Form No. 3350–765 DFS Vac Collection System 100 Series Z Master Model No. 78500—Serial No.
Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety and Instruction Decals . . . . . . . . . . . . . . . . . Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loose Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Before Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the Mower for Existing Holes . . . .
• Never operate with the discharge deflector raised or removed and never altered, unless using a grass catcher or mulching baffles. This manual uses two other words to highlight information. Important calls attention to special mechanical information and Note: emphasizes general information worthy of special attention. • Keep hands and feet away from moving parts. Do not make adjustments with the engine running.
107-1613 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. Step Description 1 Template 1 Bolt, #6 x1/2 inch 1 Bolt, 7/16 x 4–1/2 inch—Kawasaki engines only 1 Bolt, 7/16 x 4 inch—Kohler engines only 1 2 Qty.
Step Description 8 9 10 Bagger 1 Clevis pin 2 Hairpin cotter 2 Spring 1 Bagger belt 1 Spacer 3 Weight—left 1 Weight—right 1 Weight bracket—left 2 Weight bracket—right 2 Support plate 1 Bolt, 3/8 x 6–1/2 inch 4 Bolt, 5/16 x 1 inch 2 Nut, 3/8 inch 8 Lock washer, 3/8 inch 8 Flat washer, 3/8 inch 16 Bolt, 3/8 x 4–1/2 inch 4 Bolt, 3/8 x 3/4 inch 2 Self tapping bolt, 3/8 x 5/8 inch 1 Weight 1 Weight bracket 2 Large Washer 2 Locknut, 5/16 inch 2 Bolt, 5/16 x 1–1/4 i
Drilling Holes in the Clutch Before Installation Use the metal template, included with the bagger, to locate the clutch holes. Checking the Mower for Existing Holes 1. Remove the clutch strap for the clutch (Fig. 3). 2. Unplug the clutch connector (Fig. 3). Check the mower for existing holes. Use any existing holes in the mower that align with any of the parts to be installed in their correct positions. Step 1 3 1 4 2 m–4119 Figure 3 Parts needed for this step: 1. Clutch strap 2.
Note: Before drilling holes, place a piece of metal between the clutch and pulley. This will prevent drilling into the clutch. Step 7. Using the template, drill one 1/8 inch pilot hole into the pulley (Fig. 5). 8. Install the screw (#6 x 1/2 inch) into the 1/8 inch hole (Fig. 5). This will hold the template in place while drilling the other two holes. 2 9. Using the template, drill the remaining two 1/8 inch pilot holes into the pulley (Fig. 5). Parts needed for this step: 10.
Step 1 2 3 3 4 5 No parts needed for this step. 6 or 7 Removing the Drive Wheels 8 5 Danger 6 or 7 m–6007 Mechanical or hydraulic jacks may fail to support machine and cause a serious injury. Figure 6 1. 2. 3. 4. 5. Clutch Clutch connector Pulley spacer Drive pulley assembly Curved washers 6. Bolt, 7/16 x 4–1/2 inch for Kawasaki engines 7. Bolt, 7/16 x 4 inch for Kohler engines 8. Drive spacer • Use jack stands when supporting machine. • Do not use hydraulic jacks. 1.
Step 4 Step No parts needed for this step. 5 Parts needed for this step: • 1 Template Removing the Rear Heat Shield Drilling Holes for the Bagger 1. Remove the 8 bolts and nuts securing the rear of the heat shield to the engine straps and the rear bumper (Fig. 7). 1. Check if there is a large opening in the rear bumper. (Fig. 8). If there is no large opening, proceed to next step. 2.
Step 6 2. Loosely install the bagger mounting bracket to the side of the rear bumper and the engine guard straps, with 8 bolts (5/16 x 1 inch), 6 flat washers (5/16 inch), and 8 flange nuts (5/16 inch) (Fig. 10). Note: The bagger mounting bracket is to be installed to the inside of the engine guard straps.
Step 7 2 5 Parts needed for this step: • 1 Idler pulley assembly with bracket • 5 Bolts, 5/16 x 7/8 inch • 5 Flange nuts, 5/16 inch • 1 Spring bracket • 1 Skid plate 3 • 1 Shoulder bolt, 3/8 x 2–1/2 inch 1 • 1 Flange nut, 3/8 inch 4 • 1 Spring Figure 12 1. Skid plate 2. Idler pulley bracket 3. Rear bumper Installing the Bagger Idler Pulley and the Skid Plate 4. Bolt, 5/16 x 7/8 inch 5. Flange nut, 5/16 inch 4.
Step 8 Step 9 Parts needed for this step: Parts needed for this step: • 1 Bagger • 1 Bagger belt • 2 Clevis pins Installing the Bagger Belt • 2 Hairpin cotters 1. Remove the 2 wing nuts (5/16 inch) securing the pulley guard to the bottom of the bagger (Fig. 15). Installing the Bagger 1. Install the bagger onto the bagger mounting bracket (Fig. 14). 2. Install clevis pins into the bagger and bagger mounting bracket. Secure them with hairpin cotter pins (Fig. 14). 2 1 1 2 3 Figure 15 2 1.
