Operator’s Manual
English (EN)
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. 78503
2
All Rights Reserved
Printed in the USA
2003 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
Contents
Page
Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 4. . . . . . . . . . . . . . . .
Setup 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before Installation 7. . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Mower for Existing Holes 7. . . . . . .
Removing the Mower 7. . . . . . . . . . . . . . . . . . . . . .
Preparing the Mower 8. . . . . . . . . . . . . . . . . . . . . .
Removing the Cutting Chamber Stiffeners 8. . . . . .
Installing the Front Tunnel Baffle 9. . . . . . . . . . . .
Installing the Rear Tunnel Baffle 10. . . . . . . . . . . . .
Installing the Center Rear Baffle 11. . . . . . . . . . . . .
Installing the Left Rear Baffle 12. . . . . . . . . . . . . . .
Installing the Right Rear Baffle 13. . . . . . . . . . . . . .
Removing the Existing Mower Pulley 14. . . . . . . . .
Installing the Pulley Assembly 14. . . . . . . . . . . . . . .
Installing the Belt Cover and Bagger Belt 14. . . . . .
Installing the Mounting Plates 15. . . . . . . . . . . . . . .
Installing the Mower and PTO Drive Belts 16. . . . .
Removing the Drive Wheels 17. . . . . . . . . . . . . . . .
Installing the Bagger Brackets 17. . . . . . . . . . . . . . .
Installing the Blower Assembly 19. . . . . . . . . . . . . .
Installing the Bagger Belt and Idler Spring 19. . . . .
Installing the Hood Assembly and Bags 21. . . . . . . .
Installing the Bagger Tube 23. . . . . . . . . . . . . . . . . .
Installing the Weights 24. . . . . . . . . . . . . . . . . . . . . .
Installing the Blades 25. . . . . . . . . . . . . . . . . . . . . . .
Using the Grass Deflector 25. . . . . . . . . . . . . . . . . .
Installing the Grass Deflector 26. . . . . . . . . . . . . . . .
Operation 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emptying the Grass Bags 27. . . . . . . . . . . . . . . . . . .
Clearing Obstructions From the Bagger System 27.
Removing the Bagger 28. . . . . . . . . . . . . . . . . . . . . .
Operating and Bagging Tips 29. . . . . . . . . . . . . . . . .
Maintenance 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Maintenance Schedule 30. . . . . . . . .
Cleaning the Hood Screen 30. . . . . . . . . . . . . . . . . .
Cleaning the Bagger 30. . . . . . . . . . . . . . . . . . . . . . .
Checking and Adjusting the Bagger Belt Tension 30
Checking and Adjusting the Blower Latch 32. . . . . .
Replacing the Blower Belt 33. . . . . . . . . . . . . . . . . .
Greasing the Blower 33. . . . . . . . . . . . . . . . . . . . . . .
Checking the Blower Liner 34. . . . . . . . . . . . . . . . .
Replacing the Blower Liner 34. . . . . . . . . . . . . . . . .
Inspecting the Bagger 35. . . . . . . . . . . . . . . . . . . . . .
Inspecting the Mower Blades and Baffles 35. . . . . .
Storage 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction
Read this manual carefully to learn how to operate and
maintain your product properly. The information in this
manual can help you and others avoid injury and product
damage. Although Toro designs and produces safe
products, you are responsible for operating the product
properly and safely.
Whenever you need service, genuine Toro parts, or
additional information, contact an Authorized Service
Dealer or Toro Customer Service and have the model and
serial numbers of your product ready. Figure 1 illustrates
the location of the model and serial numbers on the
product.
m–6231
1
Figure 1
1. Location of the model and serial numbers
Write the product model and serial numbers in the space
below:
Model No.
Serial No.
This manual identifies potential hazards and has special
safety messages that help you and others avoid personal
injury and even death. Danger, Warning, and Caution are
signal words used to identify the level of hazard. However,
regardless of the hazard, be extremely careful.
