Toro Bagger Kit, Z Master 4000 Series Riding Mower User manual

FormNo.3443-711RevA

BaggerKit

ZMaster

®

4000SeriesRidingMower

ModelNo.78463—SerialNo.400000000andUp

Registeratwww.Toro.com.

OriginalInstructions(EN)

*3443-711*

WARNING

CALIFORNIA

Proposition65Warning

UseofthisproductmaycauseexposuretochemicalsknowntotheStateofCalifornia

tocausecancer,birthdefects,orotherreproductiveharm.

Introduction

Readthisinformationcarefullytolearnhowtooperate

andmaintainyourproductproperlyandtoavoid

injuryandproductdamage.Youareresponsiblefor

operatingtheproductproperlyandsafely.

Visitwww.Toro.comforproductsafetyandoperation

trainingmaterials,accessoryinformation,helpnding

adealer,ortoregisteryourproduct.

Wheneveryouneedservice,genuineToroparts,or

additionalinformation,contactanAuthorizedService

DealerorToroCustomerServiceandhavethemodel

andserialnumbersofyourproductready.Figure1

andFigure2identifythelocationofthemodeland

serialnumbersontheproduct.Writethenumbersin

thespaceprovided.

g341471

Figure1

1.Baggermodelandserialnumberlocation

g341472

Figure2

1.Blowermodelandserialnumberlocation

ModelNo.

SerialNo.

8111LyndaleAvenueSouth

Bloomington,MN55420

2

Contactusatwww.Toro.com.

PrintedintheUSA

AllRightsReserved

Thismanualuses2wordstohighlightinformation.

Importantcallsattentiontospecialmechanical

informationandNoteemphasizesgeneralinformation

worthyofspecialattention.

Thesafety-alertsymbol(Figure3)appearsbothin

thismanualandonthemachinetoidentifyimportant

safetymessagesthatyoumustfollowtoavoid

accidents.Thissymbolwillappearwiththeword

Danger,Warning,orCaution.

•Dangerindicatesanimminentlyhazardous

situationwhich,ifnotavoided,willresultindeath

orseriousinjury.

•Warningindicatesapotentiallyhazardous

situationwhich,ifnotavoided,couldresultin

deathorseriousinjury.

•Cautionindicatesapotentiallyhazardoussituation

which,ifnotavoided,mayresultinminoror

moderateinjury.

g000502

Figure3

Safety-alertsymbol

Contents

Safety.......................................................................4

SafetyandInstructionalDecals..........................5

Setup........................................................................7

1PreparingtheMachine.....................................9

2InstallingtheROPSPivotShoulder

Bolts................................................................9

3InstallingtheWeights.......................................9

4InstallingtheBaggerSupportsand

Brackets........................................................10

5InstallingtheBaggerFrame...........................12

6InstallingtheBags.........................................13

7InstallingtheHitchCover...............................13

8RemovingtheExistingBeltCover,Bracket,

andDischargeChute....................................14

9InstallingtheBlower-PulleyAssemblyand

Belt-CoverBracket........................................15

10InstallingtheBafe.......................................18

11InstallingtheBlowerAssembly.....................19

12InstallingtheBlowerBelt,Spring,and

Blower-BeltCover.........................................20

13InstallingtheDischargeTubes.....................22

14AdjustingtheParkingBrake.........................24

15CheckingtheTirePressure..........................24

Operation................................................................25

EmptyingtheGrassBags.................................25

ClearingObstructionsfromtheBagger

System..........................................................26

RemovingtheBagger.......................................26

TransportingtheMachine.................................26

OperatingTips.................................................27

Maintenance...........................................................28

RecommendedMaintenanceSchedule(s)...........28

CleaningtheHoodScreen................................28

InspectingtheBaggerAttachment....................29

CleaningtheBaggerandBags.........................29

InspectingtheBlowerBelt................................29

ReplacingtheBlowerBelt.................................29

GreasingtheIdlerArm......................................30

InspectingtheBagger.......................................30

InspectingtheMowerBlades............................30

SelectingtheMowerBlades.............................30

ReplacingtheGrassDeector..........................31

Storage...................................................................31

Troubleshooting......................................................32

3

Safety

•Becomefamiliarwiththesafeoperationofthe

equipment,withtheoperatorcontrols,andsafety

signs.

•Useextracarewithgrasscatchersorother

attachments.Thesecanchangetheoperating

characteristicsandthestabilityofthemachine.

•Followthemanufacturer'srecommendations

foraddingorremovingwheelweightsor

counterweightstoimprovestability.

•Donotuseagrasscatcheronsteepslopes.A

heavygrasscatchercouldcauselossofcontrol

oroverturnthemachine.

•Slowdownanduseextracareonhillsides.Be

suretotravelintherecommendeddirectionon

hillsides.Turfconditionscanaffectthestabilityof

themachine.Useextremecautionwhileoperating

neardrop-offs.

•Keepallmovementonslopesslowandgradual.

Donotmakesuddenchangesinspeed,direction,

orturning.

•Thegrasscatchercanobstructtheviewtothe

rear.Useextracarewhenoperatinginreverse.

