Form No. 3329–570 Rev A 62 inch Triple Bagger and Finishing Kit 200 Series Z Master Model No. 78456—Serial No. 230000001 and Up Model No.
Replacing the Blower Belt . . . . . . . . . . . . . . . . . . Greasing the Blower . . . . . . . . . . . . . . . . . . . . . . . Checking the Blower Liner . . . . . . . . . . . . . . . . . Replacing the Blower Liner . . . . . . . . . . . . . . . . . Inspecting the Bagger . . . . . . . . . . . . . . . . . . . . . . Inspecting the Mower Blades and Baffles . . . . . . Installing Mower Blades . . . . . . . . . . . . . . . . . . . . Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
This manual identifies potential hazards and has special safety messages that help you and others avoid personal injury and even death. Danger, Warning, and Caution are signal words used to identify the level of hazard. However, regardless of the hazard, be extremely careful. • 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.
Safety and Instruction 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. 79-0350 1-653554 79-0360 106-0871 80-8040 98-4387 1. Warning—wear hearing protection.
Setup Note: Determine the left and right sides of the machine from the normal operating position. Loose Parts Note: Use the chart below to verify all parts have been shipped. Important installation. This kit and bagger will require significant time to install the first time.
Step 11 12 13 14 15 16 17 18 Description Qty.
Step 19 20 Description Qty. Caster weight 2 U–bolt 2 Nut, 1/2 inch 4 Lock washer, 1/2 inch 4 Plate 2 Top weight 2 Bolt, 1/2 x 3 inch 2 Plate 2 No parts needed Use Installing the weights Adjusting the parking brake Before Installation Checking the Mower for Existing Holes Check for existing holes. Use any existing holes in the mower that align the baffles in their correct positions.
Removing the Mower Note: If the mower is removed from the bottom bolts attaching the chains to the mower, the mower will not need to be leveled. 4 2 1. Remove the PTO drive belt from the rear idler arm (Figures 3 and 5). 1 3 2 m–4451 Figure 5 Top View 1 1. Center mower pulley 2. PTO Drive belt M–4417 3. Fixed idler pulley assembly 4. Rear idler pulley Figure 3 1. Center bolt, spring loaded idler 2. Alignment hole 4.
Removing the Existing Blades 9. Remove the nuts and bolts holding the push arm pins (Fig. 7). 10. Remove the push arm pins (Fig. 7). Note: In most mowing conditions, improved bagging performance can be achieved by using bagging blades (high lift). Contact an Authorized Service Dealer for the proper blades for different mowing conditions. 11. Raise the height of cut lever and slide the mower out from under the machine (Fig. 7). 1. Remove the existing blades from the spindles.
Step 1 1 2 Parts needed for this step: • 1 Center cutting chamber baffle • 5 Bolts, 5/16 x 5/8 inch m–6774 • 5 Flange nuts, 5/16 inch Figure 10 1. Baffle flange Installing the Center Rear Baffle 2. Baffle to top of cutting chamber, 3–5/8 in. 3. Clamp the center baffle in place, tightly against the cutting chamber. A right angle drill will be needed to perform this installation. 4. Using the baffle as a template, mark, center punch and drill 1/8 inch pilot holes at the 5 locations (Fig. 11).
Step 2. Align the left rear baffle within 3/16 inch and flush with the bottom of the center baffle (Fig. 13). 2 3. Position the left rear baffle so the baffle flange is 3–5/8 in. (92 mm) from the top of the cutting chamber (Fig. 9). Important Make sure the baffle flange is 3–5/8 inch (92 mm) from the top of the cutting chamber at all locations (Fig. 9). Parts needed for this step: • 1 Left rear baffle Note: If 3–5/8 inch (92 mm) can not be achieved, the bottom welds have to be ground down.
3 m–6773 1 Step 8 7 6 3 Parts needed for this step: • 1 Tunnel baffle—rear • 2 Bolts, 5/16 x 5/8 inch 4 • 2 Flange nuts, 5/16 inch 4 5 5 2 Installing the Rear Tunnel Baffle 4 1. Place the rear tunnel baffle against the rear wall of the discharge tunnel (Fig. 16). Figure 14 1. 2. 3. 4. Left rear baffle Left side of mower Bolt, 1/4 x 5/8 inch Flange nut, 1/4 inch 5. 6. 7. 8.