Danger signals an extreme hazard that will cause serious
injury or death if you do not follow the recommended
precautions.
3
Warning signals a hazard that may cause serious injury or
death if you do not follow the recommended precautions.
Caution signals a hazard that may cause minor or moderate
injury if you do not follow the recommended precautions.
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.
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.
• Slow down and use extra care on hillsides. Be sure to
travel in the recommended direction on hillsides. Turf
conditions can affect the machine’s stability. Use
extreme caution while operating near drop–offs.
• Keep all movement on slopes slow and gradual. Do not
make sudden changes in speed, directions or turning.
• The grass catcher can obstruct the view to the rear. Use
extra care when operating in reverse.
• Use care when loading or unloading the machine into a
trailer or truck
• Never operate with the discharge deflector raised or
removed and never altered, unless using a grass catcher
or mulching baffles.
• Keep hands and feet away from moving parts. Do not
make adjustments with the engine running.
• Stop on level ground, disengage drives, set the parking
brake, chock or block wheels, shut off engine before
leaving the operator’s position for any reason including
emptying the grass catcher or unclogging the chute.
• If you remove the grass catcher, be sure to install any
discharge deflector or guard that might have been
removed to install the grass catcher. Do not operate the
mower without either the entire grass catcher or the
grass deflector in place.
• Turn off the engine and wait for all moving parts to
stop before removing the grass catcher or
unclogging the chute.
• Do not use your hands to unclog the chute, blower or
bagger.
• Do not leave grass in grass catcher for extended periods
of time.
• Grass catcher components are subject to wear, damage
and deterioration, which could expose moving parts or
allow objects to be thrown. Frequently check
components and replace with manufacturer’s
recommended parts, when necessary.
4
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
79-0360
80-8040
88-8950
93-1122
1-653554
106-0871
98-4387
1. Warning—wear hearing protection.
5
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 This kit and bagger will require significant time to install the first time. A right angle drill is recommended for
installation.
Step Description Qty. Use
1
Tunnel baffle—front
Carriage bolt, 5/16 x 5/8 inch
Flange nut, 5/16 inch
1
4
4
Installing the front tunnel baffle
2
Tunnel baffle—rear
Carriage bolt, 5/16 x 5/8 inch
Flange nut, 5/16 inch
1
3
3
Installing the rear tunnel baffle
3
Center rear baffle
Button Head Socket Bolt, 5/16 x
3/4 inch
Flange nut, 5/16 inch
1
3
3
Installing the center rear baffle
4
Left rear baffle
Button Head Socket Bolt, 5/16 x
3/4 inch
Flange nut, 5/16 inch
1
3
3
Installing the left rear baffle
5
Right rear baffle
Button Head Socket Bolt, 5/16 x
3/4 inch
Carriage bolt, 5/16 x 5/8 inch
Flange nut, 5/16 inch
1
2
1
3
Installing the right rear baffle
6
Removing the mower existing pulley
assembly
7
Pulley assembly
Bagger Belt
Pulley cover
1
1
1
Installing the pulley assembly, belt and
cover
8
Mounting plate
Bolt, 3/8 x 1–1/4 inch
Flange nuts, 3/8 inch
2
4
4
Installing the mounting plate
9
No parts needed
Installing the mower and PTO drive
belts
10
No parts needed Removing the drive wheels
6
Step UseQty.Description
11
Bagger mounting bracket
Left side bagger bracket
Right side bagger bracket
Bolt, 3/8 x 1 inch
Flange nut, 3/8 inch
Belleville washer, 3/8 inch
1
1
1
10
10
8
Installing the bagger brackets
12
Blower assembly 1 Installing the blower assembly
13
Blower belt cover
Idler spring
1
1
Installing the bagger belt and idler
spring
14
Hood assembly
Bag
Clevis pin
Hairpin cotter
1
2
2
2
Installing the hood assembly and bags
15
Bagger tube
Clamp
Knob
Blower adapter
1
1
2
1
Installing the bagger tube
16
Caster weight
U–bolt
Nut, 1/2 inch
Lock washer, 1/2 inch
Plate
2
2
4
4
2
Installing the weights
7
Before Installation
Checking the Mower for
Existing Holes
Check for existing holes. Use any existing holes in the
mower that align the baffles in their correct positions.