7 2 6 3 4 1 m–7649 Figure 17 1. Bagger belt 2. Tensioner pulley 2 3. 1–3/4 to 2–1/8 inch gap 1 3 2. To adjust the belt tension: A. Loosen the 2 nuts on the lower fan shaft pillow block (Fig. 18). 5 6 B. Insert a spacer behind the pillow block (Fig. 18). m–6832 C. Tighten the nuts. Figure 16 1. 2. 3. 4. Tensioner spring Idler arm Bagger tensioner pulley Bagger pulley D. Check the belt gap and repeat procedure as required. 5. Bagger belt 6. Clutch drive pulley 7. Clutch 7.
11 1. Remove the two outside bolts that connect the front floor pan to the carrier frame (Fig. 19). Save this hardware. Step 2. Remove the 4 bolts and washers that hold the front floor pan to the front frame (Fig. 19). Save this hardware.
Note: After the weights are installed, pivot the caster wheels near the weights to ensure clearance between the wheels and the weights. Adjust the weights if needed. 5 11 6 1 10 7 6 2 3 3 5 4 m–6111 12 Figure 21 1. Flange nut, 5/16 inch 2. Bolt, 5/16 x 1 inch 3. Existing flat washer, 5/16 inch 4. Front floor pan 5. Support plate 6. Hole to drill if needed 1 4 9. Using the support plate as a template, drill one 5/16 inch hole into the front floor pan (Fig. 22). 7 2 8 10.
12 Step 3 3 4 5 2 Installing the Front Weight 1. Front of footpan 2. Front weight 3. Weight bracket • 1 Weight • 1 Weight bracket • 2 Locknut, 5/16 inch • 2 Bolt, 5/16 x 1–1/4 inch • 2 Large Washer • 2 Washer, 11/32 inch Procedure 1. Remove the existing top bolts and washers from the front of the footpan. Save the washers. 2. Install the weight brackets to the front of the footpan with 2 bolts (5/16 x 1–1/4 inch) and 2 large washers and 2 washers previously removed (Fig. 23).
13 Step 11 3 4 6 2 5 Parts needed for this step: • 1 Bagger bracket 9 1 • 8 Carriage bolts, 5/16 x 1 inch 10 • 8 Flange nuts, 5/16 inch Installing the Boot and Discharge Tubes 8 7 1. Disengage the PTO, set the parking brake, and chock or block the drive wheels. m–5889 Figure 25 2. Turn off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 1. 2. 3. 4. 5. 6. 3.
14 15 Step Step Parts needed for this step: No parts needed for this step. • 1 Bolt, 1/2 x 1–3/4 inch Adjusting the Bagger Dump Lever • 2 Jam nuts, 1/2 inch Installing the Bagger Dump Lever Stop Bolt The bagger lever needs to be adjusted to remove slack in the bagger cable. 1. Move the bagger dump lever rearward to increase the slack in the bagger cable (Fig. 26). 1. Loosen the nuts on both sides of the stop bracket (Fig. 27). 2.
16 Step No parts needed for this step. Checking the Tire Pressure Check the air pressure in the front caster wheel (Fig. 22) and rear tires (Fig. 28). Use the following tire pressures when the bagger is installed. Pressure: Rear tires—20 psi (138 kPa) Front caster wheels—25 psi (241 kPa) 1 m–1872 Figure 28 1.
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, and chock or block the tires when leaving the machine unattended, even if just for a few minutes. Always remove the ignition key, set the parking brake and chock or block tires when leaving the machine unattended, even if just for a few minutes.
Holding the Bagger Door Open Clearing Obstructions From the Bagger System Warning Danger Hands, fingers and arms can get pinched between the back and front sections of the collector. When the bagger is in operation, the blower can be rotating and cut off or injure hands. • Keep people away from collector while emptying it. • If working on the inside, use the holding pin to hold the collector door open.
Installing the Grass Deflector 4. Remove the tube assembly from the bagger (Fig. 25). 5. Remove the boot from the mounting bracket (Fig. 25). The grass deflector spring will have either an L end or a straight end (Fig. 31). 6. If you are changing to side discharge mode, install the grass deflector. Refer to Installing the Grass Deflector on page 22. Note: Make sure the grass deflector is installed when the bagger and tubes are removed.
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 boot 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.
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 on page 27 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 mower baffles while loading and going over a curb.
Maintenance Important If the machine is on a slope, set the parking brake and chock or block the wheels to prevent the machine from slowly rolling.
Greasing the Fan Shaft Bearings Inspecting the Mower Blades and Baffles Grease the upper and lower bagger fan shaft bearings (Fig. 33 & 34) every 100 hours. 1. Inspect the mower blades and baffles regularly and whenever a blade strikes a foreign object. 2. If blades or baffles are badly worn or damaged, install new blades or baffles. Refer to your mower operator’s manual for complete blade maintenance. Storage 1. Clean the bagger attachment. Refer to Cleaning the Bagger Attachment on page 25. 2.
Troubleshooting Problem Abnormal vibration. Reduced bagging performance. Boot and tubes plug g too frequently. q y Debris blowout. Possible Causes 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 blade mounting bolt. 3. Loose bagger pulley or pulley assembly. 3. Tighten the appropriate pulley. 4. Bagger belt is worn or damaged. 4. Replace the bagger belt. 5. Bagger impeller is out of balance.
