Form No. 3329–568 52 inch Twin Bagger and Finishing Kit 200 Series Z Master Model No. 78498—Serial No. 230000001 and Up Model No.
Inspecting the Mower Blades and Baffles . . . . . . Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety and Instruction Decals . . . . . . . . . . . . . . . . Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning signals a hazard that may cause serious injury or death if you do not follow the recommended precautions. • Do not leave grass in grass catcher for extended periods of time. Caution signals a hazard that may cause minor or moderate injury if you do not follow the recommended precautions. • Grass catcher components are subject to wear, damage and deterioration, which could expose moving parts or allow objects to be thrown.
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. A right angle drill is recommended for Step Description Qty.
Step 11 12 13 14 15 16 Description Qty.
Before Installation 3 Checking the Mower for Existing Holes 5 2 1 Check for existing holes. Use any existing holes in the mower that align the baffles in their correct positions. 4 m–6783 Removing the Mower Figure 3 1. Center mower pulley 2. PTO Drive belt 3. Idler pulley 1. Remove the PTO drive belt from the rear idler arm (Figures 2 and 4). 4. Mower belt 5. Right side pulley 2 3 2 1 1 M–4417 Figure 2 1. Center bolt, spring loaded idler 2. Alignment hole m–4451 2.
Note: If the mower is removed from the bottom bolts, attaching the chains to the mower, the mower may not need to be leveled. Check the level of the mower after all installation is complete. Warning Contact with sharp blade can cause serious personal injury. 6. Remove the four bolts at the bottom of the chains that are attached to the mower (Fig. 5). • Wear gloves or wrap sharp edges of the blade with a rag. 7. Remove the nuts and bolts holding the push arm pins (Fig. 5).
Step 4. Clamp the baffle in place. 1 5. Using the baffle as a template, mark, center punch and drill 1/8 inch pilot holes at the 4 locations (Fig. 8). 6. Remove the clamp. 7. Drill 11/32 inch dia. holes through the pilot holes (Fig. 8). 8. Install the front tunnel baffle to the mower with 4 carriage bolts (5/16 x 5/8 inch) and 4 flange nuts (5/16 inch) (Fig. 8).
Step 6. Drill 11/32 inch dia. holes through the pilot holes (Fig. 10). 2 7. Install the rear tunnel baffle with 3 carriage bolts (5/16 x 5/8 inch) and 3 flange nuts (5/16 inch) (Fig. 10). Important Make sure the bolt heads are installed on the inside of the cutting chamber. Parts needed for this step: 1 2 • 1 Tunnel baffle—rear • 3 Carriage bolt, 5/16 x 5/8 inch • 3 Flange nut, 5/16 inch Installing the Rear Tunnel Baffle 6 1.
Step 3 4 1 2 3 m–6229 Figure 12 1. Baffle flange 2. Blade 3. Spindle Parts needed for this step: • 1 Center cutting chamber baffle 4. Blade clearance, 9/16 to 11/16 inch (14 mm to 17 mm) • 3 Button Head Socket Bolts, 5/16 x 3/4 inch • 3 Flange nuts, 5/16 inch 4. Clamp the center baffle tightly against the cutting chamber (Fig. 13). Installing the Center Rear Baffle 5. Using the baffle as a template, mark, center punch and drill 1/8 inch pilot holes at the 3 locations (Fig. 13).
Step 6. Install the left rear baffle with 3 button head socket bolts (5/16 x 3/4 inch) and 3 flange nuts (5/16 inch) (Fig. 15). 4 Important Make sure the bolt heads are installed on the inside of the cutting chamber. See figure 15. 6 2 Parts needed for this step: • 1 Left rear baffle 3 • 3 Button Head Socket Bolts, 5/16 x 3/4 inch • 3 Flange nuts, 5/16 inch 7 Installing the Left Rear Baffle 5 1. Place the left rear baffle behind the left cutting chamber (Fig. 14).
