Form No. 3351–335

Conversion Kit

Z200 to Z500 DFS Bagger

Part No. 107–7650

Installation Instructions

Loose Parts

Note: Use the chart below to identify parts for assembly.

Step

1

No parts needed

Description

2

Stop plate

3

Bagger arm

4

Foam grip

5

Cable

Long clevis, liquid cooled machines only

Short clevis

Clevis pin

Cotter pin

6

No parts needed

7

8

Pulley

Plate

Bearing housing

Key

Bolt, 3/8 x 5/8 inch

Spring washer, 3/8 inch

Tensioner bracket template

Eyebolt template

9

Tensioner bracket

10

No parts needed

11

No parts needed

2004 by The Toro Company

8111 Lyndale Avenue South

Bloomington, MN 55420-1196 1

Qty.

–

Use

Removing the bagger arm

1

1

2

1

1

1

1

1

–

2

2

2

2

1

1

1

1

1

–

–

Installing the stop plate

Installing the bagger arm

Installing the latch lever

Installing the new cable

Adjusting the bagger arm

Installing the drive pulley assembly

Drilling holes for the idler bracket and the eyebolt

Installing the tensioner bracket and the eyebolt

Installing the bagger tensioner assembly and the belt

Adjusting the bagger belt

Contact us at www.Toro.com

All Rights Reserved

Printed in the USA

Step

12

No parts needed

Description

13

Middle tube

14

Mounting plate

15

16

Boot

Middle tube

Flexible tube

Clamp

Weight

U–Bolt, 3/8 X 6 inch

Lock nut, 3/8 inch

Washer, 3/8 inch

Spacer

1

1

4

4

2

4

1

1

1

1

Qty.

–

Use

Installing and adjusting the mower belt

1

Installing hardware onto a new middle tube

Installing the existing boot and brackets to the new mounting plate

Installing the boot and discharge tubes

Installing the weight

5

2 4 7 8

Step

1

Removing the Existing Bagger

Arm

Parts needed for this step:

None

Procedure

1. Remove the shoulder bolt and cable from the bagger arm (Fig. 1).

2. Loosen the nut and pulley on the bagger and remove the cable from the pulley (Fig. 1).

3. Remove the cable from the bagger door hinge (Fig. 1).

Save all the hardware.

6 3

1 m–6136

1.

Bagger arm

2.

Cable

3.

Shoulder bolt

4.

Pulley and nut

Figure 1

5.

Bagger door hinge

6.

Cable tie

7.

Latch lever

8.

Grip

4. Loosen the setscrew holding the latch lever (Fig. 6).

5. Remove the plastic cable ties on the handle and slide the latch lever down the handle (Fig. 1).

6. Remove the grip from the bagger arm (Fig. 3).

2

7. Remove the cotter pin and washer from the bagger arm

(Fig. 2). Save the washer and cotter pin.

8. Slide the bagger arm and washer out from the bagger frame (Fig. 2). Save the washer.

3 m–6206

2

4

1

Figure 2

3.

Cotter pin

4.

Washer

1.

Bagger arm

2.

Bagger

9. Remove the latch lever off of the bagger arm and discard the the bagger arm (Fig. 3).

4

Step

2

Installing the Stop Plate

Parts needed for this step:

Qty.

1 Stop plate

Part

Procedure

1. Remove the existing stop bolt and jam nuts from the bagger frame (Fig. 4).

2. Install the stop plate to the stop bracket using the bolt and jam nut previously removed (Fig. 4). Do not tighten.

2

3

1

1

2

3

6

7

5

4

5

1.

Bagger dump lever

2.

Bagger cable

3.

Bagger cable clevis

4.

Bolt, 1/2 x 1–3/4 inch

Figure 4

5.

Jam nut, 1/2 inch

6.

Stop bracket

7.

Stop plate m–7513

1.

Bagger Arm

2.

Latch lever

Figure 3

3.

Foam grip m–7173

3

Step

3

Installing the Bagger Arm

Parts needed for this step:

Qty.

1 Bagger arm

Part

Procedure

1. Install the latch lever onto the bagger arm.

2. Install 1 washer previously removed onto the bagger arm pivot and install the bagger dump handle into the bagger frame (Fig. 5).

3. Secure the bagger handle with the previously removed washer and cotter pin (Fig. 5).

Step

4

Installing the Latch Lever

Parts needed for this step:

Qty.

