Toro Z Master Z593 110-0891 Mount Operator's Manual PDF

Form No. 3355-269 Rev A

Mounting Kit for DFS Vac Collection System on a Z593 and Z595 Series Z Masters Model No. 1100891

Register at www.Toro.com. Original Instructions (EN)

Introduction Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage. You are responsible for operating the product properly and safely.

You may contact Toro directly at www.Toro.com for product and accessory information, help finding a dealer, or to register your product.

Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready. Figure 1 identifies the location of the model and serial numbers on the product. Write the numbers in the space provided.

Figure 1 1. Model and serial number location

Model No.

Serial No.

This manual identifies potential hazards and has safety messages identified by the safety alert symbol (Figure 2), which signals a hazard that may cause serious injury or death if you do not follow the recommended precautions.

Figure 2 1. Safety alert symbol

This manual uses 2 other words to highlight information. Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention.

Contents Introduction................................................................. 2 Safety ........................................................................... 3

Safety and Instructional Decals ............................. 3 Setup............................................................................ 4

1 Removing the Existing Bagger, Mounting Bracket, andWeights ........................................ 5

2 Installing the BaggerMounting Bracket .............. 7 3 Tightening all Mounting Bolts ............................ 8 4 Installing the Bagger Drive Pulley....................... 9 5 Installing the Spring Loaded Idler Pulley and Spring Anchor.................................................. 9

6 Installing the Fixed Idler Pulley......................... 10 7 Installing the Idler ArmBracket........................ 11 8 Installing the Bagger ........................................ 11 9 Installing the Bagger Belt ................................. 12 10 Checking and Adjusting the Bagger Belt Tension .......................................................... 13

11 Installing theWeights ..................................... 13 12 Installing the Boot and Discharge Tubes ............................................................. 14

13 Adjusting the Bagger Dump Lever.................. 15 14 Checking the Tire Pressure ............................. 16

Operation................................................................... 16 Positioning the Adjustable Baffle ........................ 17 Opening the Bagger ........................................... 17 Holding the Bagger Door Open.......................... 17 Adjusting the Bagger Door Opening and Cable.............................................................. 17

Clearing Obstructions From the Bagger System............................................................ 18

Removing the Discharge Tubes........................... 18 Removing the Bagger ......................................... 19 Securing the Bagger Idler Pulley.......................... 19 Replacing the Grass Deflector............................. 20 Operating Tips ................................................... 20

Maintenance............................................................... 22 RecommendedMaintenance Schedule(s) ................ 22 Cleaning the Screens........................................... 22 Cleaning the Bagger............................................ 22 Checking the Bagger Belt.................................... 22 Greasing the Idler Arm....................................... 22 Greasing the Fan Shaft Bearings.......................... 22 Inspecting the Bagger ......................................... 23 Inspecting theMower Blades .............................. 23

Troubleshooting......................................................... 24

2007The Toro Company 8111 Lyndale Avenue South Bloomington, MN 55420 2

Contact us at www.Toro.com. Printed in the USA. All Rights Reserved

Safety The following list contains safety information specific to Toro products and other safety information you must know.

Become familiar with the safe operation of the equipment, with the operator controls, and safety signs.

Use extra care with grass catchers or other attachments. These can change the operating characteristics and the stability of the machine.

Follow the manufacturers recommendations for adding or removing wheel weights or counterweights to improve stability.

Do not use a grass catcher on steep slopes. A heavy grass catcher could cause loss of control or overturn the machine.

Slow down and use extra care on hillsides. Be sure to travel in the recommended direction on hillsides. Turf conditions can affect the machines stability. Use extreme caution while operating near drop-offs.

Keep all movement on slopes slow and gradual. Do not make sudden changes in speed, directions or turning.

The grass catcher can obstruct the view to the rear. Use extra care when operating in reverse.

Use care when loading or unloading the machine into a trailer or truck

Never operate with the discharge deflector raised, removed or altered, unless using a grass catcher.

Keep hands and feet away from moving parts. Do not make adjustments with the engine running.

Stop on level ground, disengage drives, chock or block wheels, shut off engine before leaving the operators position for any reason including emptying the grass catcher or unclogging the chute.

If you remove the grass catcher, be sure to install any discharge deflector or guard that might have been removed to install the grass catcher. Do not operate the mower without either the entire grass catcher or the grass deflector in place.

Stop the engine before removing the grass catcher or unclogging the chute.

Do not leave grass in grass catcher for extended periods of time.

Grass catcher components are subject to wear, damage and deterioration, which could expose moving parts or allow objects to be thrown. Frequently check components and replace with manufacturers recommended parts, when necessary.

Safety and Instructional Decals

Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost.

107-1613

104-8569 106-3339

3

Setup Loose Parts Use the chart below to verify that all parts have been shipped.

Procedure Description Qty. Use

1 No parts required Remove the existing bagger, mounting bracket, and weights.

Side bracketright 1 Side bracketleft 1 Bolt, (3/8 x 21/2) 2 Bolt, (3/8 x 3/4 inch) 2 Flange Locknut, (3/8 inch) 4

2 Spacers 2

Install the bagger mounting bracket.

