Toro Z Master 72-inch 100-9678 Recycler Kit Installation Instructions PDF

Printed in USA

The Toro Company 2001 All Rights Reserved

FORM NO. 3325215

INSTALLATION INSTRUCTIONS

MODEL NO. 1009678

ZRecycler Kit for 72 in. Side Discharge Mowers

Loose Parts

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

DESCRIPTION QTY. USE

Right front baffle

Left front baffle

1

1 Install left and right front baffle

Center baffle

Bolt, 5/16 x 23/4 in.

Locknut, 5/16 in.

1

2

2

Install center baffle

Right baffle

Left baffle

Bolt, 5/16 x 41/2 in.

Locknut, 5/16 in.

1

1

2

2

Assemble baffles

Baffles assembled

Bolt, 5/16 x 3/4 in.

Bolt, 5/16 x 23/4 in.

Locknut, 5/16 in.

1

2

4

6

Install left and right baffles

Carriage Bolt, 5/16 x 3/4 in.

Flange nut, 5/16 in.

Rear baffle

3

3

1

Install rear baffle

Blades 3 Replaces side discharge blades.

Before Installation

1. Remove mower unit (see Operators Manual for instructions).

2. Thoroughly clean mower deck. All debris must be removed to ensure baffles will fit properly against mower deck.

3. Repair all bent or damaged areas of mower deck and replace any missing parts.

Installation Instructions

2

4. Tip mower deck upside down and block up ends to ease installation of recycler components.

Removing Existing Blades

1. Remove blades and anti-scalp cups, if equipped with, from spindles.

Note: Save blades and antiscalp cups for use when in side discharging mode.

A blade is sharp. Contact with sharp blade can cause serious personal injury.

Wear gloves or wrap sharp edges of the blade with a rag.

Warning

Installing New Front Baffles

1. Remove existing front baffles. Discard old baffles.

Note: Save hardware used for old front baffles.

2. Place the new front baffles into deck and install using existing hardware (Fig. 1).

2

1

2

4

4

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3

Figure 1

1 Right front baffle 2 Left front baffle

3 Bolt 4 Lock Nut

Installing Center Baffle

Note: Holes in deck may not be predrilled for installing baffles. You will then need to mark and drill holes.

If holes in deck are already drilled then go to Assemble Baffles section.

Installation Instructions

3

m5344

5 1 6 4

3 6

3 10

2

6

66

5

7

7

3

8

9

9

9

9

Figure 2

1 Right baffle 2 Left baffle 3 Blade (Sail faces deck) 4 Center baffle 5 Bolt, 5/16 x 3/4 in.

6 Lock Nut, 5/16 in. 7 Bolt, 5/16 x 41/2 in. 8 Deck front 9 Hole to drill 10 Bolt, 5/16 x 23/4 in.

1. To determine where you need to drill holes, place center baffle into deck and against the the front part of the deck (Fig. 2).

2. Install only the center mulching blade (Fig. 2).

IMPORTANT: The sail part of the blade (i.e., the turned up section) must face the inside of the mower (Fig. 2).

3. Tighten the blade mounting bolt to 85110 ft-lb (115150 Nm).

A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders.

Always replace bent or damaged blade with a new blade.

Never file or create sharp notches in the edges or surfaces of blade.

Warning

4. Rotate the center blade to ensure that there is equal clearance between the blade tips and the center baffle (Fig. 3).

2

1 3

3

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Figure 3

1 Center Blade 2 Center baffle

3 Equal clearance

5. Mark the location for center baffle mounting holes and then remove baffle (Fig. 2).

6. Drill two 11/32 in. holes at the marked locations in the mower.

Assemble Baffles

1. Assemble center baffle to the left and right baffles using 2 bolts (5/16 x 41/2 in.) and 2 lock nuts (Fig. 2).

2. Place baffles into the cutting chamber (Fig. 5).

3. Rotate the center blade to ensure that there is equal clearance between both blade tips and the center baffle (Fig. 3).

Installation Instructions

4

Note: When installing bolts, the bolt heads need to be on the inside of cutting deck.

4. Install center baffle to deck with 2 bolts (5/16 x 23/4 in.) and 2 lock nuts (5/16 in.) (Fig. 2).

Installing Left and Right Baffles

1. Place the left and right baffles, while connected to center baffle, against the front part of the deck (Fig. 2).

2. Install left and right mulching blades after the baffles are in place (Fig. 2).

IMPORTANT: The sail part of the blades (i.e., the turned up section) must face the inside of the mower (Fig. 2).

