Form No. 3355-144 Rev A 48 and 52in Twin Bagger For Z400 Series Z Master Mowers Model No. 78531—Serial No. 260000001 and Up Model No. 78532—Serial No. 260000001 and Up Register your product at www.Toro.
Introduction Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage. You are responsible for operating the product properly and safely. You may contact Toro directly at www.Toro.com for product and accessory information, help finding a dealer, or to register your product.
4 Installing the Hood Assembly and Bags............................................... 9 5 Routing the Bagger Belt into the Blower Assembly...................................... 11 6 Installing the Blower Assembly .................... 11 7 Adjusting the Flow Baffle ............................ 13 8 Installing the Discharge Tubes ..................... 14 9 Installing the Belt Cover.............................. 17 10 Installing the Weight for a 48 inch Bagger..........................................
Safety • Never operate with the discharge deflector raised, removed or altered, unless using a grass catcher. The following list contains safety information specific to Toro products and other safety information you must know. • Keep hands and feet away from moving parts. Do not make adjustments with the engine running. • Become familiar with the safe operation of the equipment, with the operator controls, and safety signs.
103-3507 106-3339 112-2318 5
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Step 1 Qty. Description Use No parts required – Prepare the mower. Bagger bracket Bolt (5/16 x 1 inch), Flange nut (5/16 inch) Bagger bracket Bolt (5/16 x 1 inch), Flange nut (5/16 inch) Hood assembly Bags Clevis pin Hairpin cotter pin 1 8 8 1 8 8 1 2 2 2 Install the bagger bracket (Z400 Mowers with 48 inch mower decks).
Step 1 Preparing the Mower No Parts Required Procedure Perform the following procedure to prepare the mower for attaching the blower and finishing kit. 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Repair all bent or damaged areas of mower deck and replace any missing parts. 4.
Figure 8 1. Correct position 3. Incorrect position 6. Install the bagger bracket and heat shield to the rear of the engine straps and rear bumper with 8 new bolts (5/16 x 1 inch) and 8 new flange nuts (5/16 inch) (Figure 9). Figure 6 1. Heat shield notch 2. Back of bagger 2. Bottom of heat shield 7. Install the bagger bracket and heat shield to the side of the engine straps, tailpipe guard and rear bumper with 4 bolts, 4 washers and 4 flange nuts, previously removed (Figure 9). 5.
Step 3 Installing the Bagger Bracket (Z400 Mowers with 52 inch Mower Decks) Parts needed for this step: 1 8 8 Bagger bracket Bolt (5/16 x 1 inch), Flange nut (5/16 inch) Figure 11 1. Procedure Correct position 2. Incorrect position 2. Install the bagger bracket and weight to the engine straps, tailpipe guard, and rear bumper with the 8 existing bolts and nuts previously removed (Figure 12). Note: Use these instructions if machine is equipped with a rear weight. 1.
Step 4 Installing the Hood Assembly and Bags Parts needed for this step: 1 2 2 2 Figure 14 Hood assembly Bags Clevis pin Hairpin cotter pin 1. Hood assembly 2. Bagger mounting bracket 3. 4. Hairpin cotter pin Clevis pin 3. Install the bag tab into the notch in the hood assembly. Do this for all bags (Figure 15). Procedure 1. Install the hood assembly into the bagger mounting bracket (Figure 13). Note: The bags will rest on the bagger frame. Figure 15 1. Hood assembly 2. Bag 3. Bag tab 4. 5.
Step 5 Routing the Bagger Belt into the Blower Assembly Parts needed for this step: 1 Bagger belt (from Blower and Drive Kit) Procedure 1. Loosen the belt guide bolt (Figure 18). 2. Install the belt around the blower pulley (Figure 18). Figure 16 1. Hood 2. Bag 3. 4. Bagger latch Latch hook 3. Install the belt between the fixed idler pulley and the belt guide bolt. 5. Position the bagger latch under the latch hook (Figure 17). 4. Install the belt onto the spring loaded idler pulley (Figure 18). 6.