Step 2 1 4 Parts needed for this step: • 1 Right rear baffle • 3 Bolts, 1/4 x 5/8 inch • 3 Flange nuts, 1/4 inch m–6767 Figure 16 1. Rear tunnel baffle Installing the Right Rear Baffle 2. Drill an 11/32 inch hole here 1. Place the right baffle behind the right cutting chamber (Fig. 18). The tabs will mount on the outside of the mower. 7. Drill a, 9/32 inch diameter, hole through the side of the right cutting chamber (Fig. 17). 2.
Step 4 1 5 Parts needed for this step: • 1 Tunnel baffle—front • 3 Carriage bolts, 5/16 x 5/8 inch • 3 Flange nuts, 5/16 inch 2 3 Installing the Front Tunnel Baffle m–6813 Figure 18 1. Center Baffle 2. Right baffle 1 2 1. Remove the existing right front blowout baffle. Save baffle and hardware for use when bagging baffles are removed. 3. Flush with center baffle 4. Right cutting chamber 2. Place the front tunnel baffle against the the front wall of the discharge tunnel. (Fig. 20). 4 3.
Bottom View 2 2 1 3 3 1 4 2 4 4 m-5958 6 Figure 21 1. Front tunnel baffle 2. Mounting bracket 3. Flush edge with mounting bracket 4. Grass deflector 3 5 m–6765 Figure 22 4. Clamp the baffle in place. 1. Front tunnel baffle 2. Carriage Bolt, 5/16 x 5/8 inch 3. Nut, 5/16 inch 5. Using the baffle as a template, mark, center punch and drill 1/8 inch pilot holes at the 3 locations (Fig. 22). 6. Remove the clamp. 7.
Step Step 6 Parts needed for this step: 7 No Parts needed for this step. • 3 Blade stiffeners Removing the Existing Mower Pulley and Right Rear Gage Wheel Installing the Blade Stiffener Note: In most mowing conditions, improved bagging performance can be achieved by using bagging blades (high lift). Contact an Authorized Service Dealer for the proper blades for different mowing conditions. Note: Clean the area around pulley before removing pulley assembly. Hold spindle up from underneath the deck.
Step Step 8 9 Parts needed for this step: Parts needed for this step: • 1 Pulley assembly • 2 Mounting plates • 1 Template Installing the Pulley Assembly • 4 Bolts, 3/8 x 1–1/4 inch 1. Install new pulley assembly onto the spindle. Install it so the large pulley is on the bottom (Fig. 25). • 4 Flange nuts, 3/8 inch 2. Install the washer and nut (Fig. 25). Installing the Mounting Plates Important torque. Tighten the nut to 115 ft–lb ± 15 ft–lb Drilling the Holes into the Mounting Bracket 3.
Installing the Mounting Plates Step 10 1. Install the mounting plates to the inside of the mounting bracket with 4 bolts (3/8 x 1–1/4 inch) and 4 flange nuts (3/8 inch) (Fig. 27). 3 1 1 Parts needed for this step: • 1 Bolt, 3/8 x 4–1/4 5 • 1 Roller bushing Installing the Gage Wheel 1. Install the gage wheel to the new mounting plate with a new bolt (3/8 x 4–1/4 inches), new roller bushing, existing flat washer, and existing nut (Fig. 29).
Step 6 11 6 4 5 7 m–4451 Installing the Mower and PTO Drive Belts 2 3 1 M–4373 Figure 30 1. 2. 3. 4. Installing the Mower Belt 1. Install the mower belt around the spindle pulleys, belt guide, the idler pulley, and in the lower groove of the center and right side spindle pulleys (Fig. 29). 2. Using a socket and torque wrench, rotate the idler adjusting nut until the torque is 25–30 ft–lb (34–41 N m). Tighten the two idler nuts. 5. Machine frame 6. 1/4 inch Belt Twist 7. 1/8 inch Belt Twist 2.
Step 12 2 1 No parts needed for this step. m–3746 Removing the Drive Wheels and Bumper Guard Figure 32 1. Fixed Idler 2. Adjustment slot Danger 4. Check belt tension again. The center bolt of spring loaded idler must be between the two alignment holes in left support plate (Fig 31). Adjust, if necessary, and tighten all hardware securely. Mechanical or hydraulic jacks may fail to support machine and cause a serious injury. • Use jack stands when supporting machine. • Do not use hydraulic jacks.