3 No parts required Tighten all mounting bolts.

Bagger drive pulley 1 Pulley spacer 3 Bolt, (3/8 x 1-3/4 inches) 44 Flange nut, (3/8 inch) 4

Install the bagger drive pulley

Spring loaded idler pulley 1 Idler arm 1 Carriage bolt, (3/8 x 2 inches) 1 Bolt, (3/8 x 41/2 inches) 1 Lock nut, (3/8 inch) 2 Washer, 7/16 inch 1 Washer, 13/32 inch 1 Long round spacer 1 Flange nut, (3/8 inch) 1

5

Spring anchor, (3/8 inch) 1

Install the spring loaded idler pulley

Fixed idler pulley 1 Fixed idler bracket 1 Bolt, (3/8 x 1-1/2 inches) 1 Bolt, (3/8 x 3/4 inch) 2 Lock nut, (3/8 inch) 1 Flange nut, (3/8 inch) 2

6

Washer, 13/32 inch 1

Install the fixed idler pulley

Idler arm bracket 1 Bolt, (3/8 x 3/4 inch) 27 Flange nut, (3/8 inch) 2

Install the idler arm bracket.

Bagger (from previous bagger) 1 Clevis pin (from previous bagger) 28 Hairpin cotter (from previous bagger) 2

Install the bagger

Bagger belt 19 Spring 1 Install the bagger belt.

10 No parts required Check and adjust the bagger belt.

Large top weight 111 Bolt, (1/2 x 5 inches) (for top weights) 2 Install the weights

4

Procedure Description Qty. Use Boot (from previous bagger) 1 Middle tube (from previous bagger) 1 Upper tube (from previous bagger) 112 Clamp (from previous bagger) 1

Install the boot and discharge tubes

13 No parts required Adjust the bagger dump lever.

14 No parts required Check the tire pressure.

Note: Use this manual when the DFS bagger is installed and used on a Z593D Z Master. Save the previous DFS bagger manual and parts not used for when the bagger is installed again on a gas engine Z Master.

Note: Determine the left and right sides of the machine from the normal operating position.

1 Removing the Existing Bagger, Mounting Bracket, and Weights

No Parts Required

Procedure This procedure is for air cooled machines and liquid cooled machines.

1. Remove the spring from the eyebolt (Figure 36).

Figure 3 1. Idler spring 3. Belt 2. Eyebolt

2. Remove the idler arm and pulley from the bagger and store it (Figure 4).

Figure 4 1. Idler arm and pulley 3. Nuts 2. Bolts

3. Remove the 2 clevis pins and 2 hairpin cotter pins from the bagger and bagger mounting bracket (Figure 5). Save this hardware.

4. Remove the bagger from the bagger mounting bracket Figure 5

5

Figure 5 1. Bagger 3. Hairpin cotter 2. Bagger mounting bracket 4. Clevis pin

5. Remove the existing bagger mounting bracket hardware from the back of the existing Z Master. Discard this hardware (Figure 6).

6. For air cooled machines only, remove the frame spacer and store it (Figure 6).

Figure 6 1. Bagger mounting bracket 4. Bumper 2. Bolt, (3/8 x 1-1/4 inches) 5. Air cooled frame spacer 3. Flange nut, (3/8 inch) 6. Bolt, (3/8 x 1-3/4 inches)

7. Remove the ROPS, bagger mounting bracket, and side brackets by removing the bolts, curved washers, and nuts (Figure 7).

8. Retain this hardware. This hardware will be used again when installing the bagger onto a Z593 Z Master.

Figure 7 1. Bagger mounting bracket 4. Flange nut, (3/8 inch) 2. Curved washer, (3/8 inch) 5. ROPS 3. Bolt, (3/8 x 1-1/2 inches)

9. Remove the side brackets from the bagger mounting bracket and store them. Do not remove the bracket stiffener from the bagger mounting bracket (Figure 8).

10. Retain this hardware. This hardware will be used again when installing the bagger onto a Z593 Z Master.

Figure 8 1. Left side bracket 6. Right side bracket 2. Bolt, (3/8 x 1-1/4 inches) 7. Long frame spacer 3. Bracket stiffener 8. Bolt, (3/8 x 1-1/2 inches) 4. Flange nut, (3/8 inch) 9. Short frame spacer 5. Bagger mounting bracket 10. Bolt, (3/8 x 3/4 inch)

11. Remove bolt and the 2 small top weights from each front caster weight (Figure 9).

6

Figure 9 1. Top weight 3. Front caster weight 2. Bolt, (1/2 x 4 inches) 4. Front caster wheel

12. Remove the plate, nuts (1/2 inch), and lock washer (1/2 inch) under the frame and weight (Figure 10).

13. Remove the caster weights on the front casters.

Figure 10 1. Front caster weight 4. Nut 2. U-bolt 5. Front caster 3. Plate 6. Lock washer

2 Installing the Bagger Mounting Bracket

Parts needed for this procedure: 1 Side bracketright

1 Side bracketleft

2 Bolt, (3/8 x 21/2)

2 Bolt, (3/8 x 3/4 inch)

4 Flange Locknut, (3/8 inch)

2 Spacers

Procedure Important: Do not tighten any bolts until both side brackets and bagger mounting bracket are fit loose on the machine. Refer to Tightening the Mounting Bolts for the correct procedure to tighten the bolts.

