Form No. 3350–769 DFS Vac Collection System 500 Series Z Master Model No. 78506—Serial No.
Contents Inspecting the Mower Blades . . . . . . . . . . . . . . . . Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety and Instruction Decals . . . . . . . . . . . . . . . . 3 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Caution signals a hazard that may cause minor or moderate injury if you do not follow the recommended precautions. • The grass catcher can obstruct the view to the rear. Use extra care when operating in reverse. 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.
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 1 2 3 4 5 6 7 8 Description Qty.
Step Description 9 Bagger 1 Clevis pin 2 Hairpin cotter 2 Bagger tensioner pulley 1 Bolt, 3/8 x 2 inch 1 Lock Nut, 3/8 inch 1 Washer, 3/8 inch 1 Bagger belt 1 10 11 12 13 14 15 16 17 18 Qty.
Step 1 No parts needed for this step. 1 m–6859 Removing the Drive Wheels Figure 3 1. Drive wheel Danger 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. 1. Loosen the drive wheel nuts. 2. Raise the rear of the machine and support with jack stands (Fig. 2). 1 1 Figure 2 1. Jack stand 3. Remove the nuts and the drive wheels (Fig. 3).
Step 2 1 No parts needed for this step. Removing the Roll Over Protection System (ROPS) 2 1. Loosen the front handles securing the center roll bar section to the right and left sections (Fig. 4). m–6893 Figure 5 1. Pin 2 2. Hair pin cotter 3. Loosen the center roll bar bolts allowing the roll bar to be pivoted to the down position (Fig. 6). 1 m–6835 2 Figure 4 1. Front handle 2. Center roll bar section 1 2.
5. Remove the following fasteners (Fig. 7) securing each (right and left) roll bar section to the frame: Step • Lock nut (3/8 inch) and curved washer. Do not remove bolt from frame. • Bolt (3/8 x 1 inch), curved washer and flange nut (3/8 inch). • Bolt (3/8 x 1 inch), curved washer and flange nut (3/8 inch). 3 Parts needed for this step: • Bolt (3/8 x 4-1/2 inches), curved washer and flange nut (3/8 inch).
2. In the top two holes, install 2 bolts (3/8 x 1–1/2 inch), 2 flange nuts (3/8 in.) one long frame spacer, and one short frame spacer (Fig. 8). 3 4 5 3 1 Note: Make sure the long frame spacers are installed as shown in figure 8. 3. In the bottom hole, install a bolt (3/8 x 1–1/4 inch) and a flange nut (3/8 in.) (Fig. 8). 4. Install a bracket stiffener to the side bracket and bagger mounting bracket. Use 4 bolts (3/8 x 3/4 inch) and 4 flange nuts (3/8 in.) (Fig. 8). 3 5.
6 Step 5 4 3 3 7 4 7 3 10 Parts needed for this step: 1 • 6 Bolt, 3/8 x 1–1/2 inch • 6 Flange Nut, 3/8 inch 9 • 6 Curved washer 6 8 2 • 4 Spacer m–5979 Figure 10 1. 2. 3. 4. 5. 4 Bagger mounting bracket Bolt, 3/8 x 1–1/4 inch Flange nut, 3/8 inch Bracket stiffener Left side bracket 6. 7. 8. 9. 10.
Note: Make sure the bolts are installed on the outside of the roll bar. 2 6 4 Note: Make sure the lanyard tab is installed as shown and points forward. 3 5 1 6 2 3 1 2 Figure 12 1. Side bracket 2. Curved washer, 3/8 inch 3. Bolt, 3/8 x 1–1/2 inch 4. Flange nut, 3/8 inch 5. ROPS 6. Spacer 2. Make sure the lanyard clips are on the 2 bolts (1/2 x 3-1/4 inches) (Fig. 13). m–6891 Figure 14 1. Center roll bar section 1 5.
Note: No more than one thread should be exposed outside the nut. Step 5 No parts needed for this step. Tightening all Mounting Bolts 2 The following steps are the correct sequence to tighten the side brackets and the bagger mounting bracket. 1 All 3/8 inch mounting bolts need to be torqued to 35 ft.–lb. (48 N m). 1. Tighten the bagger mounting bracket to the rear frame first (Figures 9 or 11). m–6891 2. Tighten the bagger mounting bracket to the side brackets (Figures 9 or 11). Figure 16 1.