Removing the Mower
1. Remove the PTO drive belt from the rear idler arm
(Figures 2 and 4).
1
2
M–4417
Figure 2
1. Center bolt, spring loaded
idler
2. Alignment hole
2. Remove the PTO drive belt from the center mower
pulley (Fig. 3 and 4).
4
3
2
m–6783
1
5
Figure 3
1. Center mower pulley
2. PTO Drive belt
3. Idler pulley
4. Mower belt
5. Right side pulley
m–4451
2
1
3
Figure 4
1. Center mower pulley
2. PTO Drive belt
3. Rear idler pulley
3. Pull on the idler pulley to release tension on the mower
belt and remove the belt from the right side pulley
(Fig. 3).
4. Raise the height of cut lever.
5. Place wood blocks at the corners of the mower and
lower the mower onto the wood blocks.
8
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.
6. Remove the four bolts at the bottom of the chains that
are attached to the mower (Fig. 5).
7. Remove the nuts and bolts holding the push arm pins
(Fig. 5).
Note: The gage wheels may need to be removed to allow
the push arm pins to be removed (Fig. 5).
8. Remove the push arm pins (Fig. 5).
9. Raise the height of cut lever and slide the mower out
from under the machine (Fig. 5).
1
4
7
m–6062
2
3
5
6
Figure 5
1. Mower
2. Chain
3. Chain Bolt
4. Push Arm
5. Push Arm Bolt
6. Push Arm Nut
7. Push Arm Pin
8. Gage wheel
9. Nut
Preparing the Mower
1. Tip the mower upside down and block up ends to ease
installation of components.
2. Thoroughly clean the mower. All debris must be
removed to ensure baffles will fit properly against the
mower.
3. Repair all bent or damaged areas of the mower and
replace any missing parts.
Contact with sharp blade can cause serious
personal injury.
• Wear gloves or wrap sharp edges of the blade
with a rag.
Warning
Removing the Cutting
Chamber Stiffeners
Note: This section is only for mowers with stiffeners
welded to the cutting chamber (Fig. 6).
1. Remove the cutting chamber stiffeners from the mower
(Fig. 6).
2. Grind the welds flat on rear part of the chamber. This
will allow the correct fit for the cutting chamber baffle.
2
m–6081
1
Figure 6
1. Cutting chamber 2. Cutting chamber stiffener
9
1
Step
Parts needed for this step:
• 1 Tunnel baffle—front
• 4 Carriage bolts, 5/16 x 5/8 inch
• 4 Flange nuts, 5/16 inch
Installing the Front Tunnel
Baffle
Note: Blades and spindles are not shown in the graphics for
clarity.
1. Remove the existing right front blowout baffle. Save the
baffle and hardware for use when the bagging baffles
are removed.
2. Place the front tunnel baffle against the front wall of the
discharge tunnel (Fig. 7).
3. Align the front baffle, flush with the outside of the
mounting bracket (Fig. 7).
3
1
2
m–6733
4
Figure 7
1. Front tunnel baffle
2. Flush edge with outside of
mounting bracket
3. Outside of mounting
bracket
4. Hole to drill
4. Clamp the baffle in place.
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).
1
2
2
34
3
m–6734
Figure 8
1. Front tunnel baffle
2. Carriage Bolt, 5/16 x
5/8 inch
3. Flange nut, 5/16 inch
4. Front tunnel wall
10
2
Step
Parts needed for this step:
• 1 Tunnel baffle—rear
• 3 Carriage bolt, 5/16 x 5/8 inch
• 3 Flange nut, 5/16 inch
Installing the Rear Tunnel
Baffle
1. Place the rear tunnel baffle against the rear wall of the
discharge tunnel (Fig. 9).