Step 1 13 3 2 Parts needed for this step: 1 • 1 Left side bagger bracket 6 • 1 Right side bagger bracket 2 5 • 1 Bagger mounting bracket 4 • 10 Bolts, 3/8 x 1 inch m–6742 Figure 35 • 10 Flange nuts, 3/8 inch 1. Bagger bracket—left side shown 2. Bolt, 3/8 x 1 inch 3. Flange nut, 3/8 inch • 8 Belleville washers, 3/8 inch 4. Machine side frame 5. Existing hole 6.
5 2 3 1 Step 2 14 4 Parts needed for this step: 6 • 1 Blower assembly 6 3 4 Installing the Blower Assembly 2 m–6743 Important Make sure the mounting plate is installed to the mower. Refer to the Finishing Kit. Figure 36 1. 2. 3. 4. Bagger mounting bracket Bolt, 3/8 x 1 inch Flange nut, 3/8 inch Belleville washer, 3/8 inch 1. Disengage the PTO and set the parking brake. 5. Rear frame 6. Existing bolts located here 2.
6. Install the new belt cover over the pulley assembly and secure the latches (Fig. 39). Step 15 1 2 2 Parts needed for this step: • 1 Blower belt cover • 1 Idler spring • 1 Bagger belt m–6755 Figure 39 • 1 Pulley cover 1. Belt cover Installing the Bagger Belt and Idler Spring 2. Latch 7. Install the bagger belt between the top mower pulley and the belt cover (Fig. 40). Important The idler spring and bagger belt need to be installed together.
10. Route the bagger belt around the spring–loaded idler pulley (Fig. 41). The backside of belt will be touching the pulley. 15. Install the belt cover over the pulley assembly and secure the 3 cover latches into the blower (Fig. 43). 3 11. Route the bagger belt around the fixed idler pulley (Fig. 41). 2 12. Route the bagger belt around the blower pulley (Fig. 41). 3 6 4 7 1 m–6236 1 5 Figure 43 m–6732 2 1. Blower assembly 2. Blower belt cover Figure 41 1. 2. 3. 4.
Step Step 16 17 Parts needed for this step: Parts needed for this step: • 1 Tube support • 1 Hood assembly • 1 Elbow • 3 Bags • 4 Bolts, 1/4 x 1–1/2 inch • 2 Clevis pins • 4 Nuts, 1/4 inch • 2 Hairpin cotter pins • 4 Flat washers, 1/4 inch Installing the Hood Assembly and Bags Installing the Bagger Tube Support and Elbow Warning 1. Position the elbow inside the bagger hood (Fig. 44). 2.
2. Install the 2 clevis pins into the hood assembly and bagger mounting bracket. Secure it with 2 hairpin cotter pins (Fig. 46). 4. Lower the bagger hood over the bags. 1 3 3 4 2 4 m–6719 Figure 48 1 1. Hood 2. Bags 2 3 4 5. Position the bagger latch under the latch hook (Figures 48 and 49). m–6741 Figure 46 1. Hood assembly 2. Bagger mounting bracket 3. Bagger latch 4. Latch hook 6. Push down on the bagger latch until it locks into place (Fig. 49). 3. Hairpin cotter pin 4. Clevis pin 1 3.
Step 4 18 1 3 4 5 Parts needed for this step: 2 • 1 Bagger tube • 1 Clamp • 2 Knobs m–6252 • 1 Blower adapter Figure 51 1. Tube 2. Blower assembly 3. Top blower stud Installing the Bagger Tube Note: To ease assembly of the bagger tube to the blower adapter, apply soapy water to both the bagger tube and the adapter. 4. Knob 5. Side blower stud Note: There are nubs on the inside of the bagger elbow that hold the upper end of the bagger tube (Fig. 52). 1.
Step 2 19 1 3 1 6 4 Parts needed for this step: 5 • 2 Caster weights • 2 Top weights • 2 U–bolts m–5882 • 4 Nuts, 1/2 inch Figure 53 • 2 Plates 1. Front caster weight 2. U–bolt 3. Plate • 4 Lock washers, 1/2 inch 4. Nut 5. Front caster 6. Lock washer • 2 Bolts, 1/2 x 3 inch Installing the Weights Installing the Extra Top Weight To comply with ANSI/OPEI B71.4–1999 Standard, weights must be added to the machine. 1.