Important: Use the existing hardware when the bagger mounting bracket was removed.

1. Install the side brackets to the bagger mounting bracket (Figure 11).

2. In the top two holes, install 2 bolts (3/8 x 1-1/2 inches), 2 flange nuts (3/8 inch), 2 long frame spacers, and one short frame spacer (Figure 11).

Note: Make sure the long frame spacers are installed as shown in Figure 11).

3. In the bottom hole, install a bolt (3/8 x 1-1/4 inches) and a flange nut (3/8 inch) (Figure 11).

4. Install a bracket stiffener to the side bracket and bagger mounting bracket. Use 4 bolts (3/8 x 3/4 inch) and 4 flange nuts (3/8 inch) (Figure 11).

5. Repeat the previous steps for the opposite side (Figure 11).

7

Figure 11 1. Bagger mounting bracket 7. Long frame spacer 2. Bolt, (3/8 x 1-1/4 inches) 8. Bolt, (3/8 x 1-1/2 inches) 3. Flange nut, (3/8 inch) 9. Short frame spacer 4. Bracket stiffener 10. Right side bracket 5. Left side bracket 11. Use these holes in the

bracket stiffener 6. Bolt, (3/8 x 3/4 inch)

6. Remove the bolts, nuts, and washers holding the roll bar to one side of the machine. Discard the nuts, bolts, and washers (Figure 12).

7. Install the bagger side plate and the roll bar section to the side of the machine using 4 bolts (3/8 x 1-1/2 inches), 4 curved washers (3/8 inch), and 4 flange nuts (3/8 inch) (Figure 12).

8. Repeat the steps above for the opposite side (Figure 12).

Note: Make sure the curved washer are installed as shown in Figure .

Figure 12 1. Side bracket 4. Flange nut, 3/8 inch 2. Curved washer, 3/8 inch 5. ROPS 3. Bolt, 3/8 x 1-1/2 inch

9. Install the bagger mounting bracket to the rear frame of the machine (Figure 13).

10. In the top two holes, install 2 bolts (3/8 x 2-1/2), 2 round spacers, and 2 flange nuts (3/8 inch).

11. In the bottom two holes, install 2 bolts (3/8 x 3/4 inch) and a 2 flange nuts (3/8 inch)(Figure 13).

Figure 13 1. Bagger mounting bracket 4. Bumper 2. Bolt, (3/8 x 3/4 inch) 5. Round spacer 3. Flange nut, (3/8 inch) 6. Bolt, (3/8 x 2-1/2)

8

3 Tightening all Mounting Bolts No Parts Required

Procedure The following steps are the correct sequence to tighten the side brackets and the bagger mounting bracket.

All 3/8 inch mounting bolts need to be torqued to 35 ft-lb (48 Nm). 1. Tighten the bagger mounting bracket to the rear

frame first (Figure 13). 2. Tighten the bagger mounting bracket to the side

brackets (Figure 11). 3. Tighten the bracket stiffeners to both the side plates

and the bagger mounting bracket (Figure 11). 4. Tighten the side brackets to the side of the mower

(Figure 12).

4 Installing the Bagger Drive Pulley Parts needed for this procedure:

1 Bagger drive pulley

3 Pulley spacer

4 Bolt, (3/8 x 1-3/4 inches)

4 Flange nut, (3/8 inch)

Procedure 1. Remove the mower belt from the gearbox pulley

assembly (Figure 14). 2. Remove the 2 set screws, square key, and gearbox

pulley from the gearbox.

Note: Make sure the pulley that is removed has 4 holes around the center hole. If it does not, contact an Authorized Service Dealer for the correct pulley.

3. Install the bagger drive pulley to the gearbox pulley with 3 bolts (3/8 x 1-3/4 inches), 3 spacers, and 3 flange nuts (3/8 inch) (Figure 14).

4. Install the gearbox pulley and bagger drive pulley to the gearbox with 2 set screws and a square key (Figure 14). The pulley hub needs to be flush with the end of the gearbox shaft.

5. Install the mower belt back onto the upper gearbox pulley (Figure 14).

Figure 14 1. Gearbox 5. Spacer 2. Flange nut, 3/8 inch 6. Bagger drive pulley 3. Gearbox drive pulley 7. Bolt, 1/2 x 1-3/4 inch 4. Set screw

9

5 Installing the Spring Loaded Idler Pulley and Spring Anchor

Parts needed for this procedure: 1 Spring loaded idler pulley

1 Idler arm

1 Carriage bolt, (3/8 x 2 inches)

1 Bolt, (3/8 x 41/2 inches)

2 Lock nut, (3/8 inch)

1 Washer, 7/16 inch

1 Washer, 13/32 inch

1 Long round spacer

1 Flange nut, (3/8 inch)

1 Spring anchor, (3/8 inch)

Procedure 1. Install the spring loaded idler assembly to the idler

arm with a carriage bolt (3/8 x 2 inches), washer (13/32 inches), and a locknut (3/8 inch).

2. Install the spring anchor to the left rear bottom frame with a flange nut (3/8 inch)(Figure 15).

3. Install the spring loaded idler pulley to the right rear bottom frame with a bolt (3/8 x 4 inches), long spacer, washer (7/16 inches), and a locknut (3/8 inch) (Figure 15).

