1.
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Installing the Blades Installing the Mower and Mower Belt Note: In certain mowing conditions, improved bagging performance can be achieved by using bagging blades. Contact an Authorized Service Dealer for the proper blades for different mowing conditions. 1. Install the mower to the machine. Reverse the instructions in Removing the Mower on page 2. Note: If the mower was already level and was removed from the top bolts, the mower will not need to be leveled.
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Using the Grass Deflector Installing the Grass Deflector Important Make sure the grass deflector is installed when the bagger and tubes are removed. Important Make sure the grass deflector is installed when the bagger and tubes are removed. The grass deflector spring will have either an L end or a straight end (Fig. 22). Warning Warning Without the grass deflector, bagger tubes or complete bagger assembly mounted in place, you and others are exposed to blade contact and thrown debris.
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