Form No. 3359-396 Rev B 48in and 52in DFS E-Z Vac Bagger Z400 Series Z Master Mowers Model No. 78541—Serial No. 280000001 and Up Model No. 78542—Serial No. 280000001 and Up Register at www.Toro.com.
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. Figure 2 Bagger Serial Number 1.
Safety 7 Adjusting the Flow Baffle (if equipped)............. 11 8 Installing the Discharge Tubes.......................... 12 9 Installing the Belt Cover................................... 15 10 Installing the Weights for a 48 inch Bagger............................................................ 15 11 Installing the Weight for a 52 inch Bagger............................................................ 16 12 Adjusting the Parking Brake ........................... 17 13 Checking the Tire Pressure........
Frequently check components and replace with manufacturer’s recommended parts, when necessary. Safety and Instructional 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.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 1 Description Use Qty.
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. Figure 4 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 1. Full heat shield 2. Engine straps 3. Repair all bent or damaged areas of mower deck and replace any missing parts. 3.
Figure 8 1. Correct 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. Incorrect position 3. 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.
3 Installing the Bagger Bracket (Z400 Mowers with Rear Weight) Parts needed for this procedure: 1 Bagger bracket 8 Bolt (5/16 x 1 inch), 8 Flange nut (5/16 inch) Figure 11 1. Correct position Procedure 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.
4 Installing the Hood Assembly Parts needed for this procedure: 1 Hood assembly 1 Knob 1 Carriage bolt 2 Clevis pin 2 Hairpin cotter Procedure 1. Pivot the handle out into the handle bracket and secure it with a carriage bolt and knob (Figure 13). Figure 14 1. Hood assembly 2. Bagger mounting bracket Figure 13 1. Knob 2. Handle bracket 3. Carriage bolt 2. Install the hood assembly into the bagger mounting bracket (Figure 14). 3.
5 6 Routing the Blower Belt into the Blower Assembly Installing the Blower Assembly Parts needed for this procedure: Parts needed for this procedure: 1 Blower belt (from Blower and Drive Kit) 1 Blower assembly (from Blower and Drive Kit) 1 Spring (from Blower and Drive Kit) Procedure Procedure 1. Loosen the belt guide bolt (Figure 15). 2. Install the belt around the blower pulley (Figure 15).
2. Slide the blower assembly peg into the pivot hole (Figure 17). Figure 19 1. Spring loaded idler pulley 2. Short hook end 3. Long hook end 5. Pull the spring loaded idler pulley back and route the belt around the mower deck pulley. Ensure the belt is routed around the blower pulleys correctly (Figure 20). Figure 17 48 inch Mower Deck 1. Blower assembly 2. Mower deck (48 inch mower deck shown) 3. Pivot hole 4. Blower assembly peg 3. Close the blower assembly to see if the latch is adjusted correctly.
7 8 Adjusting the Flow Baffle (if equipped) Installing the Discharge Tubes Parts needed for this procedure: No Parts Required Procedure 1. To adjust the cam lock, swing the lever up to loosen the cam lock (Figure 21). 2. Align the flow baffle and cam lock in the slot to the edge of the blower assembly. 1 Upper tube 1 Lower tube 3 Bolt, (#10 x 3/4 inches) 3 Locknut, (#10) 3 Washer, (7/32 inch) Procedure 3. Swing the lever back over to tighten the baffle and cam lock (Figure 21).
Measure from the hood plate to the edge of the tube as shown in Figure 23. This distance needs to be 3/4 inch (19 mm). Figure 23 1. Hood plate 2. Upper tube 3. Hood 4. 3/4 inch (19 mm) 5. Edge of tube Figure 24 1. Upper tube 3. Bagger hood 2. Rubber seal protruding out 4. Mark here 6. 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.
Note: There is a latch on the top and bottom of the blower housing. Figure 27 1. Collector hood 2. Mark at rubber seal 3. Drill 7/32 inch diameter holes here (use upper tube as a template) 4. Upper tube 5. Lower tube 6. Blower assembly Figure 26 1. Blower assembly 2. Lower tube 11. Remove the tubes. 3. Latch 12. 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 28). 9.
9 Installing the Belt Cover No Parts Required Procedure 1. Lower the mower deck to the lowest height-of-cut position. 2. Install the new belt cover so the notches on both sides go over the belt cover supports and secure the latch (Figure 29). Figure 28 1. Lower tube 2. Upper tube 3. Flat washer, (7/32 inch) 4. Locknut, (#10) 5. Bolt, (#10 x 3/4 inches) 13. Install the tubes onto the blower housing and bagger and secure it with the latches (Figure 26). Figure 29 1. 2. 3. 4.
10 11 Installing the Weights for a 48 inch Bagger Installing the Weight for a 52 inch Bagger Parts needed for this procedure: Parts needed for this procedure: 2 Weight 1 Weight 2 Bolt, (3/8 x 3 inches) 2 Bolt, (3/8 x 2 inches) 2 Locknut, (3/8 inch) 2 Locknut, (3/8 inch) 4 Washer, (3/8 inch) 4 Washer, (3/8 inch) Procedure Procedure To comply with ANSI/OPEI B71.4-2004 Standard, front weight must be added to the machine. To comply with ANSI/OPEI B71.