1 Foam grip

Part

Procedure

1. Position the latch lever 6 inches (15.2 cm) down from the end of the bagger arm. See Figure 6.

5

3

1

2

6

2

1 2 4

1.

Bagger arm pivot

2.

Washer

Figure 5

3.

Cotter pin

4.

Bagger frame m–7515

3

1.

Bagger arm end

2.

Latch lever position

3.

Latch lever cable

4

Figure 6

4.

Set screw

5.

Foam grip

6.

6 inches (15.2 cm) m–7175

2. Position the latch lever at the 10 o’clock position when looking at the end of the handle (Fig. 7).

4

2 1

4

3

7

8

5

3

1

4

2

1.

Latch lever

2.

End of handle

Figure 7

End view of handle

3.

10 o’clock position

4.

12 o’clock position m–7176

3. Tighten the setscrew that holds the latch lever (Fig. 6).

4. Install the cable ties (Fig. 9).

5. Install the foam grip onto the bagger arm (Fig. 6).

Step

5 m–7178

1.

Bagger arm

2.

Cable

3.

Shoulder bolt

4.

Pulley and nut

Figure 8

5.

Bagger door hinge

6.

Cable tie

7.

Nut

8.

Washer

Note: Install the long cable clevis onto the bagger dump handle if it is for a liquid cooled machine (Fig. 9).

3. Secure the bagger cable clevis to the bagger arm with the clevis pin and cotter pin (Fig. 9).

4. Install the cable into the cable clevis installed on the bagger handle (Fig. 9).

2

3

8

1

Installing the New Cable

Parts needed for this step:

Qty.

1

1

1

1

1

Part

Cable

Long clevis, liquid cooled machines only

Short clevis

Clevis pin

Cotter pin

Procedure

1. Install the new cable to the top of the bagger with the previously removed shoulder bolt, washer and nut

(Fig. 8).

2. Install the cable into the pulley and tighten the nut

(Fig. 8).

7

6 9 5 4

5 m–7520

1.

Bagger dump lever

2.

Bagger cable

3.

Long cable clevis—liquid cooled machines only

4.

Bolt, 1/2 x 1–3/4 inch

Figure 9

5.

Jam nut, 1/2 inch

6.

Stop bracket

7.

Clevis pin

8.

Cotter pin

9.

Stop plate

5. Adjust the handle stop, refer to Adjusting the Bagger

Arm, page 6.

6

5

Step

6

Step

7

Adjusting the Bagger Arm

Parts needed for this step:

None

Procedure

The bagger arm needs to be adjusted to remove slack in the bagger cable with the bagger door closed.

1. Loosen the nuts on both sides of the stop bracket

(Fig. 10).

2. Adjust the stop bolt until there is no slack in the bagger cable (Fig. 10).

3. Tighten the nuts on both sides of the stop bracket

(Fig. 10).

1

4

1 5 2 6 5

Installing the Drive Pulley

Assembly

Parts needed for this step:

2

2

2

Qty.

2

1

1

Part

Pulley

Plate

Bearing housing

Bolt, 3/8 x 5/8 inch

Spring washer, 3/8 inch

Key

Procedure

1. Remove the existing drive belts from the machine

(Fig. 21).

2. Remove the existing drive pulley assembly from the machine (Fig. 11).

3 m–7514

1.

Bagger dump lever

2.

Stop bracket

3.

Stop bolt

Figure 10

4.

Bagger cable

5.

Nut

6.

Stop plate

6

5

1

2

10

9

8

7

1

6

4

2

7

5

3

1.

Rear frame

2.

Drive pulley assembly

3.

Bolt, 1/2 x 1–1/4 inch

4.

Nut, 1/2 inch

Figure 11

5.

Washer, 1/2 inch

6.

Cut–out

7.

Pulley plate m–6001

3. Remove the pulleys from the existing assembly.

4. Remove the plate from the existing bearing housing.

5. Install the new bearing housing and existing spacers to the new plate (Fig. 12).

Note: Install the new small pulley nearest the cutout in the plate (Fig. 12).

6. Install the new pulleys to the bearing housing with 2 bolts (3/8 x 5/8 inch), 2 spring washer (3/8 inch) and 2 keys (Fig. 12).

7

8

9

6

3

11

4 m–7495

1.

New small pulley

2.

New bearing housing

3.

New plate

4.

Bolt

5.

