Form No. 3352–448 44 , 48 and 52 Twin Soft Bagger Z100 and Z400 Series Z Master Model No. 78507—Serial No. 250000001 and Up Operator’s Manual Register your product at www.Toro.
You may contact Toro directly at www.Toro.com for product and accessory information, help finding a dealer, or to register your product. Contents Page Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety and Instruction Decals . . . . . . . . . . . . . . . . 4 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Loose Parts . . . . . . . . . . . . . . . . . . . .
Safety The following list contains safety information specific to Toro products and other safety information you must know. • 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. • Do not use a grass catcher on steep slopes. A heavy grass catcher could cause loss of control or overturn the machine.
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.
Step 1 3 5 1 2 Parts needed for this step: 3 • 1 Bagger bracket 4 6 • 8 Bolts, 5/16 x 1 inch • 8 Flange nuts, 5/16 inch 2 m–6221 Figure 3 1. Bagger bracket 2. Bolt, 5/16 x 1 inch 3. Flange nut, 5/16 inch Installing the Bagger Bracket (All Z100 Mowers and Z400 Mowers with 44in and 48in Mower Decks) 4. Rear bumper 5. Engine guard strap 6. Rear heat shield 4. Remove the 8 bolts and nuts securing the rear of the heat shield to the engine straps and rear bumper (Fig. 4). Discard the bolts and nuts.
8. Slide the heat shield down until the holes align with the bagger bracket holes (Fig. 7). 5 1 3 2 4 m–6812 Figure 5 1. Heat shield 2. Bagger bracket 3. Bar 4. Heat shield notch 5. Front of bagger bracket m–6810 Figure 7 7. With the bagger bar in the heat shield notches, push the bottom of the heat shield towards the rear and past the back of the bagger bracket (Fig. 6). Note: Make sure to install the bagger bracket correctly, as shown in figure 8. 1 2 1 m–6805 Figure 8 2 1.
Step 1 4 2 2 Parts needed for this step: 2 • 1 Bagger bracket Installing the Bagger Bracket (Z400 Mowers with 52in Mower Decks) 5 3 m–6809 Note: Use these instructions if machine is equipped with a rear weight. Figure 9 1. Bagger bracket 2. Engine straps 3. Rear bumper 4. Tailpipe guard 5. Heat shield 1. Remove the rear weight from the back of the machine (Fig. 10). Save the bolts and flange nuts. 2 4 1 2 3 5 1 m–7783 Figure 10 1. Bolt 2. Flange nut 3. Rear bumper 8 4.
Note: Make sure to install the bagger bracket correctly, as shown in Figure 11. 1 Step 2 3 Parts needed for this step: • 1 Blower assembly Installing the Blower Assembly Important Make sure the mounting plate is installed to the mower. Refer to the Finishing Kit. m–7782 Figure 11 1. Correct position 1. Disengage the PTO, set the parking brake, and chock or block the drive wheels. 2. Incorrect position 2.
5. Check if the latch fully engages the front latch peg. Refer to Checking and Adjusting the Blower Latch on page 22. 5 Note: There must not be any gap between the blower assembly and the mounting plate. Step 4 4 2 3 1 m–6276 Figure 14 Parts needed for this step: 1. Idler spring 2. Blower assembly 3. Idler arm eye bolt • 1 Blower belt cover 4. Blower eye bolt 5.
3 1 6 4 7 4 3 4 1 1 5 2 m–6253 Figure 16 3 1. 2. 3. 4. 2 Blower pulley Mower Blower assembly Top pulley of mower pulley assembly 5. Spring loaded idler pulley (belt back side touching pulley) 6. Fixed idler pulley 7. Front latch (colored red) m–6271 11. Close the blower assembly and ensure the blower front latch engages onto the front peg (Fig. 17). Figure 15 1. 52 inch mower belt cover 2. Blower assembly 3. Top mower pulley 4. Bagger belt 6.
. Adjust the bagger belt tension. Refer to Adjusting the Bagger Belt Tension on page 21. 13. Install the belt cover over the pulley assembly and secure the 3 cover latches into the blower (Fig. 19). 3 2 1 m–6236 Figure 18 1. Blower assembly 2. Blower belt cover 3. Latch 14. For 44 inch (112 cm) mowers, install the new belt cover over the pulley assembly and secure the latch (Fig. 19). 2 3 1 m–6255 Figure 19 1. Mower 2. 44 inch (112 cm) mower belt cover 3.