Step 6 Step 7 No parts needed for this step. No parts needed for this step. Installing The Drive Wheels Removing the Mower Belt and the Right Rear Idler Pulley 1. Mount the wheels with the valve stem to the outside and secure them with the nuts previously removed (Fig. 18). 1. Loosen the idler plate bolts and loosen the mower idler plate (Fig. 19). 2. Torque the nuts to 95 ft-lb (128 N m). 3 4 1 m–6859 2 2 Figure 18 1. Drive wheel 2. Nuts m–6826 1 Figure 19 3.
2. Remove the mower belt from the mower and the rear fixed idler pulley (Fig. 20). Step 1 3 5 8 Parts needed for this step: 4 2 • 1 Pulley assembly • 4 Bolt, 1/2 x 1–1/4 inch 4 6 • 4 Lock nut, 1/2 inch m–6825 Figure 20 1. Clutch 2. Mower belt 3. Right rear fixed idler pulley • 4 Washer, 1/2 inch 4. Belt guide 5. Mower spindle pulley 6. Mower idler pulley • 1 Template Installing the Drive Pulley Assembly 3. Remove the fixed idler pulley from the right rear frame of the machine (Fig. 21). 1.
2. Install the pulley assembly under the rear frame, and loosely install 4 bolts (1/2 x 1–1/4 inch), 4 washers (1/2 in.) and 4 locknuts (1/2 inch) (Fig. 22). Do not tighten bolts now. Step Positioning the Drive Pulley Assembly on an Air Cooled Machine 1. Push the drive pulley assembly all the way forward and then rearward a 1/4 inch (6 mm) (Fig. 22). 9 Parts needed for this step: Note: The bolt head on the drive pulley assembly, should be approximately centered horizontally, in the frame slot (Fig.
10 3. Tighten bolts that hold the engine shroud. Step 4. Remove the cable guide and bolt from the frame of the bagger (Fig. 25). 5. Install the cable guide, bolt, and nut with the cable behind the cable guide (Fig. 25). Note: Make sure the cable guide can rotate. 6. Locate template number 1 in the back of this manual. Cut out template number 1 as indicated on the template (Fig. 25). Parts needed for this step: 7. Position the template on the right–hand side of the engine shroud (Fig. 25).
7. Install the tensioner spring onto the eyebolt attached to the bagger (Fig. 28 and 31). 8. Adjust the bagger belt for proper tension. Refer to Adjusting the Bagger Belt on page 18. 9. Adjust the Mower belt tension. Refer to Adjusting the Mower Belt Tension on page 19. 10. Install the skid plate (Fig. 26). 3 2 6 3 1 2 5 4 M–6908 4 1 Figure 27 1. Bolt, 3/8 x 2 inch 2. Idler arm 3. Lock nut, 3/8 inch m–5773 Figure 29 4. Washer, 3/8 inch 5. Bagger tensioner pulley 6. Bagger 1. Drive pulley 2.
11 6. If the gap measurement is too small: Step A. Loosen the 2 nuts on the lower fan shaft pillow block (Fig. 32). B. Insert a spacer behind the pillow block (Fig. 32). C. Tighten the nuts. D. Check the belt gap and repeat procedure as required. No parts needed for this step Adjusting the Bagger Belt 1. Check the belt tension (Fig 31). 2. Measure the gap, at the bagger tensioner pulley, between the tight and slack side of the belt when the bagger tensioner pulley and spring are installed (Fig. 31).
12 5. Check the belt tension. The spring loaded idler center bolt needs to be near the top alignment hole in left support plate (Fig 34). Step 1 2 No parts needed for this step. 3 Installing and Adjusting the Mower Belt M–4417 1 Figure 34 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 1. Center bolt 2. Alignment hole 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3.
13 10. Check the distance from the rubber stop and the arm of the spring loaded idler pulley when the idler plate is tightened. It needs to be 0 to 1/4 inch (0 to 6 mm) from the rubber stop (Fig. 36). 6 4 Step 3 5 Parts needed for this step: • 2 Caster weight • 2 U–bolt • 4 Nut, 1/2 inch 2 m–6825 • 4 Lock washer, 1/2 inch 1 • 2 Plate Figure 36 1. Spring loaded idler pulley 2. Top alignment hole 3. 0 to 1/4 inch gap (0 to 6 mm) • 4. Idler pulley arm 5. Belt 6.
2 1 3 1 6 4 5 m–5882 Figure 37 1. Front caster weight 2. U–bolt 3. Plate 4. Nut 5. Front caster 6. Lock washer Installing the Extra Top Weights 1. Install 2 top weights on top of each caster weight and secure them with a bolt (1/2 x 3 inch) (Fig. 38). 2 1 3 4 m–5882 Figure 38 1. Top weight 2. Bolt, 1/2 x 3 inches 3. Front caster weight 4.