Nut

6.

Spacer

Figure 12

7.

Bolt, 3/8 x 5/8 inch

8.

Spring washer, 3/8 inch

9.

Key

10. New large pulley

11. Cut–out

7. Install the mower belt onto the drive pulley assembly

(Figures 13 and 21).

Note: Make sure the cut–out in the pulley plate is on the left–hand side of the machine (Fig. 11). This cut–out allows room for the mower spring loaded idler pulley.

8. Install the pulley assembly under the rear frame, and loosely install 4 bolts (1/2 x 1–1/4 inch), 4 washers

(1/2 in.) and 4 locknuts (1/2 inch) (Fig. 11). Do not tighten bolts now.

Positioning the Drive Pulley Assembly on an Air Cooled Machine

1. Push the drive pulley assembly all the way forward and then rearward a 1/4 inch (6 mm) (Fig. 11).

Note: The bolt head on the drive pulley assembly, should be approximately centered horizontally, in the frame slot

(Fig. 13). View this from the right–hand side of the machine.

2. Tighten the 4 bolts (1/2 x 1–1/4 inch), 4 washers

(1/2 in.) and 4 locknuts (1/2 inch) (Fig. 11).

7

3

1

4

Important A final adjustment may be needed when installing the bagger belt.

Positioning the Drive Pulley Assembly on a Liquid Cooled Machine

1. Pull the drive pulley assembly all the way rearward and then forward a 1/4 inch (6 mm) (Fig. 11).

Note: The bolt head on the drive pulley assembly, should be approximately a 1/4 inch (6mm) rearward of the center in the frame slot (Fig. 13). View this from the right–hand side of the machine.

5

2

Step

8

Drilling Holes for the Tensioner

Bracket and Eyebolt

Parts needed for this step:

Qty.

1

1

Part

Tensioner bracket template

Eyebolt template

Procedure

1. Remove the four bolts in the skid plate (Fig. 14).

2. Remove the skid plate (Fig. 14). This will make it easier to remove and install the hardware and belts.

6 m–5861

1.

Drive pulley assembly

2.

Bolt head—air cooled machine only

3.

Mower drive belt

Figure 13

4.

Bolt head—liquid cooled machine only

5.

Frame slot

6.

1/4 inch—liquid cooled

2. Tighten the 4 bolts (1/2 x 1–1/4 inch), 4 washers

(1/2 in.) and 4 locknuts (1/2 inch) (Fig. 11).

Important A final adjustment may be needed when installing the bagger belt.

m–6984

1.

Bolts

2.

Skid plate

1

2

4 3

Figure 14

3.

Bagger tensioner assembly

4.

Existing tensioner bracket

3. Remove the existing bagger tensioner assembly from the tensioner bracket (Fig. 14). Save the hardware.

4. Remove the existing tensioner bracket and eyebolt from the bagger frame. Save the hardware.

5. Place the tensioner bracket template flush against the wall and bottom of the bagger bracket and tight against the side of the bagger bracket (Fig. 15).

8

6. Align the eyebolt template with the existing hole in the bagger frame (Fig. 15).

Note: Make sure the templates are tight against the bagger frame (Fig. 15).

3

4

1

5

2

5

1

1.

Tensioner bracket template

2.

Eyebolt template

2 m–7491

Figure 15

3.

Bagger frame

4.

Correct template position

5.

Bagger wall

7. Using the templates, mark and center punch the holes.

8. Drill three 1/8 inch pilot holes into the frame (Fig. 16).

9. Remove the templates and discard them.

10. Drill 2 holes, 11/32 inch diameter, into the 1/8 inch pilot holes from the tensioner bracket template (Fig. 16).

11. Drill 1 hole, 9/32 inch diameter, into the 1/8 inch pilot holes from the eyebolt template (Fig. 16).

4

3

2 1

1.

9/32 inch hole to drill

2.

11/32 inch holes to drill

3.

Bagger frame

Figure 16

4.

Tensioner bracket template

5.

Eyebolt template m–7492

9

Step

9

Installing the Tensioner

Bracket and Eyebolt

Parts needed for this step:

Qty.

1 Tensioner bracket

Part

Procedure

1. Install the tensioner bracket to the bagger frame with the previously removed nuts (Fig. 14).

2. Install the previously removed eyebolt with the previously removed nuts (Fig. 14).

5 3

Step

10

Installing the Bagger Tensioner

Assembly and Belt

Parts needed for this step:

None

Procedure

1. Install the bagger tensioner assembly to the tensioner bracket with with the previously removed bolt, washers and lock nut (Fig. 18).