Step 5 Parts needed for this step: 2 • 1 Hood assembly • 2 Bags 1 • 2 Clevis pins • 2 Hairpin cotter pins Installing the Hood Assembly and Bags m–6806 Warning Figure 20 1. Bagger bracket Components around engine will be hot if the machine has been running. Touching hot components can cause burns. 2. Hood assembly 2. Install clevis pins and hairpin cotters into the bagger bracket and hood assembly (Fig. 21). • Do not touch engine components when hot.
3. Install the bag tab into the notch in the hood assembly (Fig. 22). Do this for both bags. 4. Lower the bagger hood over the bags. Note: The bag will rest on the bagger frame (Fig. 22). 1 3 3 4 4 2 5 m–6761 Figure 23 1 1. Hood 2. Bags 3. Bagger latch 4. Latch hook 3 5. Position the bagger latch under the latch hook (Figures 23 and 24). 2 6. Push down on bagger latch until it locks into place (Fig. 24). m–6760 1 Figure 22 1. Hood assembly 2. Bag 3. Bag tab 4. Notch 5.
Step 6 4 1 3 4 5 Parts needed for this step: 2 • 1 Bagger tube • 1 Clamp • 2 Knobs m–6252 • 1 Blower adapter Figure 26 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 hood that hold the upper end of the bagger tube (Fig. 27). 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 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.
Position B 4. Compress the debris into the bags. With both hands, lift up on the bag and unhook it from the bagger bracket. Use this position when bagging. 5. Grab the handle on the bottom of the bag and tip it over to empty the bag (Fig. 31). Middle Position 2 m–6880 Figure 29 1 Position C This is the full open position. The suggested use for this position is as follows. • Use in tall, dense grass mowing conditions. m–6242 Figure 31 • Use in wet conditions. 1.
Clearing Obstructions From the Bagger System 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. Danger 3. Remove the knobs and then the tube from the blower assembly (Fig. 26). When the bagger is in operation, the blower can be rotating and cut off or injure hands. 4. Remove the tube from the bagger hood (Fig. 27).
Transporting Machines Caution Do not leave grass or debris in the bagger while transporting the machine. As the bagger fills, extra weight is added to the back of the machine. If you stop and start suddenly on hills, you may lose steering control or the machine may tip. Warning • Do not start or stop suddenly when going uphill or downhill. Avoid uphill starts. • If you do stop the machine when going uphill, disengage the PTO. Then back down the hill using a slow speed.
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.
Checking and Adjusting the Bagger Belt Tension 7. Adjust the fixed idler towards the front to shorten the spring and decrease belt tension (Fig. 33). Check the bagger belt tension every 25 hours. 8. Tighten the two bolts that hold the fixed idler to the blower assembly (Fig. 33). Note: When checking the belt tension, the spring length needs to be between 4 inches and 4–3/4 inches (102 and 121 mm) (Fig. 32). 9. Close the blower assembly and measure the spring length again.
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. 34). If there is a gap, proceed to step 3 and shorten the latch. 3 Top view 4 1 1 2 m–6721 Figure 35 1. Blower front latch (Red) 2. Front peg 3. To adjust the blower latch, loosen the jam nut. (Fig. 36). 4. To lengthen the latch turn the hex nut counterclockwise to loosen the nut. (Fig. 36). 5.
3 Replacing the Blower Belt 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. 16). This will automatically remove the tension from the blower belt. 1 4.
Checking the Blower Liner 3 Check the blower liner inside the blower every 40 hours and more often in extreme mowing and bagging conditions. 1. Remove the blower adapter and tube from the blower (Fig. 26). 2 2. Check the liner for any excessive wear. Do not use your hands to check the liner or remove debris. 3. Replace the liner if any excessive wear is noticed. 4 Replacing the Blower Liner 1 1. Disengage the PTO and set the parking brake. 2.
Inspecting the Bagger 3 Inspect the bagger attachment after the first 8 hours of operation and 100 hours thereafter. 5 4 1. Disengage the PTO, set the parking brake, and chock or block the drive wheels. 2 1 2. Turn off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3 4 M–4226 3. Check the tube, blower assembly, and the bagger hood. Replace these parts if they are cracked or broken. Figure 43 1. Sail Area of Blade 2. Blade 3. Spring Disk 4.
8 6 4 2 3 5 1 10 7 m–6085 Figure 44 1. 2. 3. 4. 5. 6. Bolt Spacer Locknut Spring Spring installed Grass Deflector 7. L end of spring, place behind mounting bracket before installing bolt 8. J hook end of spring 9. Mounting bracket 10. Straight end—possible style of spring Storage 1. Clean the bagger attachment. Refer to Cleaning the Bagger on page 20. 2. Inspect the bagger attachment for damage. Refer to Inspecting the Bagger on page 20. 3. Make sure the bags are empty and thoroughly dry. 4.
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.