Note: The rear tunnel baffle must not extend past the
outside of the mounting bracket.
2. Align the rear tunnel baffle, flush with the outside of the
mounting bracket (Fig. 9).
3
1
2
m–6735
Figure 9
1. Rear tunnel baffle
2. Mounting bracket
3. Flush edge with outside of
mounting bracket
3. Clamp the baffle in place.
4. Using the baffle as a template, mark, center punch and
drill 1/8 inch pilot holes at the 3 locations (Fig. 10).
5. Remove the clamp.
6. Drill 11/32 inch dia. holes through the pilot holes
(Fig. 10).
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.
1
2
3
4
5
6
4
4
m–6736
Figure 10
1. Rear tunnel baffle
2. Carriage Bolt, 5/16 x
5/8 inch
3. Flange nut, 5/16 inch
4. Hole to drill
5. Tunnel rear wall
6. Mounting bracket
11
3
Step
Parts needed for this step:
• 1 Center cutting chamber baffle
• 3 Button Head Socket Bolts, 5/16 x 3/4 inch
• 3 Flange nuts, 5/16 inch
Installing the Center Rear
Baffle
A right angle drill is recommended to install this baffle.
1. Place the center rear baffle behind the center cutting
blade chamber (Fig. 13).
2. Align the center rear baffle so the baffle ends are
touching the back mower flange (Fig. 11).
Note: The center baffle ends will rest on the mower flange
(Fig. 11).
3. Align the middle part, of the center rear baffle, 9/16 to
11/16 inch from the blade tip. Refer to Figures 11
and 12 for positions to measure.
1
2
m–6256
3
4
5
Figure 11
1. Mower flange
2. Center baffle
3. Center baffle end
touching mower
4. Blade clearance,
9/16 to 11/16 inch
(14 mm to 17 mm)
5. Center blade
Important Make sure the baffle flange is
9/16 to 11/16 inch (14 mm to 17 mm) from the mower
blade (Figures 11 and 12).
m–62291
4 32
Figure 12
1. Baffle flange
2. Blade
3. Spindle
4. Blade clearance,
9/16 to 11/16 inch
(14 mm to 17 mm)
4. Clamp the center baffle tightly against the cutting
chamber (Fig. 13).
5. Using the baffle as a template, mark, center punch and
drill 1/8 inch pilot holes at the 3 locations (Fig. 13).
6. Drill 11/32 inch dia. holes through the pilot holes
(Fig. 13).
7. Install the center baffle with 3 button head socket bolts
(5/16 x 3/4 inch) and 3 flange nuts (5/16 inch) (Fig. 13).
Important Make sure the bolt heads are installed on the
inside of the cutting chamber (Fig. 13).
4
1
5
2
53
2 m–6737
Figure 13
1. Center Baffle
2. Hole to drill
3. Center cutting blade
chamber
4. Flange nuts, 5/16 inch
5. Button head socket bolt,
5/16 x 3/4 inch
12
4
Step
Parts needed for this step:
• 1 Left rear baffle
• 3 Button Head Socket Bolts, 5/16 x 3/4 inch
• 3 Flange nuts, 5/16 inch
Installing the Left Rear Baffle
1. Place the left rear baffle behind the left cutting chamber
(Fig. 14). The tabs will mount on the outside of the
mower.
2. Align the left rear baffle tight against and flush with the
bottom of the center baffle and against the mower
flange (Figures 14 and 15).
Note: If the holes for the left rear baffle are existing, there
will be a a gap between it and the center rear baffle
(Fig. 14).