14 6. Place the rear hook over the rear of the mounting bracket (Fig. 40). Step 7. Install the upper tube into the bagger (Fig. 40). 8. Slide the clamp onto the middle tube (Fig. 40). 9. Align the knob on the middle tube with the notch in the upper tube. Slide the middle tube into the upper tube and twist the middle tube 60 degrees (Fig. 40). 10. Tighten the clamp around the upper and middle tube connection (Fig. 40). Parts needed for this step: • 1 Boot 11.
15 16 Step Step Parts needed for this step: Parts needed for this step: • 1 Dump handle • 1 Bolt, 1/2 x 1–3/4 inch • 2 Washers, 13/16 inch • 2 Jam nuts, 1/2 inch • 1 Cotter pin • 1 Long clevis, liquid cooled machines only Installing the Bagger Dump Handle Installing the Bagger Dump Lever Stop Bolt 1. Unfasten the dump handle from the crate. 1. Move the bagger dump lever rearward to increase the slack in the bagger cable (Fig. 42). 2.
17 Note: Install the long cable clevis onto the bagger dump handle if it is for a liquid cooled machine (Fig. 43). Step 6. Secure the bagger cable clevis to the bagger dump handle with the clevis pin and cotter pin previously removed (Fig. 42 or Fig. 43). 1 2 3 8 No parts needed for this step. Adjusting the Bagger Dump Lever 7 The bagger lever needs to be adjusted to remove slack in the bagger cable. 6 1. Loosen the nuts on both sides of the stop bracket (Fig. 44). 4 5 4 2.
18 Step No parts needed for this step. Checking the Tire Pressure Note: The tire pressure needs to increase due to the additional weight. Check and increase the air pressure in the front caster wheels (Fig. 38) and rear tires (Fig. 45). Pressure: Rear tires—20 psi (90 kPa) Front caster wheels—25 psi (90 kPa) 1 m–1872 Figure 45 1.
Positioning the Adjustable Baffle Operation Note: Determine the left and right sides of the machine from the normal operating position. Adjust the baffle to position B (middle position) for bagging. Refer to the machines Operator Manual for the baffle adjustment procedure. Important If the machine is on a slope, chock or block the wheels to prevent the machine from slowly rolling.
Holding the Bagger Door Open 2. Turn off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Warning 3. Close the bagger. 4. Remove the cotter pin and clevis pin (Fig. 49). Hands, fingers and arms can get pinched between the back and front sections of the collector. 5. Adjust the bagger cable to the desired hole position (Fig. 49). • Keep people away from collector while emptying it.
7. After you remove the obstruction, install the complete bagger system and resume operation. Refer to Installing the Discharge Tubes on page 22. 8. Replace the grass deflector spring. Refer to Replacing the Grass Deflector Spring on page 28. 9. Remove both the top weights and caster weights (Fig. 24). Removing the Discharge Tubes Replacing the Grass Deflector Note: Remember to replace the L end of the spring when in side discharge mode. Refer to Replacing the Grass Deflector on page 28. Warning 1.
Bagging Long Grass Operating and Bagging Tips 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. Excessively long grass is heavy and may not be propelled completely into the bagger. If this happens, the tube and boot may plug. To avoid plugging the bagging system, mow the grass at a high height-of-cut, then lower the mower to your normal cutting height and repeat the bagging process.
higher than 6 inches (152 mm), cross it at a sharp angle with the deck fully raised. Use extreme caution when loading onto a trailer. Maintenance Important If the machine is on a slope, chock or block the wheels to prevent the machine from slowly rolling. Note: Determine the left and right side of the machine from the normal operating position.
Greasing the Fan Shaft Bearings Inspecting the Mower Blades 1. Inspect the mower blades regularly and whenever a blade strikes a foreign object. Grease the upper and lower bagger fan shaft bearings (Fig. 52 & 53) every 100 hours. 2. If blades are badly worn or damaged, install new blades. 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 30. 2. Inspect the bagger attachment for damage.
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.
Template No. 1 Do Not cut out to sharp point. Cut with a radius as shown. Scale 1 inch 26 mm Use this for liquid cooled engines only. Cut the engine shroud along this edge. 34 Cut out template here Template No. 1 Line up mark where handle hits the engine shroud. Cut out template here Cut the engine shroud along this edge.
