Form No. 3355-269 Rev A Mounting Kit for DFS Vac Collection System on a Z593 and Z595 Series Z Masters Model No. 110–0891 Register at www.Toro.com.
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. 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. Contents Introduction................................................................. 2 Safety .................
Safety • Use care when loading or unloading the machine into a trailer or truck The following list contains safety information specific to Toro products and other safety information you must know. • 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. • Become familiar with the safe operation of the equipment, with the operator controls, and safety signs.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description Use Qty. 1 No parts required – Remove the existing bagger, mounting bracket, and weights. 2 Side bracket—right Side bracket—left Bolt, (3/8 x 2–1/2) Bolt, (3/8 x 3/4 inch) Flange Locknut, (3/8 inch) Spacers 1 1 2 2 4 2 Install the bagger mounting bracket. 3 No parts required – Tighten all mounting bolts.
Procedure 12 13 14 Description Use Qty. Boot (from previous bagger) Middle tube (from previous bagger) Upper tube (from previous bagger) Clamp (from previous bagger) 1 1 1 1 Install the boot and discharge tubes No parts required – Adjust the bagger dump lever. No parts required – Check the tire pressure. Note: Use this manual when the DFS bagger is installed and used on a Z593–D Z Master.
Figure 5 1. Bagger 2. Bagger mounting bracket 3. Hairpin cotter 4. Clevis pin Figure 7 1. Bagger mounting bracket 2. Curved washer, (3/8 inch) 3. Bolt, (3/8 x 1-1/2 inches) 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). 4. Flange nut, (3/8 inch) 5. ROPS 9. Remove the side brackets from the bagger mounting bracket and store them.
2 Installing the Bagger Mounting Bracket Parts needed for this procedure: Figure 9 1. Top weight 2. Bolt, (1/2 x 4 inches) 3. Front caster weight 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).
Figure 12 1. Side bracket 2. Curved washer, 3/8 inch 3. Bolt, 3/8 x 1-1/2 inch Figure 11 1. 2. 3. 4. 5. Bagger mounting bracket 7. Long frame spacer Bolt, (3/8 x 1-1/4 inches) 8. Bolt, (3/8 x 1-1/2 inches) Flange nut, (3/8 inch) 9. Short frame spacer 10. Right side bracket Bracket stiffener 11. Use these holes in the Left side bracket bracket stiffener 6. Bolt, (3/8 x 3/4 inch) 4. Flange nut, 3/8 inch 5. ROPS 9. Install the bagger mounting bracket to the rear frame of the machine (Figure 13). 10.
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. 3 Tightening all Mounting Bolts 5. Install the mower belt back onto the upper gearbox pulley (Figure 14). 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 N⋅m). 1.
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 4–1/2 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) Figure 15 1. Lock nut, (3/8 inch) 7. Carriage bolt, (3/8 x 2 inches) Washer, 7/16 inch 8. Right rear bottom frame Spring loaded idler pulley 9.
Figure 16 1. 2. 3. 4. Fixed idler pulley Washer, Nut, Nut, 5. 6. 7. 8. Figure 17 Bolt, Fixed Idler pulley bracket Left rear bottom frame Bolt, (3/8 x 3/4 inch) 1. Bolt, (3/8 x 3/4 inch) 2. idler arm bracket 8 7 Installing the Bagger Installing the Idler Arm Bracket Parts needed for this procedure: Parts needed for this procedure: 1 Idler arm bracket 2 Bolt, (3/8 x 3/4 inch) 2 Flange nut, (3/8 inch) 3. Nut, (3/8 inch) 4.
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). Figure 18 1. 2. 3. 4. Bagger dump lever Engine shroud Template Cable guide 5. Mark on template 6. Template bottom 7. Shroud bottom This will make it easier to install the bagger belt. 6. Install the bagger onto the bagger mounting bracket Figure 19 7.
Figure 22 1. Drive pulley 2. Bagger pulley 3. Spring loaded idler pulley 4. Fixed idler pulley 5. Bagger belt 6. 1–1/8 inch ± 1/8 inch (29 mm ± 3 mm) Figure 21 1. Spring loaded idler pulley 2. Fixed idler pulley 3. Spring 2. If the gap is not enough, remove the spring. 4. Spring Anchor 5. Belt 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). 10 C. Tighten the nuts.
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. Figure 25 1. Small top weight 2. Bolt, (1/2 x 4 inches) 3. Front caster weight 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. 4.
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 Figure 27 6. Place the rear hook over the rear of the mounting bracket (Figure 27). 1. 2. 3. 4. 5. 6. 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.
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 operator’s manual for your mower before using this attachment. Figure 28 1. Bagger dump lever 2. Stop bracket 3. Stop bolt 4. Bagger cable 5.
Positioning the Adjustable Baffle Holding the Bagger Door Open Adjust the baffle to position B (middle position) for bagging. Refer to the machine’s Operator’s Manual for the baffle adjustment procedure. 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.
2. Turn off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 6. Using a stick or similar object, carefully remove and clear the obstruction from the mower, upper tube, middle tube, or boot assembly. 3. Close the bagger. 7. After you remove the obstruction, install the complete bagger system and resume operation. Refer to Installing the Discharge Tubes. 4. Remove the cotter pin and clevis pin (Figure 33). 5.
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.
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 2. Spacer 3. Locknut 4. Spring 5. Spring installed 6. Grass Deflector 7. L end of spring, place behind deck edge before installing bolt 8. J hook end of spring Figure 36 1. Clevis pin 2. Bagger idler arm 3. Idler arm bracket 4.
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. 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.
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.
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.
Troubleshooting Problem Abnormal vibration. Reduced bagging performance. Possible Cause 1. Cutting blade(s) is/are bent or unbalanced. 1. Install new cutting blade(s). 2. 3. 4. 5. 2. 3. 4. 5. Blade mounting bolt is loose. Engine mounting bolts are loose. Loose bagger or pulley assembly. Bagger belt is worn or damaged. 1. Always operate the bagger at full throttle. 2. Plugged fan screen. 2. Remove debris, leaves or grass clippings from the fans screen.. 3. Tighten the bagger belt. 4.
Notes: 26
Notes: 27
The Toro Total Coverage Guarantee Landscape Contractor Equipment (LCE) A Limited Warranty Conditions and Products Covered Owner Responsibilities 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.