3. Clamp the baffle in place.
3
1
2
4
5
m–6738
Figure 14
1. Center Baffle
2. Left rear baffle against
mower flange
3. Flush with bottom of
center baffle
4. Left cutting chamber
5. Tab
4. Using the baffle as a template, mark, center punch and
drill 1/8 inch pilot holes at the 3 locations (Fig. 15).
5. Drill 11/32 inch dia. holes through the pilot holes
(Fig. 15).
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).
Important Make sure the bolt heads are installed on the
inside of the cutting chamber. See figure 15.
3
1
4
2
5
6
5
7
8
m–6739
Figure 15
1. Left rear baffle
2. Left side of mower
3. Button head socket bolt,
5/16 x 3/4 inch
4. Flange nut, 5/16 inch
5. Hole to drill
6. Rear center baffle
7. Mower flange
8. Tab
13
5
Step
Parts needed for this step:
• 1 Right rear baffle
• 2 Button Head Socket Bolts, 5/16 x 3/4 inch
• 1 Carriage bolts, 5/16 x 5/8 inch
• 3 Flange nuts, 5/16 inch
Installing the Right Rear Baffle
1. Place the right rear baffle behind the right cutting
chamber (Fig. 16). The tabs will mount on the outside
of the mower.
2. Align the right rear baffle tight against and flush with
the bottom of the center baffle and against the mower
flange (Fig. 16 and 17).
3
2
4
1
m–6744
Figure 16
1. Center Baffle
2. Right rear baffle against
mower flange
3. Flush with bottom of
center baffle
4. Right cutting chamber
3. Clamp the baffle in place.
4. Using the baffle as a template, mark, center punch and
drill 1/8 inch pilot holes at the 2 locations (Fig. 17).
5. Drill 11/32 inch dia. holes through the pilot holes
(Fig. 17).
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.
8. Install the right rear baffle to the rear tunnel baffle with
a carriage bolt (5/16 x 5/8 inch) and a flange nut
(5/16 inch) (Fig. 17).
15
2
5
4
3
5
4
6
7
m–6745
Figure 17
1. Right rear baffle
2. Right side of mower
3. Carriage Bolt, 5/16 x
5/8 inch
4. Button head socket bolt,
5/16 x 3/4 inch
5. Flange nut, 5/16 inch
6. Holes to drill
7. Mower flange
9. Rotate the blades and check if the blades make contact
with the baffles.
10.If contact is made, do not use the mower. Adjust and
make sure all baffles are installed properly.
14
6
Step
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.
2. Remove the right belt cover from the mower and
discard.
3. Remove the nut and washer on top of the spindle
(Fig. 18). Save the nut and washer.
4. Remove the existing pulley assembly.
7
Step
Parts needed for this step:
• 1 Pulley assembly
• 1 Bagger Belt
• 1 Pulley cover
Installing the Pulley Assembly
1. Install new pulley assembly onto the spindle. Install it
so the large pulley is on the bottom (Fig. 18).
2. Install the washer and nut (Fig. 18).
Important Tighten the nut to 115 ft–lb ± 15 ft–lb
torque.
3. Grease the spindle to fill bearings with grease.
5
1
2
3
4
7
6
m–6753
Figure 18
1. Nut
2. Washer
3. Pulley Assembly
4. Blade spindle
5. Mower
6. Lower pulley
7. Upper pulley
Installing the Belt Cover and
Bagger Belt
Refer to Installing The Bagger Belt and Idler Spring on
page 19.
15
8
Step
Parts needed for this step:
• 2 Mounting plates
• 1 Template
• 4 Bolts, 3/8 x 1–1/4 inch
• 4 Flange nuts, 3/8 inch
Installing the Mounting Plates
Drilling the Holes into the Mounting
Bracket
This kit contains a metal template for locating the mounting
bracket holes to drill.
1. Remove the grass deflector from the mower (Fig. 44).
2. Position the template onto the the mounting bracket and
align with the top and sides of the mounting bracket.
(Fig. 19).
3. Clamp the template to the mounting bracket (Fig. 19).
4. Mark and center punch the 4 holes and remove the
template (Fig. 19).
