Form No. 3450-633 Rev A Bagger Kit Z Master® 4000 Series Riding Mower Model No. 78479—Serial No. 400000000 and Up Model No. 78489—Serial No. 400000000 and Up Register at www.Toro.com.
WARNING CALIFORNIA Proposition 65 Warning Use of this product may cause exposure to chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. 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. Visit www.Toro.
Contents This manual uses 2 words to highlight information. Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention. Safety ....................................................................... 4 Safety and Instructional Decals .......................... 5 Setup ........................................................................ 7 1 Preparing the Machine.....................................
Safety • 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 manufacturer's 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.
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 missing. decal133-8061 133-8061 decal126-4659 126-4659 1. Warning—hot pulley; allow to cool. decal126-9595 126-9595 1. Rotation indicator 2. Impeller/Rotating Blades hazard-Keep hands away from moving parts. Keep all safety devices in place and working.
decal126-4662 126-4662 1. Warning—read the Operator’s Manual for the correct quantity of counterbalance weight(s). 2. Loss of traction and steering or reduced stability hazard—Ez Vac counterbalance weight(s) installed without the Ez Vac may cause loss of traction and steering control. The Ez Vac installed without the Ez Vac counterbalance weight(s) can cause reduced stability. Install weight(s) only when the Ez Vac is installed. decal126-9451 126-9451 1.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 1 2 3 4 5 6 7 8 9 Description Use Qty. No parts required – Prepare the machine. Shoulder bolt Wave washer Locknut (1/2 inch) 12.
Procedure Description 10 11 12 13 14 Use Qty. Baffle Carriage bolt (5/16 x 7/8 inch) Flange nut (5/16 inch) Carriage bolt (3/8 x 7/8 inch) Flange nut (3/8 inch) Blower assembly Pivot pin Latch Hex-head bolt (3/8 x 1-1/2 inches) Spacer Locknut (3/8 inch) Blower-belt cover Cover knob Upper tube Lower tube Bolt (#10 x 3/4 inch) Locknut (#10) Washer (7/32 inch) 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 3 3 3 No parts required – Install the baffle. Install the blower assembly.
1 Preparing the Machine No Parts Required Procedure 1. Park the machine on a level surface. 2. Move the motion-control levers to the NEUTRAL-LOCK position. 3. Engage the parking brake. 4. Shut off the engine and remove the key. g037289 Figure 5 2 Installing the ROPS Pivot Shoulder Bolts Parts needed for this procedure: 2 Shoulder bolt 2 Wave washer 2 Locknut (1/2 inch) Procedure 1. 2. Secure the shoulder bolt to the roll bar using a wave washer and locknut (1/2 inch) as shown in Figure 6.
3 Installing the Weights Parts needed for this procedure: 2 12.
60-inch Machines 1. Remove the existing 2 carriage bolts and 2 nuts from the top of the caster weight (Figure 7). 2. Discard the 2 carriage bolts and 2 nuts. Secure the 12.5 lb weight plate to the caster weight and bracket using the 2 carriage bolts (3/8 x 2-1/2 inches) and 2 hex-socket flange nuts (3/8 inch) as shown in Figure 7.
3. Secure the assembled caster weight to the caster arm using 2 carriage bolts (3/8 x 1 inch) and 2 flange nuts (3/8 inch) as shown in Figure 8. g375807 Figure 8 1. Carriage bolt (3/8 x 1 inch) 3. Flange nut (3/8 inch) 2. Weight 4. Repeat steps 1 through 3 on the other side. 5. Secure the weight bracket assembly to the frame using 4 carriage bolts (3/8 x 1 inch) and 4 flange nuts (3/8 inch) as shown in Figure 9. 6.
g375806 Figure 9 13
72-inch Machines 1. Secure the weight to the caster arm using 2 carriage bolts (3/8 x 1 inch) and 2 flange nuts (3/8 inch) as shown in Figure 10. 2. Repeat this procedure on the other side.
2. Remove the 2 torx-head bolts and 2 nuts from the left, rear guard (Figure 12). 4. Note: Perform the step above on 1 side of the machine, then the other. Loosely secure the lower support to the engine plate using 2 carriage bolts (5/16 x 2-1/4 inches), 1 backer plate, and 2 flange nuts (5/16 inch) as shown in Figure 14. Note: Perform the step above on 1 side of the machine, then the other. g341515 Figure 12 3. Torx-head bolt 1. Left, rear guard 2. Nut 3.
2. 5 Insert the lock pin through the bagger frame and cross brace (Figure 16). Note: You may need to loosen the hardware to align the lock pin to the hole. Installing the Bagger Frame Parts needed for this procedure: 1 Bag support 2 Lock-pin assembly Procedure 1. Arrange the bagger frame around the pivot pins on the support bracket and rotate it forward (Figure 15). g038187 Figure 16 1. Hairpin cotter g341549 Figure 15 1. Pivot pin 2. Bagger frame 16 2. Lock pin 3.
