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All Rights Reserved
Printed in the USA
2002 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
Boot and Tube Kit
100 Series Z Master 52 Mowers
200 Series Z Master 52 Mowers
Model No. 78493
Model No. 78494
Form No. 3327–684
Installation Instructions
Set Up
Loose Parts
Note: Use the chart below to verify all parts have been shipped.
Description Qty. Use
Tunnel baffle—front
Carriage bolt, 5/16 x 5/8 in.
Socket button head bolt, 5/16 x 3/4 in.
Flange nuts, 5/16 in.
1
2
1
3
Installing the front tunnel baffle
Tunnel baffle—rear
Carriage bolt, 5/16 x 5/8 in.
Flange nuts, 5/16 in.
1
3
3
Installing the rear tunnel baffle
Tunnel baffle—center
Carriage bolt, 5/16 x 5/8 in.
Flange nuts, 5/16 in.
1
2
2
Installing the center tunnel baffle
Cutting chamber baffle
Socket button head bolt, 1/4 x 5/8 in.
Lock nuts, 1/4 in.
Socket button head bolt, 5/16 x 3/4 in.
Flange nuts, 5/16 in.
1
2
2
3
3
Installing the cutting chamber baffle
Lower bagger tube
Tube clamp
Upper bagger tube
Boot assembly
1
1
1
1
Installing the discharge tubes
Note: Note if the mower is removed from the machine, it
must be leveled when installed.
Removing the Mower
1. Lower the mower onto wood blocks.
2. Remove the four bolts at the bottom of chains that
attached to mower (Fig. 1).
3. Remove the nuts and bolts holding pins in the push
arm (Fig. 1).
4. Remove the pins (Fig. 1).
5. Raise height of cut lever and slide mower out (Fig. 1).
2
1
4
7
m–6062
2
3
5
6
Figure 1
1. Mower
2. Chain
3. Chain Bolt
4. Push Arm
5. Push Arm Bolt
6. Push Arm Nut
7. Push Arm Pin
Before Installation
1. Tip mower upside down and block up ends to ease
installation of components.
2. Thoroughly clean the mower. All debris must be
removed to ensure baffles will fit properly against the
mower.
3. Repair all bent or damaged areas of mower and
replace any missing parts.
Contact with sharp blade can cause serious
personal injury.
• Wear gloves or wrap sharp edges of the
blade with a rag.
Warning
Removing the Cutting
Chamber Stiffener
Note: This section is only for mowers with a stiffener
welded to the cutting chamber (Fig. 2).
1. Remove the cutting chamber stiffener from the mower
(Fig. 2).
2. Grind the welds flat on rear part of the chamber. This
will allow the correct fit for the cutting chamber
baffle.
2
m–6081
1
Figure 2
1. Cutting chamber 2. Cutting chamber stiffener
Installing the Mower Baffles
Note: Use figure 3 for an overall view of where to install
the baffles.
m–5932
5
3
4
2
1
Figure 3
1. Front tunnel baffle
2. Rear tunnel baffle
3. Front of mower
4. Center tunnel baffle
5. Cutting chamber baffle
3
Installing the Front Tunnel
Baffle
1. Place the front tunnel baffle against the front wall of
the discharge tunnel (Fig. 5).
2. Align the front baffle, flush with the outside of the
mounting bracket (Fig. 4).
m–6027
1
2
3
4
Figure 4
1. Front tunnel baffle
2. Mounting bracket
3. Flush edge with outside of
mounting bracket
4. Outside of mounting
bracket
3. Clamp the baffle in place.
4. Using the baffle as a template, drill two, 11/32 in.
diameter, holes into the top of the mower (Fig. 5).
5. Drill one, 11/32 in. diameter, hole into the front wall
of the discharge tunnel (Fig. 5).
6. Install the front tunnel baffle to the top of the mower
with 2 carriage bolts (5/16 x 5/8 in.) and 2 flange nuts
(5/16 in.) (Fig. 5).
7. Install the front tunnel baffle to the front wall of the
discharge tunnel with 1 socket button head bolt (5/16 x
3/4 in.) and 1 flange nut (5/16 in.) (Fig. 5).
1
2
3
4
m–5933
5
3
4
6
Figure 5
1. Front tunnel baffle
2. Carriage Bolt, 5/16 x
5/8 in.
3. Flange nut, 5/16 in.
4. Hole to drill
5. Socket button head bolt,
5/16 x 3/4 in.
6. Front tunnel wall
Installing the Rear Tunnel
Baffle
Note: There is an existing hole in the top of the mower for
installing the rear tunnel baffle.
1. Place the rear tunnel baffle against the rear wall of the
discharge tunnel (Fig. 6).
2. Loosely, install a carriage bolt (5/16 x 5/8 in.) and
flange nut (5/16 in.) into the existing hole in the top of
the mower (Fig. 7).
Note: The rear tunnel baffle must not extend past the
outside of the mounting bracket.
3. Slide the rear tunnel baffle along the rear wall until
there is a 3/16 in. gap between the blade and the baffle
tab (Fig. 6).
4
4
1
1
2
m–6043
3
5
Figure 6
1. Rear tunnel baffle
2. 3/16 in. gap
3. Baffle tab
4. Blade
5. Tunnel rear wall
4. Tighten the carriage bolt (5/16 x 5/8 in.) into the top of
the mower (Fig. 7).
5. Clamp the baffle in place.
6. Using the baffle as a template, drill one, 11/32 in.
diameter, hole into the top of the discharge tunnel
(Fig. 7).
7. Drill one, 11/32 in. diameter, hole into the rear wall of
the discharge tunnel (Fig. 7).