Checking the Tire Pressure 4 5 7 Check and adjust the air pressure in the front and rear tires. 6 Front tire pressure: 25 psi (172 kPa) (Fig. 54). Rear tire pressure: 20 psi (140 kPa) (Fig. 55). 1 1 3 2 m–3788 Figure 56 1. Brake lever 2. Spring 2–5/8 inch (67 mm) 3. Adjusting nut and jam nut below the spring m–1872 Figure 55 1. Valve stem 4. 5. 6. 7. Collar on brake rod 5/16 inch (8 mm) Yoke and jam nut Trunnion roller 3.
Using the Grass Deflector Installing the Grass Deflector Note: Make sure the grass deflector is installed when the bagger and tubes are removed. Note: Make sure the grass deflector is installed when the bagger and tubes are removed. The grass deflector spring will have either an L end or a straight end (Fig. 57). Warning Warning Without the grass deflector, bagger tubes or complete bagger assembly mounted in place, you and others are exposed to blade contact and thrown debris.
Operation Caution Note: Determine the left and right sides of the machine from the normal operating position. Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. Important Set the parking brake when leaving the machine unattended, even for just a few minutes. Always remove the ignition key and set the parking brake when leaving the machine unattended, even for just a few minutes.
Clearing Obstructions From the Bagger System Danger When the bagger is in operation, the blower can be rotating and cut off or injure hands. • Before adjusting, cleaning, repairing and inspecting the blower, and before unclogging the chute, turn off the engine and wait for all moving parts to stop. Remove the key. • Use a stick, not your hands, to remove an obstruction from the blower and tube.
Operating and Bagging Tips Bagging Long Grass Machine Size Excessively long grass is heavy and may not be propelled completely into the bagger. If this happens, the tube and blower assembly may plug. 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. Bagging Wet Grass If possible, always try to cut grass when it is dry. Wet grass can cause plugging.
Maintenance Important If the machine is on a slope and set the parking brake to prevent the machine from slowly rolling.
Checking and Adjusting the Bagger Belt Tension 7. Adjust the fixed idler towards the front to shorten the spring and decrease belt tension (Fig. 60). 8. Tighten the two bolts that hold the fixed idler to the blower assembly (Fig. 60). Check the bagger belt tension after the first 8 hours of use. 9. Close the blower assembly and measure the spring length again. Adjust the fixed idler until the correct spring length is achieved. Check the bagger belt tension every 25 hours.
Checking and Adjusting the Blower Latch Adjust the blower latch when it is does not engage the front peg correctly. 1. There must not be a gap between the mounting plate the the blower assembly (Fig. 61). If there is a gap, proceed to step 3 and shorten the latch. 3 Topview 4 1 1 2 m–6721 Figure 62 1. Blower front latch (Red) 2. Front peg 3. To adjust the blower latch, loosen the jam nut. (Fig. 63). 4. To lengthen the latch turn the hex nut counterclockwise to loosen the nut. (Fig. 63). 5.
Replacing the Blower Belt 3 6 4 7 Check the bagger belt for wear and cracks after the first 8 hours and then every 25 hours. 1. Disengage the PTO and set the parking brake. 2. Turn off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Push down on the front latch and open the blower assembly (Fig. 65). This will automatically remove the tension from the blower belt. 4. Remove the blower belt cover (Fig. 64). 1 5 2 5.
Checking the Blower Liner 9. Loosely install 2 bolts into the liner and the blower (Fig. 68). Check the blower liner inside the blower every 40 hours and more often in extreme mowing and bagging conditions. 3 1. Remove the blower adapter and tube from the blower (Fig. 51). 2. Check the liner for any excessive wear. Do not use your hands to check the liner or remove debris. 2 3. Replace the liner if any excessive wear is noticed. 4 Replacing the Blower Liner 1 1.
Inspecting the Bagger Inspect the bagger attachment after the first 8 hours of operation and 100 hours thereafter. 1. Disengage the PTO and set the parking brake. 2. Turn off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Check the tube, blower assembly, and the bagger hood. Replace these parts if they are cracked or broken. 4. Check the bags, bagger frame, and screen. Replace any parts that are cracked, worn or broken. 5.
Troubleshooting Problem Abnormal vibration. Reduced bagging performance. Blower and tube plug g too f frequently. tl Debris blowout. Blower impeller does not spin freely. Possible Causes Corrective Action 1. Cutting blade(s) bent or unbalanced. 1. Install new cutting blade(s). 2. Blade mounting bolt is loose. 2. Tighten blade mounting bolt. 3. Loose blower pulley or pulley assembly. 3. Tighten the appropriate pulley. 4. Blower belt is worn or damaged. 4. Replace the blower belt. 5.