Important: Make sure the idler arm and spring anchor is installed in the correct holes shown in Figure 15 .

Figure 15 1. Lock nut, (3/8 inch) 7. Carriage bolt, (3/8 x 2

inches) 2. Washer, 7/16 inch 8. Right rear bottom frame 3. Spring loaded idler pulley 9. Spring anchor 4. Washer, 13/32 inch 10. Flange nut, (3/8 inch) 5. Long round spacer 11. Bolt, (3/8 x 41/2 inch) 6. Idler arm 12. Left rear bottom frame

6 Installing the Fixed Idler Pulley Parts needed for this procedure:

1 Fixed idler pulley

1 Fixed idler bracket

1 Bolt, (3/8 x 1-1/2 inches)

2 Bolt, (3/8 x 3/4 inch)

1 Lock nut, (3/8 inch)

2 Flange nut, (3/8 inch)

1 Washer, 13/32 inch

Procedure 1. Install the fixed idler pulley to the fixed idler bracket

with a bolt (3/8 x 1-1/2 inches), washer (13/32 inches), and a locknut (3/8 inch).

2. Install the fixed idler assembly to the left rear bottom frame with 2 bolts (3/8 x 3/4 inch) and 2 flange nuts (3/8 inch) (Figure 16).

10

Figure 16 1. Fixed idler pulley 5. Bolt, 2. Washer, 6. Fixed Idler pulley bracket 3. Nut, 7. Left rear bottom frame 4. Nut, 8. Bolt, (3/8 x 3/4 inch)

7 Installing the Idler Arm Bracket

Parts needed for this procedure: 1 Idler arm bracket

2 Bolt, (3/8 x 3/4 inch)

2 Flange nut, (3/8 inch)

Procedure Install the idler arm bracket to the right rear bottom frame with 2 bolts (3/8 x 3/4 inch) and 2 flange nuts (3/8 inch) (Figure 17).

Figure 17 1. Bolt, (3/8 x 3/4 inch) 3. Nut, (3/8 inch) 2. idler arm bracket 4. Idler pulley

8 Installing the Bagger Parts needed for this procedure:

1 Bagger (from previous bagger)

2 Clevis pin (from previous bagger)

2 Hairpin cotter (from previous bagger)

Procedure 1. Locate template number 1 in the back of this manual.

Cut out template number 1 as indicated on the template (Figure 18).

2. Position the template on the right-hand side of the engine shroud (Figure 18).

3. Line up the circles on the template with the rivets on the shroud and the template bottom is flush with the bottom of shroud (Figure 18).

4. Tape the template to the engine shroud. Mark the outer edge of the template. (Figure 18).

5. Cut the engine shroud at the marked line. This will prevent damage to the engine shroud while using the bagger dump lever (Figure 18).

Note: Make sure to follow the template outline. Do not create any sharp corners.

11

Figure 18 1. Bagger dump lever 5. Mark on template 2. Engine shroud 6. Template bottom 3. Template 7. Shroud bottom 4. Cable guide

6. Install the bagger onto the bagger mounting bracket Figure 19

7. Install the 2 clevis pins into the bagger and bagger mounting bracket. Secure them with 2 hair pin cotters Figure 19

Figure 19 1. Bagger 3. Hairpin cotter 2. Bagger mounting bracket 4. Clevis pin

8. Remove the cable guide and bolt from the frame of the bagger (Figure 18).

9. Install the cable guide, bolt, and nut with the cable behind the cable guide (Figure 18).

Note: Make sure the cable guide can rotate.

9 Installing the Bagger Belt

Parts needed for this procedure: 1 Bagger belt

1 Spring

Procedure 1. Remove the 4 bolts in the skid plate and remove the

skid plate (Figure 20).

This will make it easier to install the bagger belt.

Figure 20 1. Gearbox drive pulley 4. Fixed idler pulley 2. Bagger pulley 5. Skid plate 3. Spring loaded idler pulley 6. Bagger belt

2. Route the bagger belt around the gearbox drive pulley and the bagger pulley (Figure 20).

3. Route the bagger belt around the spring loaded idler pulley and the fixed idler pulley (Figure 21).

4. Install the spring onto the idler arm (Figure 21).

5. Install the spring onto the spring anchor attached to the left rear bottom frame (Figure 21).

6. Install the skid plate (Figure 20).

12

Figure 21 1. Spring loaded idler pulley 4. Spring Anchor 2. Fixed idler pulley 5. Belt 3. Spring

10 Checking and Adjusting the Bagger Belt Tension

No Parts Required

Procedure 1. Measure the gap, at the bagger spring loaded idler

pulley, between the tight and slack side of the belt when the bagger idler pulley and spring are installed (Figure 21). There needs to be a gap of 1-1/8 inch 1/8 inch (29 mm 3 mm) between the belt strands (Figure 22).