Step 6 Installing the Blower Assembly Parts needed for this step: 1 1 Blower assembly (from Blower and Drive Kit) Spring (from Blower and Drive Kit) Figure 19 Procedure An uncovered discharge opening could allow the lawn mower to throw objects in the operator’s or bystander’s direction and result in serious injury. Also, contact with the blade could occur. 1. Bolt 2. Spacer 3. Locknut 5. 6. 7. 4. Spring 8.
3. Close the blower assembly to see if the latch is adjusted correctly. Loosen or tighten the bolt so the latch firmly holds the blower assembly against the mower deck , but can be released by hand (Figure 21). Figure 23 1. 2. Mower deck pulley Spring loaded Idler pulley 3. Blower assembly Figure 21 1. Latch 2. Bolt 3. Step Blower assembly 7 4. Install the spring as shown in Figure 22. Adjusting the Flow Bafe No Parts Required Procedure 1.
4. Remove the bags from the hood assembly. 5. Install the upper tube into the bagger opening and pull it back out so the rubber seal is protruding out (Figure 25). Figure 24 1. Cam lock 3. 2. Lever 4. Rotate cam to increase or decrease locking pressure Slot Figure 25 1. Upper tube 2. Bagger opening 3. Bagger hood Step 8 6. With the hood in the down position and the right-hand bag removed, measure the distance the tube is inside the hood.
Figure 26 1. Hood plate 4. 2. Upper tube 5. 3. Hood in the down position with the right-hand bag removed 3/4 inch (19 mm) Edge of tube Figure 27 7. Once the 3/4 inch (19 mm) measurement has been achieved, mark the upper tube on the out side at the point where the rubber seal protrudes out. This is marked to ensure the correct position for the upper tube when drilling the holes and connecting the upper and lower tubes (Figure 27). 1. 2. Upper tube 3. Rubber seal protruding out 4.
9. Slide the lower tube onto the boot and latch them together (Figure 29). Note: There is a latch on the top and bottom of the blower housing. Figure 30 1. Bagger hood 4. 2. Mark at rubber seal 5. 3. Drill 7/32 inch diameter 6. holes here (use upper tube as a template) Upper tube Lower tube Blower assembly 12. Remove the lower tube from the blower. 13. Join the upper and lower tubes with 3 bolts (#10 x 3/4 inches), 3 flat washers (7/32 inch), and 3 locknuts (#10) (Figure 31). Figure 29 1.
Figure 32 1. 2. 3. 4. Figure 31 1. Lower tube 2. Upper tube 3. Flat washer, (7/32 inch) 4. 5. Locknut, (#10) Bolt, (#10 x 3/4 inches) Belt cover Blower assembly Pulley assembly Hole for latch 5. Latch 6. Belt cover notch 7. Belt cover support Step 10 14. Install the lower tube onto the blower housing and secure it with the latches (Figure 29). 15. Install the bags onto the bagger.
1. Install 2 bolts (3/8 x 2 inches) and 2 washers (3/8 inch) to the frame under the foot rest (Figure 33). The bagger adds a lot of weight to the rear of the machine and may cause an unstable condition which could result in a loss of control. 2. Install the weight, with the decal facing the front, to the bolts with 2 washers (3/8 inch) and locknut (3/8 inch) under the frame (Figure 33). 1. Install 2 bolts (3/8 x 3 inches) and 2 washers (3/8 inch) to the frame under the foot rest (Figure 34). 2.
Step The measurement should be 2-3/4 inch (70 mm) between washers (Figure 35). 13 Checking the Tire Pressure No Parts Required Procedure Note: Increase the tire pressure due to the additional weight. Figure 35 1. Brake lever 2. Spring (2-3/4 inches/70 mm) 3. Adjusting nuts 4. Collar on brake rod 5. 6. 3/16–1/4 inch (5–7 mm) Jam nut and yoke 7. Trunnion roller Check and increase the air pressure in the front caster wheels and rear tires (Figure 36).
Operation Without the grass deflector, bagger tubes or complete bagger assembly mounted in place, you and others are exposed to blade contact and thrown debris. Contact with the rotating mower blade(s) and thrown debris will cause injury or death. Note: Determine the left and right sides of the machine from the normal operating position. Important: Set the parking brake when leaving the machine unattended, even if just for a few minutes.