3. Tighten the blade mounting bolts to 85110 ft-lb (115150 Nm).

4. Rotate the left and right blades to ensure that there is clearance between the blade tips and baffles.

5. Mark the location of the left and right baffle mounting holes (Fig. 2).

Note: Make sure to mark and drill the right baffle mounting holes that are on the front and side of the deck (Fig. 2).

6. Drill 11/32 in. holes at the marked locations for both baffles in the mower.

Note: When installing bolts, the bolt heads need to be on the inside of cutting deck.

7. Install left baffle to deck with 2 bolts (5/16 x 23/4 in.) and 2 lock nuts (5/16 in.) (Fig. 2).

8. Install right baffle to deck with bolts (5/16 x 23/4 in.) and 2 lock nuts (5/16 in.) (Fig. 2).

9. Install right baffle to front and side of the deck with 2 bolts (5/16 x 3/4 in.) and 2 lock nuts (5/16 in.) (Fig. 2).

Installing Rear Baffle

Note: On some decks, it may be necessary to remove roller brackets that are welded to the existing rear baffle. Remove these before installing rear baffle (Fig. 4).

m5350

2

1

Figure 4

1 Roller brackets, remove 2 Bottom view of existing rear baffle

1. Place rear baffle behind the cutting chamber (Fig. 5).

Note: Make sure it is resting on the deck surface and on the back side of rear baffle.

2. At the top part of slot, mark the location of rear baffle mounting holes and then remove baffle (Fig. 5).

3. Drill three 11/32 in. holes at the marked locations in the mower.

Installation Instructions

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4. Install rear baffle to deck with 3 carriage bolts (5/16 x 3/4 in.) and 3 flange nuts (5/16 in.) (Fig. 5).

Note: Install rear baffle so it touches the underside of deck. Adjust baffle to improve quality of cut.

m5346

3

4

5

2

5

1

Figure 5

1 Rear baffle 2 Top of slot 3 Carriage bolt,

5/16 x 3/4 in.

4 Flange Nut, 5/16 in. 5 Holes to drill

5. Make sure all holes in deck are plugged with a nut and bolt.

Open holes in the mower exposes you and others to thrown debris. Debris thrown out of holes in the mower can cause injury.

Never operate mower without hardware mounted in all holes in mower.

Install hardware in mounting holes when mulching baffle is removed.

Warning

Reinstall Deck

1. Turn mower deck over, rightside up.

2. Install mower unit (see Operators Manual for instructions).

Mulching Tips

Selecting the proper height-of-cut setting to suit conditions Remove approximately one inch or no more that 1/3 of the grass blade when cutting. In exceptionally lush and dense grass you may have to raise the height-of-cut setting another notch or convert to side discharge or bagging operations.

Mowing in extreme conditions Air is required to cut and recut grass clippings in mower housing, so do not set heightofcut too low or totally surround housing by uncut grass. Always try to have one side of the mower housing free from uncut grass, allowing air to be drawn into housing. When making an initial cut thru center of uncut area, operate machine slower and back up if mower starts to clog.

Mow at proper intervals Under most normal conditions youll need to mow every 45 days. However, grass grows at different rates at different times. Thus, in order to maintain the same height-of-cut, which is a good practice, youll need to cut more frequently in early spring; as the grass growth rate slows in mid summer, cut only every 810 days. If you are unable to mow for an extended period due to weather conditions or other reasons, convert to side discharge or bagging options or mow first with the height-of-cut at a high level; then mow again 23 days later with a lower height setting.

Always mow with sharp blades A sharp blade cuts cleanly and without tearing or shredding the grass blade like a dull blade. Tearing and shredding causes the grass to turn brown at the edges which impairs growth and increases susceptibility to disease.

After operating To ensure optimum performance, clean underside of mower housing after each use. If residue is allowed to build up in mower housing cutting performance will decrease.

Installation Instructions

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Adjusting rear baffle To ensure optimum recycling performance, slots in the rear baffle allow for adjustment. Start with the the rear baffle touching the underside of deck. In certain conditions, lower rear baffle to improve quality of cut.