Step 5. Drill 11/32 inch dia. holes through the pilot holes (Fig. 17). 5 6. Remove the clamp. 7. Install the right rear baffle to the mower with 2 button head socket bolts (5/16 x 3/4 inch) and 2 flange nuts (5/16 inch) (Fig. 17). Important Make sure the button head bolt heads are installed on the inside of the cutting chamber. See figure 17. Parts needed for this step: • 1 Right rear baffle 8.
Step 6 1 2 7 3 6 4 5 No Parts needed for this step. Removing the Existing Mower Pulley Note: Clean the area around pulley before removing pulley assembly. Hold spindle up from underneath the deck. It can fall when nut and washer are removed. 1. Turn the mower over. m–6753 Figure 18 2. Remove the right belt cover from the mower and discard. 1. 2. 3. 4. 3. Remove the nut and washer on top of the spindle (Fig. 18). Save the nut and washer. Nut Washer Pulley Assembly Blade spindle 5. Mower 6.
Step Installing the Mounting Plates 8 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. 20). 1 1 3 Parts needed for this step: • 2 Mounting plates • 1 Template • 4 Bolts, 3/8 x 1–1/4 inch 2 • 4 Flange nuts, 3/8 inch Installing the Mounting Plates Drilling the Holes into the Mounting Bracket m–6751 This kit contains a metal template for locating the mounting bracket holes to drill. 5 4 1.
Step 6 9 6 4 5 6 m–4451 2 3 No parts needed for this step. 1 M–4373 Installing the Mower and PTO Drive Belts Figure 22 1. Clutch 2. Clutch retaining strap 3. Clutch terminal 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 spindle pulley (Fig. 21). 2. Check the belt tension. The center bolt of the spring loaded idler must be between the two alignment holes in left support plate (Fig 23).
Step 1 11 2 Parts needed for this step: • 1 Left side bagger bracket m–3746 • 1 Right side bagger bracket Figure 24 1. Fixed Idler • 1 Bagger mounting bracket 2. Adjustment slot • 10 Bolts, 3/8 x 1 inch 4. Check belt tension again. The center bolt of spring loaded idler must be between the two alignment holes in left support plate (Fig 23). Adjust, if necessary, and tighten all hardware securely.
1 5 2 3 1 2 4 3 2 1 6 6 6 2 5 4 3 m–6742 4 2 m–6743 Figure 25 1. Bagger bracket—left side shown 2. Bolt, 3/8 x 1 inch 3. Flange nut, 3/8 inch Figure 26 4. Machine side frame 5. Existing hole 6. Belleville washer, 3/8 inch 1. 2. 3. 4. Bagger mounting bracket Bolt, 3/8 x 1 inch Flange nut, 3/8 inch Belleville washer, 3/8 inch 5. Rear frame 6.
Step Step 12 13 Parts needed for this step: Parts needed for this step: • 1 Blower assembly • 1 Blower belt cover • 1 Idler spring Installing the Blower Assembly • 1 Bagger belt Important Make sure the mounting plate is installed to the mower. Refer to the Finishing Kit. Installing the Bagger Belt and Idler Spring 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.
6. Route the bagger belt around the top pulley of the mower pulley assembly (Fig. 29). Important Make sure to inspect the belt and check the spring length after the first 8 hours of use. 7. Feed the belt between the idler pulleys (Fig. 29). 12. Adjust the bagger belt tension. Refer to Checking and Adjusting the Bagger Belt Tension on page 30. 8. Route the bagger belt around the spring–loaded idler pulley (Fig. 29). The backside of belt will be touching the pulley. 13.
Step 14 2 1 Parts needed for this step: • 1 Hood assembly • 2 Bags • 2 Clevis pins m–6758 Figure 33 • 2 Hairpin cotter pins 1. Hood assembly 2. Bagger mounting bracket Installing the Hood Assembly and Bags Warning Components around engine will be hot if the machine has been running. Touching hot components can cause burns. • Do not touch engine components when hot. • Allow engine to cool before performing maintenance. 1 3 1. Install the hood assembly onto the bagger mounting bracket (Fig. 33).