6 7 Installing the Bags Installing the Hitch Cover Parts needed for this procedure: Parts needed for this procedure: 3 Bag 1 Procedure Hitch cover Procedure 1. Hook the bags to the bagger frame (Figure 17). 2. Close and latch the hood assembly. Note: 72-inch machines do not come with a hitch installed. If you have the Hitch Kit installed, install the hitch cover to protect the bags. 1. Apply a lubricant to the nipple on the hitch cover. 2.
4. 8 Remove the locknut, bolt, spring, and spacer holding the deflector to the pivot brackets (Figure 21). Removing the Existing Belt Cover, Bracket, and Discharge Chute No Parts Required Procedure Note: Clean the area around the belt cover before removing it. g015594 1. Lower the mower deck to the lowest height-of-cut position. 2. Remove the right belt cover (Figure 19). Figure 21 1. Bolt 5. Spring installed 2. Spacer 6. Grass deflector 3. Locknut 7. J-hook end of spring 4. Spring 5.
9 Installing the Blower-Pulley Assembly and Belt-Cover Bracket Parts needed for this procedure: 1 Blower pulley 1 Pulley mount 3 Locknut (3/8 inch) 1 Belt-cover bracket 1 Speed nut 2 Carriage bolt (1/4 x 3/4 inch) 2 Locknut (1/4 inch) Procedure 1. g334846 Figure 22 Use a 3/8-inch ratchet in the square hole in the idler arm to remove tension on the idler spring (Figure 22). 1. Spring 4. Spring-loaded idler assembly 2. Clutch pulley 5. Ratchet 3. Mower belt 6.
3. Use a wrench (1-1/2 inches) to hold the spindle shaft, as you remove the hex nut (3/4 inch) and washer from the spindle shaft (Figure 23). Note: Retain the hex nut (3/4 inch) and washer. g341576 Figure 23 1. Hex nut (3/4 inch) 3. Right spindle shaft g341574 Figure 24 2. Washer 1. Locknut (3/8 inch) 4. Insert the threaded studs on pulley mount through the holes in the deck pulley (Figure 24). 5.
10. Ensure that the blade bolt is torqued to 75 to 81 N∙m (55 to 60 ft-lb). 11. Install the mower belt around the lower pulley of the double pulley (Figure 25). g341575 Figure 25 1. Lower pulley 2. Mower belt 12. Install the belt-cover bracket to the mower deck using 2 carriage bolts (1/4 x 3/4 inch) and 2 locknuts (1/4 inch) as shown in Figure 26. 13. Install the speed nut onto the belt-cover bracket (Figure 26). g038112 Figure 26 1. Carriage bolt (1/4 x 3/4 inch) 3. Speed nut 2.
2. 10 Install the baffle using the carriage bolt (5/16 x 7/8 inch), flange nut (5/16 inch), 2 carriage bolts (3/8 x 7/8 inch), and 2 flange nuts (3/8 inch) as shown in Figure 28 and Figure 29. Installing the Baffle Parts needed for this procedure: 1 Baffle 1 Carriage bolt (5/16 x 7/8 inch) 1 Flange nut (5/16 inch) 2 Carriage bolt (3/8 x 7/8 inch) 2 Flange nut (3/8 inch) Procedure 1.
g376167 Figure 29 72-inch shown 1. Flange nut (3/8 inch) 4. Flange nut (5/16 inch) 2. Baffle 5. Carriage bolt (5/16 x 7/8 inch) 3.
72-inch: 11 Installing the Blower Assembly Parts needed for this procedure: 1 Blower assembly 1 Pivot pin 1 Latch 1 Hex-head bolt (3/8 x 1-1/2 inches) 1 Spacer 1 Locknut (3/8 inch) Procedure Ensure that the bolts and pivot pin are installed in the correct locations on the blower assembly as shown in Figure 30 and Figure 31.
1. Align the pivot pin on the blower with the pivot-pin hole in the mower deck (Figure 32). 2. Lower the blower and slide the pivot pin into the pivot hole (Figure 32). Note: Ensure that the belt remains positioned in the blower pulley. g376058 Figure 32 1. Blower assembly 3. Pivot hole 2. Deck 4. Blower-pivot pin 3. Secure the latch to the blower assembly using the hex-head bolt (3/8 x 1-1/2 inches), spacer, and locknut (3/8 inch) as shown in Figure 33 and Figure 34.
4. Close the blower assembly to see if the latches are adjusted correctly (Figure 35 and Figure 36). Note: Loosen or tighten the bolt to ensure that the latches firmly hold the blower assembly against the mower deck but can be released by hand.
g376057 Figure 36 72-inch shown 27
Note: Ensure that the belt is correctly routed around the drive pulley. 12 Installing the Blower Belt, Spring, and Blower-Belt Cover Parts needed for this procedure: 1 Blower-belt cover 1 Cover knob Procedure 1. Arrange the blower belt around the drive pulley as shown in Figure 37. g376091 Figure 38 Installing the tension spring and aligning the belt 1. Blower assembly 5. Belt routed to the drive pulley 2. Idler-spring post 6. Spring (hook end) to post 3. Fixed spring post 7.