7

1

4

1.

Bolt

2.

Eyebolt

3.

Nut

3

2 m–7493

Figure 17

4.

New tensioner bracket

5.

Bagger frame

3

1

5

2

5

6

1.

Bagger tensioner bracket

2.

Eyebolt

3.

Lock nut

4.

Bolt

Figure 18

5.

Washer

6.

Bagger tensioner assembly

7.

Bagger frame

4 m–7496

2. Install the bagger belt onto the drive pulley

(Fig. 20 and 21).

3. Route the bagger belt onto the bagger pulley

(Figures 19 and 20).

10

3

2

1

1

5 3 6 4 m–5887

1.

Tensioner spring

2.

Eye bolt

3.

Bagger tensioner pulley

4.

Bagger pulley

Figure 19

5.

Belt

6.

Shortest space between belt strands, 1 inch

±

1/8 inch

Note: There should be a 1/4 twist in the belt when it is installed onto the bagger tensioner pulley

4. Install the spring onto the idler arm (Fig. 19).

5. Install the tensioner spring onto the eyebolt attached to the bagger (Fig. 19 and 22).

6. Adjust the bagger belt for proper tension. Refer to

Adjusting the Bagger Belt on page 11.

7. Adjust the Mower belt tension. Refer to Adjusting the

Mower Belt Tension on page 12.

8. Install the skid plate (Fig. 14).

2

4

1

1.

Drive pulley

2.

Bagger tensioner pulley

Figure 20

3.

Bagger pulley

4.

1/4 twist

3 m–5773

2

1.

Drive pulley assembly

2.

Mower belt

3.

Bagger belt

Figure 21

4.

Mounting bolts

5.

Back of machine

4 m–5892

Step

11

Adjusting the Bagger Belt

Parts needed for this step:

None

Procedure

1. Check the belt tension (Fig 22).

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. 22).

3. There must be a gap of 1 inch

±

1/8 inch (26mm

±

3 mm) between the belt strands (Fig 22).

4. If the gap is not correct, remove the tensioner spring from the eyebolt to remove the tension on the PTO spring loaded idler (Fig 22).

5. Loosen the 4 mounting bolts holding the drive pulley assembly (Fig 21).

6. If the gap measurement is too small, push the pulley assembly forward slightly [1/8–3/16 inch (3–5 mm)] from the original set–up position (Fig 21).

5

11

7. If the gap measurement is too large, pull the pulley assembly rearward slightly [1/8–3/16 inch (3–5 mm)] from the original set–up position (Fig 21).

8. Tighten the 4 mounting bolts holding the drive pulley assembly to the machine frame (Fig 21).

9. Install the tensioner spring to the eyebolt to apply tension on the PTO spring loaded idler.

10. Measure the bagger belt spacing. There must be a gap of 1 inch

±

1/8 inch (26mm

±

3 mm) between the belt strands (Fig 22).

11. Repeat this procedure if a gap of 1 inch

±

1/8 inch

(26mm

±

3 mm) was not achieved (Fig 22).

2

1

5 3 6 4 m–5887

1.

Tensioner spring

2.

Eye bolt

3.

Bagger tensioner pulley

4.

Bagger pulley

Figure 22

5.

Belt

6.

Shortest space between belt strands, 1 inch

±

1/8 inch

Step

12

Installing and Adjusting the

Mower Belt

Parts needed for this step:

None

Procedure

1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake.

2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3. Raise the mower to the transport position.

4. Ensure the mower belt is installed on all mower pulleys

(Fig 23).

Important Check the amount of twist in the belt between the pulleys. Make sure it is only what is specified in Figure 23.

1

3

3

5 3

2

1.

Clutch

2.

Mower belt

3.

1/4 turn belt twist

4

3

4

6 m–6825

Figure 23

4.

Belt guide

5.

Mower spindle pulley

6.

Mower idler pulley

Important Check and make sure the belt is installed into both the front and rear belt guides (Fig 24).

5. Check the belt tension. The spring loaded idler center bolt needs to be near the top alignment hole in the left support plate (Fig 24).

12

1

2

3

1.

Center bolt

2.

Alignment hole

1

Figure 24

3.