Figure 22 1. Drive pulley 4. Fixed idler pulley 2. Bagger pulley 5. Bagger belt 3. Spring loaded idler pulley 6. 11/8 inch 1/8 inch (29

mm 3 mm)

2. If the gap is not enough, remove the spring.

3. To adjust the belt tension complete the following:

A. Loosen the 2 nuts on the lower fan shaft pillow block (Figure 23).

B. Insert a spacer behind the pillow block (Figure 23).

C. Tighten the nuts.

D. Check the belt gap and repeat procedure as required.

Figure 23 1. Pillow block 3. Spacer 2. Fan shaft

13

11 Installing the Weights Parts needed for this procedure:

1 Large top weight

2 Bolt, (1/2 x 5 inches) (for top weights)

Procedure To comply with ANSI/OPEI B71.4-2004 Standard, weights must be added to the machine.

The bagger adds a lot of weight to the rear of the machine and may cause an unstable condition which could result in a loss of control.

1. Place previously removed caster weights on the front casters.

2. Install the plate, nuts (1/2 inch) and lock washer (1/2 inch) under the frame and weight (Figure 24).

3. Repeat for opposite side.

Figure 24 1. Front caster weight 4. Nut, (1/2 inch) 2. U-bolt 5. Front caster 3. Plate 6. Lock washer,

4. Install a large top weight on top of each caster weight (Figure 25).

5. Install the 2 small top weights on top of each large top weight and secure them with a bolt (1/2 x 5 inches) (Figure 25).

Figure 25 1. Small top weight 4. Front caster wheel 2. Bolt, (1/2 x 4 inches) 5. Large top weight 3. Front caster weight

12 Installing the Boot and Discharge Tubes Parts needed for this procedure:

1 Boot (from previous bagger)

1 Middle tube (from previous bagger)

1 Upper tube (from previous bagger)

1 Clamp (from previous bagger)

Procedure Note: Remember to replace the L or the straight end of the spring when in side discharge mode. Refer to Replacing the Grass Deflector. 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.

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.

4. Lift the grass deflector all the way back. 5. Position the boots front hook into the front slot on

the mounting bracket (Figure 26).

14

Note: If the grass deflector interferes with the boot, grind off part of the grass deflector frame. See Figure 26 for the correct part to grind off.

Figure 26 1. Grass deflector frame 2. Grind this part off

6. Place the rear hook over the rear of the mounting bracket (Figure 27).

7. Install the upper tube into the bagger (Figure 27).

8. Slide the clamp onto the middle tube (Figure 27).

9. Align the knob on the middle tube with the notch in the upper tube. Slide the middle tube into the upper tube and twist the middle tube 60 degrees (Figure 27).

10. Tighten the clamp around the upper and middle tube connection (Figure 27).

11. Slide the middle tube onto the boot and latch them together (Figure 27).

Figure 27 1. Boot 7. Mounting bracket 2. Middle tube 8. Front slot 3. Knob 9. Rear hook 4. Upper tube 10. Front hook 5. Latch 11. Clamp 6. Notch in upper tube

13 Adjusting the Bagger Dump Lever

No Parts Required

Procedure The bagger lever needs to be adjusted to remove slack in the bagger cable.

1. Loosen the nuts on both sides of the stop bracket (Figure 28).

2. Adjust the stop bolt until there is no slack in the bagger cable (Figure 28).

3. Tighten the nuts on both sides of the stop bracket (Figure 28).

15

Figure 28 1. Bagger dump lever 4. Bagger cable 2. Stop bracket 5. Nut 3. Stop bolt

14 Checking the Tire Pressure No Parts Required

Procedure Note: Increase the tire pressure due to the additional weight.

Check and increase the air pressure in the front caster wheels and rear tires (Figure 29).

Pressure: Rear tires-20 psi (90 kPa)

Front caster wheels-25 psi (90 kPa)

Figure 29 1. Valve stem

Operation Note: Determine the left and right sides of the machine from the normal operating position.

Important: If the machine is on a slope, chock or block the wheels to prevent the machine from slowly rolling.

To avoid personal injury, follow these procedures:

Become familiar with all operating and safety instructions in the operators manual for your mower before using this attachment.

Never remove the bagger or bagger tubes while the engine is running.

Always shut the engine off and wait for all moving parts to stop before clearing an obstruction from the bagging system.

Never do maintenance or repairs while the engine is running.

Without the grass deflector, bagger tubes or complete bagger assembly mounted in place, you and others are exposed to blade contact and thrown debris. Contact with the rotating mower blade(s) and thrown debris will cause injury or death.

Never remove the grass deflector from the mower because the grass deflector routes material down toward the turf. If the grass deflector is ever damaged, replace it immediately.

Never put your hands or feet under the mower.

Never try to clear the discharge area or mower blades unless you move the power take off (PTO) to off and rotate the ignition key to off. Also remove the key and pull the wire off of the spark plug(s).

16

Positioning the Adjustable Baffle Adjust the baffle to position B (middle position) for bagging. Refer to the machines Operators Manual for the baffle adjustment procedure.

Figure 30

Opening the Bagger 1. Disengage the PTO. 2. Reach back, squeeze and release the latch lever

against the bagger lever (Figure 31). This will open the latch that secures the bagger door.

3. Pull down on the bagger arm to allow the grass to fall out of the bagger (Figure 31).

4. Return the bagger arm to upright position in one quick motion. Make sure the bagger door fully engages into the latch (Figure 31).