3 1 4 2 5 1 m–6264 3 Figure 37 1. Bagger latch 2 m–6760 Figure 35 1. Hood assembly 2. Bag 3. Bag tab 4. Notch 5. Bagger frame 4. Lower the bagger hood over the bags (Fig. 36). 1 3 4 2 m–6761 Figure 36 1. Hood 2. Bags 3. Bagger latch 4. Latch hook 5. Position the bagger latch under the latch hook (Figures 36 and 37). 6. Push down on bagger latch until it locks into place (Fig. 37). 22 2.
Step 4 15 1 3 4 5 Parts needed for this step: 2 • 1 Bagger tube • 1 Clamp • 2 Knobs m–6252 • 1 Blower adapter Figure 39 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 a little 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 hood that hold the upper end of the bagger tube (Fig. 40). 1.
Step 2 16 1 3 1 6 4 Parts needed for this step: 5 • 2 Caster weights • 2 U–bolts • 4 Nuts, 1/2 inch m–5882 • 2 Plates Figure 41 • 4 Lock washers, 1/2 inch 1. Front caster weight 2. U–bolt 3. Plate Installing the Weights To comply with ANSI/OPEI B71.4–1999 Standard, weights must be added to the machine when the bagger is installed. 4. Nut 5. Front caster 6. Lock washer Checking the Tire Pressure Check and adjust the air pressure in the front and rear tires.
Installing the Blades Using the Grass Deflector Note: In certain mowing conditions, improved bagging performance can be achieved by using bagging blades. Contact an Authorized Service Dealer for the proper blades for different mowing conditions. Note: Make sure the grass deflector is installed when the bagger and tubes are removed. Warning 1. Install the blade onto the spindle shaft (Fig. 43).
Installing the Grass Deflector Operation Note: Make sure the grass deflector is installed when the bagger and tubes are removed. Note: Determine the left and right sides of the machine from the normal operating position. The grass deflector spring will have either an L end or a straight end (Fig. 44). Important Set the parking brake, and chock or block the tires when leaving the machine unattended, even if just for a few minutes.
Clearing Obstructions From the Bagger System Caution Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. Danger 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. When the bagger is in operation, the blower can be rotating and cut off or injure hands.
Removing the Bagger Warning Components around engine will be hot if the machine has been running. Touching hot components can cause burns. • Do not touch engine components when hot. • Allow engine to cool before removing the bagger. 1. Disengage the PTO, set the parking brake, and chock or block the drive wheels. 2. Turn off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the knobs and then the tube from the blower assembly (Fig. 39). 4.
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, set the parking brake and chock or block the wheels to prevent the machine from slowly rolling.
3. Close the blower assembly and measure between the spring coil ends. See Figure 46 for measuring the spring length and eye hook orientation. 3 2 4 5 1 Note: When adjustment is needed, set the spring length to 4–3/4 inches (121 mm) +/– 1/4 inch (6 mm) (Fig. 46). 5 m–6213 2 Figure 47 2 3 1 1. Fixed idler 2. Blower assembly 3. Adjust idler to the front to shorten the spring 4 m–6275 Figure 46 1. Spring 2. End of spring coils 3. Blower assembly peg 4.
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. 48). If there is a gap, proceed to step 3 and shorten the latch. 3 Topview 4 1 1 2 m–6721 Figure 49 1. Blower front latch (Red) 2. Front peg 3. To adjust the blower latch, loosen the jam nut. (Fig. 50). 4. To lengthen the latch turn the hex nut counterclockwise to loosen the nut. (Fig. 50). 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, set the parking brake, and chock or block the drive wheels. 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. 29). This will automatically remove the tension from the blower belt. 1 5 4. Remove the blower belt cover (Fig.
Checking the Blower Liner 8. Loosely install 2 bolts into the liner and the blower (Fig. 55). 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. 39). 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. Replacing the Blower Liner 4 1.
2 Storage 1 1. Clean the bagger attachment. Refer to Cleaning the Bagger on page 30. 2. Inspect the bagger attachment for damage. Refer to Inspecting the Bagger on page 30. 3. Make sure the bags are empty and thoroughly dry. 4. Check the belt for wear or cracks. 3 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. m–6220 Figure 56 1.
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.