12 13 Adjusting the Parking Brake Checking the Tire Pressure No Parts Required No Parts Required Procedure Procedure Check the parking brake for proper adjustment. Note: Increase the tire pressure due to the additional weight. 1. Disengage brake lever (lever down). Check and increase the air pressure in the front caster wheels and rear tires (Figure 33). 2. Measure the length of the spring. The measurement should be 2-3/4 inch (70 mm) between washers (Figure 32).
Operation Children or bystanders may be injured if they move or attempt to operate the tractor while it is unattended. 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. Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes.
Note: In most cases, the debris can be shaken out of the tubes. 7. If the blower assembly is plugged, unlatch the bagger blower assembly, remove the belt, and swing it open. 8. Using a stick or similar object, not your hands, to remove and clear the obstruction from the blower assembly. 9. After you remove the obstruction, install the complete collection system and resume operation. Removing the Collection System Figure 35 Components around engine will be hot if the machine has been running.
Cutting Height Using the Grass Deflector For optimum bagging performance, set the deck height-of-cut to remove no more that 2 to 3 inches (51 to 76 mm) or 1/3 of the grass height, which ever is less. Cutting off more than this will reduce the capacity of the vacuum system. Without the grass deflector, discharge cover, or complete grass catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris.
then lower the mower to your normal cutting height and repeat the bagging process. Bagging Wet Grass If possible, always try to cut grass when it is dry. Wet grass can cause plugging. Reducing Plugging To avoid plugging the bagging system, reduce ground speed and mow the grass at a high height-of-cut, then lower the mower to your normal cutting height and repeat the bagging process. Signs of Plugging As you are bagging, a small amount of grass clippings normally blow out the front of the mower.
Maintenance Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 8 hours • Inspect the blower belt. • Inspect the collection system. Before each use or daily • Clean the hood screen. • Clean the bagger. Every 25 hours • Inspect the blower belt. Every 50 hours • Grease the idler arm. Every 100 hours • Inspect the collection system. Cleaning the Hood Screen Replacing the Blower Belt Service Interval: Before each use or daily 1.
Figure 38 1. Latch 2. Bolt 3. Blower assembly Figure 36 1. 2. 3. 4. Idler pulley Mower deck pulley Spring Peg 5. 6. 7. 8. Greasing the Idler Arm Belt Belt guide bolt Fixed idler pulley Blower pulley Service Interval: Every 50 hours Grease the blower belt idler arm (Figure 39). 8. Install the spring as shown in Figure 37. Figure 39 Figure 37 1. Spring loaded idler pulley 2. Short hook end 3. Long hook end Inspecting the Collection System 9.
3. Check the upper tube, lower tube, bagger hood, and the blower assembly. Replace these parts if they are cracked or broken. 4. Check the bagger frame. Replace any parts that are cracked or broken. 5. Tighten all nuts bolts and screws. Adjusting the Arm Position The left and right bellcrank arms need to be positioned equally from the upper frame tube for proper use. 1. Disengage the PTO, move the motion control levers to the neutral locked position, and set the parking brake. Figure 41 2.
Figure 44 1. Lower lip of the molded hood 2. Measurement between an 1/8 inch (3.2 mm) and 3/8 inch (9.6 mm) Figure 42 1. Door 2. Hinge link 3. Nut 3. Upper tube of the door frame 4. If adjustment is need, the hinge stops need to be adjusted. Adjust the hinge stops on both sides so the distance between the upper tube of the door frame and the lower lip of the molded hood is between an 1/8 inch (3.2 mm) and 3/8 inch (9.6 mm). Adjusting the Door Opening Perform this after adjusting the door closing. 1.
Inspecting the Mower Blades Important: The grass deflector must be able to lower down into position. Lift the deflector up to test that it lowers into the full down position. 1. Inspect the mower blades regularly and whenever a blade strikes a foreign object. 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. 2. Inspect the bagger attachment for damage. Refer to Inspecting the Bagger. 3. Make sure the bagger is 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 Abnormal vibration. Reduced bagging performance. Blower and tubes plug too frequently. Possible Cause 1. Cutting blade(s) is/are bent or unbalanced. 1. Install new cutting blade(s). 2. 3. 4. 5. 2. 3. 4. 5. Blade mounting bolt is loose. Loose blower pulley or pulley assembly. Worn blower belt. Blower fan blade(s) is/are bent or unbalanced. 1. Always operate the bagger at full throttle. 2. Plugged screen in bagger hood. 3. Loose blower belt. 4. A plugged tube or blower. 5.
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The Toro Total Coverage Guarantee Landscape Contractor Equipment (LCE) A Limited Warranty Conditions and Products Covered Owner Responsibilities The Toro® Company and its afliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair the listed Toro Products if defective in materials or workmanship.