Note: The hopper seal must protrude outward 13 from the bagger hood. Installing the Discharge Tubes Parts needed for this procedure: 1 Upper tube 1 Lower tube 3 Bolt (#10 x 3/4 inch) 3 Locknut (#10) 3 Washer (7/32 inch) g007027 Figure 41 1. Dimple Procedure 5. 1. Lower the machine deck to the lowest height-of-cut position. 2. Remove the bags for viewing the tube under the hood. 3.
Note: There is a latch on the top and bottom diameter) where the upper and lower tubes join together (Figure 44). of the blower housing. g003449 g037981 Figure 43 1. Blower assembly Figure 44 3. Latch (twin bagger shown) 2. Lower tube 1. Bagger hood 4. Blower assembly 2. Upper tube 5. Drill holes (7/32 inch) 3. Lower tube 7. Ensure that the machine deck is in the lowest height-of-cut position. 8. Verify that the dimple from Figure 41 is still in place. 9.
11. Join the upper and lower tubes with 3 bolts (#10 x 3/4 inch), flat washers, and locknuts as shown in Figure 45. 14 Checking the Tire Pressure No Parts Required Procedure Note: Increase the tire pressure due to the additional weight. Maintain the air pressure in the front and rear tires at 90 kPa (13 psi). Uneven tire pressure can cause uneven cut. Check the tires when they are cold to get the most accurate pressure reading. g003392 Figure 45 1. Lower tube 4. Locknut (#10) 2. Upper tube 5.
Operation CAUTION Children or bystanders may be injured if they move or attempt to operate the tractor while it is unattended. Note: Determine the left and right sides of the machine from the normal operating position. Always remove the ignition key and engage the parking brake when leaving the machine unattended, even if just for a few minutes.
3. Empty the bags. 4. Unlatch the lower tube. 5. Remove the tubes from the bagger. 6. Use a stick or similar object to remove and clear the obstruction from the tube assembly. Note: In most cases, the debris can be shaken out of the tubes. 7. If the blower assembly is plugged, unlatch the bagger blower assembly, remove the belt, and swing it open. 8. Use a stick or similar object, not your hands, to remove and clear the obstruction from the blower assembly. 9.
Transporting the Machine want to slightly reduce the throttle speed and increase the ground speed of the mower. 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 mower ground speed. This helps maintain the engine speed and bagging efficiency. Mow downhill whenever possible. Do not leave grass or debris in the bagger while transporting the machine.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 8 hours • Inspect the blower belt. • Inspect the bagger. After the first 10 hours • Inspect the bagger. Before each use or daily • Clean the hood screen. • Clean the bagger. Every 25 hours • Inspect the blower belt. Every 50 hours • Grease the idler arm.
Inspecting the Bagger Attachment Inspecting the Blower Belt Service Interval: After the first 8 hours Every 25 hours Service Interval: After the first 10 hours Check belts for cracks, frayed edges, burn marks, or any other damage. Replace any belts that are damaged. Before storage Inspect the bagger attachment after the first 10 hours of operation, and monthly thereafter. 1. Check the chute, discharge tube, and the bagger top. Replace these parts if they are cracked or broken. 2.
Inspecting the Bagger Service Interval: Every 100 hours After the first 8 hours g038292 Figure 49 1. Spring-loaded idler pulley 9. 2. Spring 1. Disengage the PTO, move the motion-control levers to the NEUTRAL-LOCK position, and engeage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Check the upper tube, lower tube, bagger hood, and the blower assembly. Replace these parts if they are cracked or broken. 4.
Replacing the Grass Deflector 7. Install the bolt and the nut. 8. Place 1 J-hook end of the spring around the grass deflector (Figure 51). Important: The grass deflector must be able WARNING to rotate. Lift the deflector up to the full open position and ensure that it rotates into the full down position. An uncovered discharge opening could allow the machine to throw objects toward you or bystanders, resulting in serious injury. Also, contact with the blade could occur.
Storage 1. Empty the bagger attachment; refer to Emptying the Grass Bags (page 32). 2. Inspect the bagger attachment for damage. 3. Ensure that the bags are empty and thoroughly dry. 4. Inspect the belt for wear or cracks; refer to Inspecting the Blower Belt (page 36). 5. Store the machine in a clean, dry place, out of direct sunlight. If you must store the machine outside, cover it with a weatherproof cover. This protects the plastic parts and extends the life of the machine.
Troubleshooting Problem There is abnormal vibration. There is reduced bagging performance. Possible Cause 1. The cutting blade(s) is/are bent or unbalanced. 1. Install new cutting blade(s). 2. The blade mounting bolt is loose. 3. The blower pulley or pulley assembly is loose. 4. The blower belt is worn. 5. The blower fan blade(s) is/are bent or unbalanced. 2. Tighten the blade mounting bolt. 3. Tighten the appropriate pulley. 1. Always operate the bagger at full throttle. 2.
Notes:
Notes:
Notes:
California Proposition 65 Warning Information What is this warning? You may see a product for sale that has a warning label like the following: WARNING: Cancer and Reproductive Harm—www.p65Warnings.ca.gov. What is Prop 65? Prop 65 applies to any company operating in California, selling products in California, or manufacturing products that may be sold in or brought into California.