Note: Make sure the bagger latch is fully engaged before collecting grass.

Figure 31 1. Bagger lever 2. Latch lever

Holding the Bagger Door Open

Hands, fingers and arms can get pinched between the back and front sections of the collector.

Keep people away from collector while emptying it.

If working on the inside, use the holding pin to hold the collector door open.

1. Disengage the PTO, set the parking brake, and chock or block the tires.

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

3. Open the bagger; refer to Opening the Bagger. 4. With the bagger open, pull out the holding pin and

insert into the hole in the hinge (Figure 32).

Figure 32 1. Holding pin 3. Hole in hinge (storage) 2. Hole in hinge (open) 4. Hinge

Adjusting the Bagger Door Opening and Cable Adjusting the cable at the top of the bagger, can allow the door to open farther for your desire conditions. 1. Disengage the PTO, set the parking brake, and

chock or block the tires.

17

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

3. Close the bagger.

4. Remove the cotter pin and clevis pin (Figure 33).

5. Adjust the bagger cable to the desired hole position (Figure 33).

Note: The lower hole will allow the door to open higher. The upper hole will allow less force to open the door while using the handle.

6. Install the clevis pin and cotter pin into the bagger and cable end (Figure 33).

Figure 33 1. Bagger cable 5. Cotter pin 2. Holes in bagger door

hinge 6. Lower hole-allows door to

open higher 3. Clevis pin 7. Upper hole-allows less

force to open door 4. Hinge

Clearing Obstructions From the Bagger System 1. Empty the bagger.

2. Disengage the PTO and set the parking brake.

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

4. Remove the complete tube assembly from the bagger and boot.

5. Remove the boot from the mower.

6. Using a stick or similar object, carefully remove and clear the obstruction from the mower, upper tube, middle tube, or boot assembly.

7. After you remove the obstruction, install the complete bagger system and resume operation. Refer to Installing the Discharge Tubes.

Removing the Discharge Tubes Note: Remember to replace the L end of the spring when in side discharge mode. Refer to Replacing the Grass Deflector.

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.

3. Unlatch the middle tube from the boot and slide apart (Figure 34).

4. Remove the tube assembly from the bagger (Figure 34).

5. Remove the boot from the mounting bracket (Figure 34).

6. Lower the grass deflector back into place.

7. If you are changing to side discharge mode, install the grass deflector spring. Refer to Replacing the Grass Deflector.

18

Figure 34 1. Boot 7. Mounting bracket 2. Middle tube 8. Front slot 3. Knob 9. Rear hook 4. Upper tube 10. Front hook 5. Latch 11. Clamp 6. Notch in upper tube

Removing the Bagger

If you operate mower without the bagger installed or with the discharge tubes and boot removed, you and others may be injured by thrown debris or cut by the blade.

Always operate the mower with either the complete bagger mounted in place or use the mower in side discharge.

1. Disengage the power take off (PTO), set the parking brake, turn the ignition key to off and remove the key.

2. Remove the discharge tubes. Refer to Removing the Discharge Tubes.

3. Remove hairpin cotters and clevis pins from the bagger and bagger bracket.

4. Remove the bagger belt. Remove the idler pulley arm only if the machine frame does not have a tab to hold the idler arm (Figure 36). Refer to Securing the Bagger Idler Pulley.

5. Remove the bagger from the bagger mounting bracket.

6. Replace the grass deflector spring; refer to Replacing the Grass Deflector Spring.

7. Remove both the top weights and caster weights.

Securing the Bagger Idler Pulley For this procedure, use one of the clevis pins and hairpin cotter pins used to attach the bagger to the bagger mounting bracket.

Note: Only secure the bagger idler pulley when you are removing the bagger.

1. Check the bagger idler arm for a hole next to the pivot. If there is no hole, follow steps 2 and 3 for drilling a hole.

2. Measure 11/4 inches (31.75 mm) from the center of the pivot and mark the location (Figure 36).

3. Drill a 17/32 inch diameter hole into the bagger idler arm at the marked location.

Figure 35 1. Bagger idler arm 3. 11/4 inches (31.75 mm) 2. Drill a 17/32 inch diameter

hole here

4. Using the clevis pin from the bagger mount, secure the idler arm by inserting the clevis pin through the idler arm and idler arm bracket (Figure 36).

5. Install the hairpin cotter pin to secure the clevis pin (Figure 36).

19

Figure 36 1. Clevis pin 3. Idler arm bracket 2. Bagger idler arm 4. Hairpin cotter pin

Replacing the Grass Deflector

An uncovered discharge opening could allow the lawn mower to throw objects in the operators or bystanders direction and result in serious injury. Also, contact with the blade could occur.

Never operate the lawn mower unless you install a cover plate, a mulch plate, or a grass chute and catcher.

1. Remove the locknut, bolt, spring and spacer holding the deflector to the pivot brackets (Figure 37). Remove damaged or worn grass deflector.

2. Place spacer and spring onto grass deflector. Place the L end of spring behind deck edge.

Note: Make sure the L end of spring is installed behind deck edge before installing the bolt as shown in Figure 37.

3. Install bolt and nut. Place J hook end of spring around grass deflector (Figure 37).

Important: The grass deflector must be able to lower down into position. Lift the deflector up to test that it lowers into the full down position.

