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44 and 52 Finishing Kit
100 Series Z Master 44 Mowers
100 Series Z Master 52 Mowers
Model No. 78496
Model No. 78497
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
Tunnel baffle—front
1
Carriage bolt, 5/16 x 5/8 inch
Flange nut, 5/16 inch
Tunnel baffle—rear
2
Carriage bolt, 5/16 x 5/8 inch
Flange nut, 5/16 inch
Center rear baffle
3
Button Head Socket Bolt, 5/16 x 3/4 inch
Flange nut, 5/16 inch
Left rear baffle
4
Button Head Socket Bolt, 5/16 x 3/4 inch
Flange nut, 5/16 inch
Right rear baffle
5
Button Head Socket Bolt, 5/16 x 3/4 inch
Carriage bolt, 5/16 x 5/8 inch
Flange nut, 5/16 inch
6
7
Pulley assembly
8
Bagger Belt
Pulley cover
Mounting plate
9
Bolt, 3/8 x 1–1/4 inch
Flange nuts, 3/8 inch
2002 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
Installation Instructions
Qty.
Use
1
4
Installing the front tunnel baffle
4
1
3
Installing the rear tunnel baffle
3
1
3
Installing the center rear baffle
3
1
3
Installing the left rear baffle
3
1
2
Installing the right rear baffle
1
3
Removing the mower existing pulley
assembly
Modifying a 44 inch Mower for Belt
Clearance
1
Installing the pulley assembly, belt and
1
cover
1
2
4
Installing the mounting plate
4
1
Form No. 3329–234 Rev A
All Rights Reserved
Printed in the USA
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Summary of Contents for Toro 78496
- Page 1 Installing the pulley assembly, belt and Bagger Belt cover Pulley cover Mounting plate Bolt, 3/8 x 1–1/4 inch Installing the mounting plate Flange nuts, 3/8 inch 2002 by The Toro Company 8111 Lyndale Avenue South All Rights Reserved Bloomington, MN 55420-1196 Printed in the USA...
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Page 2: Before Installation
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. - Page 3 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.
- Page 4 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). 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...
- Page 5 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.
- Page 6 m–6229 Figure 10 1. Baffle flange 4. Blade clearance, Parts needed for this step: 9/16 to 11/16 inch 2. Blade (14 mm to 17 mm) 1 Center cutting chamber baffle 3. Spindle 3 Button Head Socket Bolts, 5/16 x 3/4 inch 4.
- Page 7 Important Make sure the bolt heads are installed on the inside of the cutting chamber. See figure 13. 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.
- Page 8 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.
- Page 9 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.
- Page 10 Parts needed for this step: Parts needed for this step: 1 Pulley assembly 2 Mounting plates 1 Bagger Belt 1 Template 1 Pulley cover 4 Bolts, 3/8 x 1–1/4 inch 4 Flange nuts, 3/8 inch Installing the Pulley Assembly Installing the Mounting Plates Note: For mowers built in 1999, check the right blade spindle for splines.
- Page 11 Installing the Mounting Plates Installing the Blades 1. Install the mounting plates to the inside of the Note: In certain mowing conditions, improved bagging mounting bracket with 4 bolts (3/8 x 1–1/4 inch) and 4 performance can be achieved by using bagging blades. flange nuts (3/8 inch) (Fig.
- Page 12 Installing the Mower and Using the Grass Deflector Mower Belt Note: Make sure the grass deflector is installed when the bagger and tubes are removed. 1. Install the mower to the machine. Reverse the instructions in Removing the Mower on page 2. Warning Note: The mower will need to be leveled when installed.
- Page 13 Installing the Grass Deflector Note: 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 An uncovered discharge opening could allow the lawn mower to throw objects in the operator’s or bystander’s direction and result in serious injury.