Figure 37 Figure 38 1. Emptying the Grass Bags Bag 2. Bottom handle 6. Repeat for the other bag. 7. Install the bag tab into the notch in the bagger support frame. Do this for both bags. 8. Lower the bagger hood over the bags. 9. Latch the bagger hood. Grass bags are heavy when full. Be careful when lifting or handling a grass bag that is full. 1. Disengage the PTO, set the parking brake, and chock or block the tires if on a slope. 2. Unlatch the bagger latch. 3. Open the bagger hood.
4. Unlatch the lower tube. 10. If you are changing to side discharge mode, ensure the grass deflector is installed and can be lowered into working position. 11. Remove the hood and bag assembly. 5. Remove the tubes from the bagger. 6. Using a stick or similar object, not your hands, to remove and clear the obstruction from the tube assembly. Using the Grass Deector Note: In most cases, the debris can be shaken out of the tubes. 7.
Bagging Long Grass sharply in confined places you may damage the attachment or other property. If the grass is ever allowed to grow longer than normal, or if it contains a high degree of moisture, raise the cutting height higher than usual and cut and bag the grass at this setting. Then cut and bag the grass again using the lower, normal setting. Trimming Always trim with the left side of the mower. Do not trim with the right side of the mower because you could damage the bagging tubes.
while loading and going over a curb. If a curb is 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 Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the rst 8 operating hours • Inspect the bagger belt. • Inspect the bagger. Before each use or daily • Clean the hood screen. • Clean the bagger. Every 25 hours • Inspect the bagger belt. Every 50 hours • Grease the idler arm. Every 100 hours • Inspect the bagger. Cleaning the Hood Screen Replacing the Bagger Belt The screens need to be cleaned before each use.
Figure 41 1. Latch 2. Bolt Figure 39 1. 2. 3. 4. Idler pulley Mower deck pulley Spring Peg 5. 6. 7. 8. 3. Blower assembly Greasing the Idler Arm Belt Belt guide bolt Fixed idler pulley Blower pulley Grease the bagger belt idler arm (Figure 42) every 50 hours. 8. Install the spring as shown in Figure 40. Figure 42 Figure 40 1. Spring loaded idler pulley 2. Short hook end 3. Long hook end Inspecting the Bagger 9. Install the belt onto the spring loaded idler pulley (Figure 39).
3. Check the upper tube, lower tube, bagger hood, and the blower assembly. Replace these parts if they are cracked or broken. 2. Remove the damaged or worn grass deflector. 3. Place the spacer and spring onto the grass deflector. Place the L end of the spring behind the deck edge. 4. Check the bags, bagger frame, and screen. Replace any parts that are cracked or broken. Note: Make sure the L end of the spring is installed behind the deck edge before installing the bolt as shown in Figure 43 5.
Storage 1. Clean the bagger attachment. Refer to Cleaning the Bagger. 2. Inspect the bagger attachment for damage. Refer to Inspecting the Bagger. 3. Make sure the bags are empty and thoroughly dry. 4. Check the belt for wear or cracks. 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.
Troubleshooting Problem Possible Cause Corrective Action Abnormal vibration. 1. Cutting blade(s) is/are bent or unbalanced. 2. Blade mounting bolt is loose. 3. Loose blower pulley or pulley assembly. 4. Worn bagger belt. 5. Blower fan blade(s) is/are bent or unbalanced. 1. Install new cutting blade(s). 2. Tighten the blade mounting bolt. 3. Tighten the appropriate pulley. 4. Replace belt. 5. Contact an Authorized Service Dealer. Reduced bagging performance. 1. Low engine speed. 2. 3. 4. 5.
Problem Blower impeller does not spin freely. Possible Cause 1. Plugged blower. 2. Impeller not aligned. 30 Corrective Action 1. Remove debris, leaves or grass clippings from the blower impeller. 2. Contact an Authorized Service Dealer.
The Toro Total Coverage Guarantee A Limited Warranty Landscape Contractor Equipment (LCE) Conditions and Products Covered Owner Responsibilities The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair the listed Toro product if defective in materials or workmanship.