Figure 37 1. Bolt 5. Spring installed 2. Spacer 6. Grass Deflector 3. Locknut 7. L end of spring, place

behind deck edge before installing bolt

4. Spring 8. J hook end of spring

Operating Tips

Machine Size Remember that the machine is longer and wider with this attachment installed. By turning too sharply in confined places you may damage the attachment or other property.

Trimming Always trim with the left side of the mower. Do not trim with the right side of the mower because you could damage the bagging tubes.

Cutting Height For optimum bagging performance, set the deck height-of-cut to remove no more that 2 to 3 inches (51 to 76 mm) or 1/3 of the grass height, which ever is less. Cutting off more than this will reduce the capacity of the vacuum system.

Cutting Frequency Cut the grass often, especially when it grows rapidly. You will have to cut your grass twice if it gets excessively long (refer to Bagging Long Grass).

20

Cutting Technique For best lawn appearance, be sure to slightly overlap the mower into the previously cut area. This helps reduce the load on the engine and reduces the chance of plugging the boot and tube.

Bagging Speed The bagging system may plug if you drive too fast and the engine speed gets too slow. On hills it may be necessary to slow the machines ground speed. Mow down hill whenever possible.

As the bagger fills, extra weight is added to the back of the machine. If you stop and start suddenly on hills, you may lose steering control or the machine may tip.

Do not start or stop suddenly when going uphill or downhill. Avoid uphill starts.

If you do stop the machine when going uphill, disengage the PTO. Then back down the hill using a slow speed.

Do not change speeds or stop on slopes.

Bagging Long Grass Excessively long grass is heavy and may not be propelled completely into the bagger. If this happens, the tube and boot may plug. To avoid plugging the bagging system, mow the grass at a high height-of-cut, then lower the mower to your normal cutting height and repeat the bagging process.

Bagging Wet Grass If possible, always try to cut grass when it is dry.

Signs of Plugging As you are bagging, a small amount of grass clippings normally blow out the front of the mower. An excessive amount of clipping blow-out indicates that the bagger is full or the boot is plugged.

Without the grass deflector, bagger tubes or complete bagger assembly mounted in place, you and others are exposed to blade contact and thrown debris. Contact with the rotating mower blade(s) and thrown debris will cause injury or death.

Never remove the grass deflector from the mower because the grass deflector routes material down toward the turf. If the grass deflector is ever damaged, replace it immediately.

Never put your hands or feet under the mower.

Never try to clear the discharge area or mower blades unless you move the power take off (PTO) to off and rotate the ignition key to off. Also remove the key and pull the wire off of the spark plug(s).

Fan Vacuum The bagging system operates by vacuum created by a rotating fan mounted in the top of the hopper. If the vacuum action is reduced, bagging performance will diminish. Refer to Troubleshooting for causes of reduced performance.

Curb Climbing and Loading Always lift the deck to the highest position when loading the machine on trailers or ascending/descending a curb. Leaving the mower in a lower position can cause damage to the mower while loading and going over a curb. If a curb is higher than 6 inches (152 mm), cross it at a sharp angle with the deck fully raised. Use extreme caution when loading onto a trailer.

21

Maintenance Recommended Maintenance Schedule(s)

Maintenance Service Interval Maintenance Procedure

After the first 10 hours Check the bagger belt. Inspect the bagger.

Before each use or daily Clean the screens. Clean the bagger.

Every 50 hours Grease the idler arm.

Every 100 hours Grease the fan shaft bearings. Inspect the bagger.

Cleaning the Screens Service Interval: Before each use or daily

The screens need to be cleaned before each use. In wet grass they will need to be cleaned more often.

1. Disengage the power take off (PTO), set the parking brake, turn the ignition key to off and remove the key.

2. Open the bagger and hold the bagger door open. Refer to Holding the Bagger Door Open.

3. Clean the debris from the screens.

4. Close the bagger door.

Cleaning the Bagger Service Interval: Before each use or daily

The bagger needs to be cleaned daily.

1. Wash the inside and outside of the bagger, upper tube, lower tube, boot assembly and the underside of the mower. Use a mild automotive detergent to remove dirt.

2. Make sure you remove matted grass from all parts.

3. After washing all parts, let them dry thoroughly.

Checking the Bagger Belt Service Interval: After the first 10 hours

The bagger belt tension needs to be checked after the first 10 hours.

Check the belt tension. Refer to Adjusting the Bagger Belt.

Greasing the Idler Arm Service Interval: Every 50 hours

Grease the bagger belt idler arm (Figure 38) every 50 hours.

Figure 38

Greasing the Fan Shaft Bearings Service Interval: Every 100 hours

Grease the upper and lower bagger fan shaft bearings (Figure 39 & Figure 40) every 100 hours.

22

Figure 39

Remove rubber plug to expose grease fitting.

Figure 40

Inspecting the Bagger Service Interval: Every 100 hours

After the first 10 hours

Inspect the bagger attachment after the first ten hours of operation, and 100 hours thereafter. 1. Disengage the power take off (PTO), set the parking

brake, turn the ignition key to off and remove the key.