8. Remove the clamp.
9. Install the rear tunnel baffle with 2 carriage bolts
(5/16 x 5/8 in.) and 2 flange nuts (5/16 in.) (Fig. 7).
Important Make sure the bolt heads are installed on
the inside of the cutting chamber.
m–5937
2
1
3
2
3
4
7
6
4
5
2
Figure 7
1. Rear tunnel baffle
2. Inside Carriage Bolt, 5/16
x 5/8 in.
3. Flange nut, 5/16 in.
4. Hole to drill
5. Tunnel rear wall
6. Mounting bracket
7. Existing hole
8. Carriage Bolt, 5/16 x
5/8 in.
Installing the Center Tunnel
Baffle
Important Do not install this baffle when bagging
grass unless blowout is a problem. This baffle is highly
recommended when bagging leaves.
Note: Remove this baffle once the cutting chamber baffle
is installed.
1. Place the center tunnel baffle between the front and
rear tunnel baffles (Fig. 8).
2. Install the center tunnel baffle to the front tunnel
baffle. The flange on the center baffle goes over and
behind the front baffle (Fig. 8).
3. Install the center tunnel baffle to the existing holes in
the front tunnel baffle. Use 2 carriage bolts (5/16 x
5/8 in.) and 2 flange nuts (5/16 in.) (Fig. 8).
5
6
3
m–5934
4
2
5
1
Figure 8
1. Center tunnel baffle
2. Carriage Bolt, 5/16 x
5/8 in.
3. Flange nut, 5/16 in.
4. Flush edge with mounting
bracket
5. Front tunnel baffle
6. Rear hole in baffle
Installing the Cutting Chamber
Baffle
1. Place the cutting chamber baffle behind the right
cutting chamber and against the mower flange
(Fig. 11).
2. Install the cutting chamber baffle to the center baffle
and rear baffle with 1 button head socket bolt (5/16 x
3/4 in.) and 1 flange nut (5/16 in.) (Fig. 12).
3. Align the cutting chamber baffle so the baffle flange is
3–1/2 in. (89 mm) from the top of the cutting chamber
(Figures 9 and 10).
Important Make sure the baffle flange is 3–1/2 in.
(89 mm) from the top of the cutting chamber and there is
blade clearance of 3/8 in. ±1/16 in. (Figures 9 and 10).
4. Clamp the baffle in place.
154 32
m–6087
Figure 9
1. Baffle flange
2. Blade
3. Spindle
4. Blade clearance,
3/8 in. ±1/16 in.
5. Baffle to top of cutting
chamber, 3–1/2 in.
4
1
2
3
m–6082
Figure 10
1. Baffle flange
2. Blade
3. Spindle
4. Baffle to top of cutting
chamber, 3–1/2 in.
5. Using the baffle as a template, drill two, 11/32 in.
diameter, holes into the side of the cutting chamber
(Fig. 11).
6. Drill two, 9/32 in. diameter, holes into the bottom of
the mower flange (Fig. 11). The holes must be
centered on the mower flange.
7. Remove the clamp.
6
8. Install the cutting chamber baffle to the side of the
cutting chamber with 2 socket button head bolts
(5/16 x 3/4 in.) and 2 flange nuts (5/16 in.) (Fig. 11).
9. Install the cutting chamber baffle to the bottom of the
mower flange with 2 socket button head bolts
(1/4 x 5/8 in.) and 2 lock nuts (1/4 in.) (Fig. 11).
61
m–5938
8
7
2
2
3
5
4
9
10
4
Figure 11
1. Cutting chamber baffle
2. Holes to drill
3. Right–hand cutting blade
chamber
4. Flange nuts, 5/16 in.
5. Socket button head bolt,
5/16 x 3/4 in.
6. Socket button head bolt,
1/4 x 5/8 in.
7. Carriage bolt, 5/16 x
5/8 in.
8. Lock nut, 1/4 in.
9. Baffle flange
10. Mower flange
10.Install the cutting chamber baffle to the rear baffle and
center baffle. Secure the baffles together with 1 socket
button head bolt (5/16 x 3/4 in.) and 1 flange nut
(5/16 in.) (Fig. 12).
Important Make sure the bolt heads are installed on
the inside of the cutting chamber.
11. Rotate the blades to ensure there is clearance between
the blade tips and the baffles, as specified in figure 9.
12.If contact is made, do not use the mower. Check and
make sure all baffles are installed properly.
2
4
1
m–5936
3
5
6
Figure 12
1. Cutting chamber baffle
2. Rear tunnel baffle
3. Center tunnel baffle
4. Flange nut, 5/16 in.
5. Socket button head bolt,
5/16 x 3/4 in.
6. Baffle flange
Installing the Discharge Tubes
Refer to the bagger operators manual for installing the
discharge tubes.
Installing the Blade
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 blade onto the spindle shaft (Fig. 13).
Important The curved part of the blade must be
pointing upward toward the inside of the mower to ensure
proper cutting.
2. Install the spring disk and blade bolt (Fig. 13). Torque
the blade bolt to 85–110 ft-lb (115–150 Nm).
3. Rotate the blades to ensure there is clearance between
the blade tips and the baffles.
4. If contact is made, do not use the mower. Check and
make sure the baffles are installed properly.
Important Do not use the mower if blades contact the
baffles.
7
1
3
2
4
M–4226
3
4
5
Figure 13
1. Sail Area of Blade
2. Blade
3. Spring Disk
4. Blade Bolt
5. Cone Towards Bolt Head
Installing the Mower
1. Install the mower to the machine. Reverse the
instructions in Removing the Mower on page 1.
Note: The mower will need to be leveled when installed.
Refer to your operator’s manual.
2. Install the mower belt after the bagger is installed.
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