5. Drill 1/8 inch pilot holes at the 4 marked locations and
then drill 7/16 inch or 1/2 inch diameter holes.
6. File the metal burrs from the drilled holes.
m–6752
1
2
3
3
Figure 19
1. Template
2. Mounting bracket
3. Mark and center punch
holes
Installing the Mounting Plates
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
4
5
3
2
1
m–6751
Figure 20
1. Mounting plate
2. Bolt, 3/8 x 1–1/4 inch
3. Flange nut, 3/8 inch
4. Mounting bracket
5. Drill 7/16 inch holes
2. When the bagger is to be used for dedicated bagging,
leave the grass deflector off the machine.
Important Remember to install the grass deflector
when changing to side discharge mode.
3. When the mower is switched between bagging and side
discharge frequently, leave the grass deflector on the
machine. The grass deflector will rest against the
blower belt cover.
16
9
Step
No parts needed for this step.
Installing the Mower and PTO
Drive Belts
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).
4
3
2
m–6783
1
5
Figure 21
1. Center mower pulley
2. PTO Drive belt
3. Idler pulley
4. Mower belt
5. Right side pulley
Replacing the PTO Drive Belt
1. Install the drive belt over the clutch, around the rear
idler pulley, installed into the idler arm assembly,
installed into the fixed idler pulley assembly and onto
the top center pulley (Figures 21 and 22).
Important Check the amount of twist in belt between
pulleys. Make sure it is only what is specified in figure 22.
1
4
m–4451
M–4373
3
2
5
6
6
6
Figure 22
1. Clutch
2. Clutch retaining strap
3. Clutch terminal
4. PTO belt
5. Machine frame
6. 1/4 inch belt twist
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).
Note: Check the position of center bolt in a low
height–of–cut. The center bolt must be at or below the top
alignment hole. Check the position of the center bolt in a
high height–of–cut. The center bolt must be at or above the
lower adjustment hole (Fig 23).
1
2
M–4417
Figure 23
1. Center bolt, spring loaded
idler
2. Alignment hole
3. If adjustment is required, loosen the fixed idler on right
support plate and move up or down in adjustment slot.
To relieve belt tension lift up on spring loaded idler.
17
m–3746
12
Figure 24
1. Fixed Idler 2. Adjustment slot
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.
10
Step
No parts needed for this step.
Removing the Drive Wheels
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 lugs or nuts.
2. Raise the rear of the machine and support with jack
stands.
3. Remove the drive wheels.
11
Step
Parts needed for this step:
• 1 Left side bagger bracket
• 1 Right side bagger bracket
• 1 Bagger mounting bracket
• 10 Bolts, 3/8 x 1 inch
• 10 Flange nuts, 3/8 inch
• 8 Belleville washers, 3/8 inch
Installing the Bagger Brackets
Installing the Left and Right Side
Brackets
Important Do not tighten any bolts until both side
brackets and bagger mounting bracket are fit loose on the
machine.
Refer to Tightening the Mounting Bolts, on page 18, for the
correct procedure to tighten the bolts.
1. Using the existing holes, install the side bagger bracket
to the side of the machine frame with 2 bolts
(3/8 x 1 inch), 2 flat washers (3/8 inch) and 2 flange
nuts (3/8 in.) (Fig. 25).
2. Repeat the previous step for the opposite side.
18
1
3
m–6742
6
2
5
4
1
2
Figure 25
1. Bagger bracket—left side
shown
2. Bolt, 3/8 x 1 inch
3. Flange nut, 3/8 inch
4. Machine side frame
5. Existing hole
6. Belleville washer, 3/8 inch
Installing the Bagger Mounting Bracket
Important Do not tighten any bolts until both side
brackets and bagger mounting bracket are fit loose on the
machine.
Important Make sure the bagger mounting bracket is
installed in the position shown in Figure 26.