2. Check the upper tube, lower tube, and the boot assembly. Replace these parts if they are cracked or broken.

3. Check the bagger, bagger frame, and screens. Replace any parts that are cracked or broken.

4. Tighten all nuts bolts and screws.

Inspecting the Mower Blades 1. Inspect the mower blades regularly and whenever a

blade strikes a foreign object. 2. If blades are badly worn or damaged, install new

blades. Refer to your mower operators manual for complete blade maintenance.

23

Troubleshooting Problem Possible Cause Corrective Action

1. Cutting blade(s) is/are bent or unbalanced.

1. Install new cutting blade(s).

2. Blade mounting bolt is loose. 2. Tighten the blade mounting bolt. 3. Engine mounting bolts are loose. 3. Tighten the engine mounting bolts. 4. Loose bagger or pulley assembly. 4. Tighten the appropriate pulley.

Abnormal vibration.

5. Bagger belt is worn or damaged. 5. Contact an Authorized Service Dealer.

1. Low engine speed. 1. Always operate the bagger at full throttle.

2. Plugged fan screen. 2. Remove debris, leaves or grass clippings from the fans screen..

3. Loose bagger belt. 3. Tighten the bagger belt. 4. Broken seal between the hopper and

rear door. 4. Ensure the rear door is latched.

5. A plugged boot. 5. Locate and remove plugged debris. 6. Improper seal around the upper tube

going into the hopper. 6. Ensure that there is a good seal at the

hopper.

Reduced bagging performance.

7. Full hopper. 7. Empty the hopper.

1. Hopper is too full. 1. Dump more frequently.

2. Low engine speed. 2. Always operate the bagger at full throttle.

3. Grass is too wet. 3. Cut grass when it is dry. 4. Grass is too long. 4. Cut no more than 2-3 inches or 1/3 of

the grass height, which ever is less. 5. Plugged fan screen. 5. Remove debris, leaves or grass

clippings from the fan screen.

Boot and tubes plug too frequently.

6. Ground speed is too fast. 6. Drive slower at full throttle.

1. Hopper is too full. 1. Dump more frequently.

2. Ground speed is too fast. 2. Drive slower at full throttle.

Debris blowout.

3. Mower deck is not leveled. 3. See the mower operators manual for leveling the mower deck.

24

25

Notes:

26

Notes:

27

Landscape Contractor

Equipment (LCE)

The Toro Total Coverage Guarantee A Limited Warranty

Conditions and Products Covered The Toro Company and its afliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair the listed Toro Products if defective in materials or workmanship. The following time periods apply from the date of purchase: This warranty applies to:

ProLine Mid-Size Mowers and Attachments 1 year Z Master Mid-Mount ZRTs and Attachments 1 year

Components Warranty Period

Traction Unit Frame and Carrier Frame 2 year All Spindles 3 years Parts

2 years Labor Engines* and /Hydraulic System 2 years Deck Shells (34-72) 2 years Z500 Series Electric Clutch 2 years Remaining Components 1 year

*Some engines used on Toro LCE Products are warranted by the engine manufacturer. This warranty includes the cost of parts and labor, but you must pay transportation costs.

Instructions for Obtaining Warranty Service If you think that your Toro Product contains a defect in materials or workmanship, follow this procedure:

1. Contact any Toro Authorized or Master Service Dealer to arrange service at their dealership. To locate a dealer convenient to you, access our website at www.Toro.com. You may also call our Toro Customer Care Department toll free at 8888655676 (U.S. Customers) or 8888655691 (Canada customers).

2. Bring the product and your proof of purchase (sales receipt) to the Service Dealer.

If for any reason you are dissatised with the Service Dealers analysis or with the assistance provided, contact us at:

LCB Customer Service Department Toro Warranty Company

8111 Lyndale Avenue South Bloomington, MN 55420-1196

Owner Responsibilities You must maintain your Toro Product by following the maintenance procedures described in the operators manual. Such routine maintenance, whether performed by a dealer or by you, is at your expense.

Items and Conditions Not Covered There is no other express warranty except for special emission system coverage on some products. This express warranty does not cover the following:

Cost of regular maintenance service or parts, such as lters, fuel, lubricants, tune-up parts, blade sharpening, brake and clutch adjustments.

Any product or part which has been altered or misused or required replacement or repair due to normal wear, accidents, or lack of proper maintenance.

Repairs necessary due to improper fuel, contaminants in the fuel system, or failure to properly prepare the fuel system prior to any period of non-use over three months.

Pickup and delivery charges.

General Conditions All repairs covered by this warranty must be performed by an Authorized Toro Service Dealer using Toro approved replacement parts. Neither The Toro Company nor Toro Warranty Company is liable for indirect, incidental or consequential damages in connection with the use of the Toro Products covered by this warranty, including any cost or expense of providing substitute equipment or service during reasonable periods of malfunction or non-use pending completion of repairs under this warranty. Some states do not allow exclusions of incidental or consequential damages, or limitations on how long an implied warranty lasts, so the above exclusions and limitations may not apply to you. All implied warranties of merchantability (that the product is t for ordinary use) and tness for use (that the product is t for a particular purpose) are limited to the duration of the express warranty. This warranty gives you specic legal rights, and you may also have other rights which vary from state to state.

Countries Other than the United States or Canada Customers wh