Left support plate

4.

Spring loaded idler

M–4417

6. If adjustment is required, loosen the mower idler plate to adjust it (Fig. 25).

7. Insert a ratchet or breaker bar into the square hole in the mower idler plate to adjust the tension (Fig. 25).

8. To increase belt tension, rotate the mower idler plate until resistance is felt and rotation stops. Do not go past when it stops (Fig. 25).

9. Tighten the idler plate bolts (Fig. 25).

3

4

Step

13

Installing Hardware onto the

New Middle Tube

Parts needed for this step:

Qty.

1 Middle tube

Part

Procedure

1. Remove the rubber latch, mounting bracket and the hardware from the existing middle tube.

2. Install the rubber latch, mounting bracket to the new middle tube with the existing hardware (Fig. 26).

1

4

3 2

4

2 m–6826

1.

Mower idler plate

2.

Square hole

1

Figure 25

3.

Ratchet or breaker bar

4.

Idler plate bolt

4 m–7497

1.

Middle tube

2.

Existing rubber latch

Figure 26

3.

Existing mounting bracket

4.

Hardware

13

Step

14

4. Install the boot to the new mounting plate with exiting hardware (Fig. 28).

3

4

2

Installing the Existing Boot and

Brackets to the New Mounting

Plate

Parts needed for this step:

Qty.

1 Mounting plate

Part

Procedure

1. Remove the existing mounting plate from the boot.

Save the hardware.

2. Remove the existing mounting bracket and bracket clamp from the existing mounting plate. Save the hardware.

3. Install the existing mounting bracket and bracket clamp to the new mounting plate (Fig. 27).

4

1

1.

New mounting plate

2.

Existing mounting bracket

3 4

4

2 m–7500

Figure 27

3.

Existing bracket clamp

4.

Existing hardware

1

1.

Boot

2.

New mounting plate

Figure 28

3.

Existing bolt

4.

Existing nut

Step

15 m–7499

Installing the Boot and

Discharge Tubes

Parts needed for this step:

Part Qty.

1

1

1

1

Upper flexible tube

Middle tube

Boot

Clamp

Procedure

Note: Remember to replace the L or the straight end of the spring when in side discharge mode.

1. Disengage the PTO and set the parking brake.

2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

14

3. To relieve the spring tension on the grass deflector, place the L or the straight end of the spring in front of the mounting bracket (Fig. 29).

4. Lift the grass deflector all the way back.

5. Position the boot’s front hook into the front slot on the mounting bracket (Fig. 30).

1

2

4

2

9

3

7

8

1

1.

Grass deflector frame

Figure 29

2.

Grind this part off m–7056

6. Place the rear hook over the rear of the mounting bracket (Fig. 30).

7. Install the upper flexible tube into the bagger (Fig. 30).

8. Slide the clamp onto the upper flexible tube (Fig. 30).

9. Slide the middle tube into the upper tube (Fig. 30).

10. Tighten the clamp around the upper and middle tube connection (Fig. 30).

11. Slide the middle tube onto the boot and latch them together (Fig. 30).

12. Adjust the flow baffle in the mower to match the opening of the boot. Refer to your mower Operator’s

Manual.

6

5

1.

Boot

2.

Middle tube

3.

Upper flexible tube

4.

Latch

5.

Mounting bracket

Figure 30

6.

Front slot

7.

Rear hook

8.

Front hook

9.

Clamp m–7498

15

Step

16

Installing the Weight

Parts needed for this step:

Qty.

1

4

4

2

4

Weight

U–Bolt, 3/8 X 6 inch

Lock nut, 3/8 inch

Washer, 3/8 inch

Spacer

Part

Procedure

1. Raise the foot pan and then remove the footrest from the machine (Fig. 31).

2

1

2

1

5 m–7501

1.

U–bolt

2.

Single weight plate

3.

Lock nut, 3/8 inch

6

3

Figure 32

4.

Front caster

5.

Spacer

6.

Washer, 3/8 inch

4

4

3

M–6961

1.

Footrest

2.

Bolt

Figure 31

3.

Nut

4.

Machine frame

2. Install the single weight plate onto the machine frame with 2 U–bolts (3/8 x 6 inch), 2 spacers, 2 washers

(3/8 inch), and 2 nuts (3/8 inch) (Fig. 32).

3. Install the footrest onto the machine and lower the footpan (Fig. 31).

16