1. Remove the existing two bolts in the bottom of the rear
frame (Fig. 26).
2. Install the bagger mounting bracket to the left and right
side bagger brackets with 4 bolts (3/8 x 1 inch),
4 Belleville washers (3/8 inch) and 4 flange nuts
(3/8 in.) (Fig. 26).
3. Install the bagger mounting bracket to the rear frame of
the machine with 2 bolts (3/8 x 1 inch) and 2 flange
nuts (3/8 in.) (Fig. 26).
6
2
2
1
2
m–6743
4
3
4
3
5
6
Figure 26
1. Bagger mounting bracket
2. Bolt, 3/8 x 1 inch
3. Flange nut, 3/8 inch
4. Belleville washer, 3/8 inch
5. Rear frame
6. Existing bolts located
here
Tightening all the Mounting Bolts
The following steps are the correct sequence to tighten the
side brackets and the bagger mounting bracket.
All mounting bolts need to be torqued to 35 ft–lb
(48 Nm).
1. Tighten the bagger mounting bracket to the rear frame
first (Fig. 26).
2. Tighten the bagger mounting bracket to the side
brackets (Fig. 26).
3. Tighten the side brackets to the side of the mower
(Fig. 25).
4. Install the drive wheels and torque to 95 ft-lb
(128 NM).
5. Lower the machine onto the drive wheels.
19
12
Step
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.
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.
3. Raise the grass deflector.
4. Slide the blower assembly peg into the hole on the
mounting plate (Fig. 27).
3
2
4
1
5
m–6748
Figure 27
1. Mower
2. Blower assembly
3. Blower assembly peg
4. Mounting plate hole
5. Mounting plate
5. Close the blower assembly. (Fig. 30).
6. Check if the latch fully engages the front latch peg.
Refer to Checking and Adjusting the Blower Latch on
page 32.
Note: There needs to be a little or no gap between the
blower assembly and the mounting plate.
13
Step
Parts needed for this step:
• 1 Blower belt cover
• 1 Idler spring
• 1 Bagger belt
Installing the Bagger Belt and
Idler Spring
Important The idler spring and bagger belt need to be
installed together.
This will create slight tension on both the spring and belt
while installing them.
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. Slide the spring into the blower eyebolt (Fig. 28).
4. Install the spring into the idler arm eyebolt (Fig. 28).
3
2
4
1
5
m–6276
Figure 28
1. Idler spring
2. Blower assembly
3. Idler arm eyebolt
4. Blower eyebolt
5. Idler arm
5. Push down on the front latch (colored red) and open the
blower assembly (Fig. 29).
20
6. Route the bagger belt around the top pulley of the
mower pulley assembly (Fig. 29).
7. Feed the belt between the idler pulleys (Fig. 29).
8. Route the bagger belt around the spring–loaded idler
pulley (Fig. 29). The backside of belt will be touching
the pulley.
9. Route the bagger belt around the fixed idler pulley
(Fig. 29).
10.Route the bagger belt around the blower pulley
(Fig. 29).
2
3
1
4
6
5
7
m–6732
Figure 29
1. Blower pulley
2. Mower
3. Blower assembly
4. 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)
11. Close the blower assembly and ensure the blower front
latch engages onto the front peg (Fig. 30).
m–6732
2
1
Figure 30
1. Blower front latch (Red) 2. Front peg
Important Make sure to inspect the belt and check the
spring length after the first 8 hours of use.
12.Adjust the bagger belt tension. Refer to Checking and
Adjusting the Bagger Belt Tension on page 30.
13.Install the belt cover over the pulley assembly and
secure the 3 cover latches into the blower (Fig. 31).
m–6236
3 2
1
Figure 31
1. Blower assembly
2. Blower belt cover
3. Latch
14.Install the new belt cover over the mower pulley
assembly and secure the latch (Fig. 32).
1
2
m–6757
Figure 32
1. Belt cover 2. Latch
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