•Usecarewhenloadingorunloadingthemachine

intoatrailerortruck.

•Neveroperatewiththedischargedeectorraised,

removedoraltered,unlessusingagrasscatcher.

•Keephandsandfeetawayfrommovingparts.Do

notmakeadjustmentswiththeenginerunning.

•Parkthemachineonalevelsurface,disengage

thedrives,shutofftheengine,leavetheoperator’s

position,andchockthewheelsbeforeperforming

anytasksuchasemptyingthegrasscatcheror

uncloggingthechute.

•Ifyouremovethegrasscatcher,besuretoinstall

anydischargedeectororguardthatmighthave

beenremovedtoinstallthegrasscatcher.Donot

operatethemowerwithouteithertheentiregrass

catcherorthegrassdeectorinplace.

•Shutofftheenginebeforeremovingthegrass

catcheroruncloggingthechute.

•Donotleavegrassinthegrasscatcherfor

extendedperiodsoftime.

•Grasscatchercomponentsaresubjecttowear,

damageanddeterioration,whichcouldexpose

youtomovingpartsorallowobjectstobethrown.

Frequentlycheckcomponentsandreplacewith

themanufacturer'srecommendedparts,when

necessary.

4

SafetyandInstructionalDecals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyarea

ofpotentialdanger.Replaceanydecalthatisdamagedormissing.

decal133-8061

133-8061

decal126-4662

126-4662

1.Warning—readtheOperator’sManualforthecorrect

quantityofcounterbalanceweight(s).

2.Lossoftractionandsteeringorreducedstabilityhazard—Ez

Vaccounterbalanceweight(s)installedwithouttheEzVac

maycauselossoftractionandsteeringcontrol.TheEzVac

installedwithouttheEzVaccounterbalanceweight(s)can

causereducedstability.Installweight(s)onlywhentheEz

Vacisinstalled.

decal126-9451

126-9451

1.Thrownobjectshazard—Donotruntheblowerwithoutthe

entirecollectionsysteminstalledandlatched.

2.Warning–ReadtheOperator’smanualaboutcounterbalance

weightinstallation.

3.Lossoftractionandsteeringorreducedstabilityhazard–Ez

Vaccounterbalanceweight(s)installedwithouttheEzVac

maycauselossoftractionandsteeringcontrol.TheEzVac

installedwithouttheEzVaccounterbalanceweight(s)can

causereducedstability.Installweight(s)onlywhentheEz

Vacisinstalled.

decal126-4659

126-4659

1.Warning—hotpulley;allowtocool.

decal126-4853

126-4853

1.Impeller/Rotatingbladeshazard—keephandsawayfrom

movingparts.Keepallsafetydevicesinplaceandworking.

Donotreachintotheblowerunlesstherotationindicator

hasstopped.

5

decal106-5517

106-5517

1.Warning—donottouchthehotsurface.

decal126-9595

126-9595

1.Rotationindicator

2.Impeller/RotatingBladeshazard-Keephandsawayfrom

movingparts.Keepallsafetydevicesinplaceandworking.

Donotreachintotheblowerunlesstherotationindicator

hasstopped.DisengagethePTO,shutofftheengine,

removethekey,andwaitforallmovingpartstostop.

6

Setup

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

ProcedureDescription

Qty.

Use

1

Nopartsrequired

–

Preparethemachine.

Shoulderbolt

2

Wavewasher2

2

Locknut(1/2inch)

2

InstalltheROPSpivotshoulderbolt.

Weight2

Carriagebolt(3/8x1inch)

4

3

Flangenut(3/8inch)

4

Installtheweights.

Lowersupport2

Uppersupport1

Left,upperbracket

1

Right,upperbracket1

Backerplate2

Carriagebolt(5/16x2-1/4inches)

4

Flangenut(5/16inch)

8

Plainwasher4

Hex-headbolt(5/16x3-1/4inches)

4

Flange-headbolt(3/8x1-1/4inches)

2

Locknut(3/8inch)

4

Flange-headbolt(5/16x1inch)

2

Installthebaggersupportsandbrackets.

Bagsupport1

5

Lock-pinassembly2

Installthebaggerframe.

6

Bags2Installthebags.

7

Hitchcover1Installthehitchcover.

8

Nopartsrequired

–

Removetheexistingbeltcover,bracket,

anddischargechute.

Blowerpulley1

Pulleymount1

Locknut(3/8inch)

3

Belt-coverbracket1

Speednut

1

Carriagebolt(1/4x3/4inch)

2

9

Locknut(1/4inch)

2

Installtheblower-pulleyassembly.

Bafe

1

Carriagebolt(5/16x7/8inch)

1

Flangenut(5/16inch)

1

Carriagebolt(3/8x7/8inch)

2

10

Flangenut(3/8inch)

2

Installthebafe.

Blowerassembly1

Pivotpin1

11

Rollpin1

Installtheblowerassembly.

Blower-beltcover1

12

Coverknob

1

Installthebaggerbelt,spring,and

blower-beltcover.

7

ProcedureDescription

Qty.

Use

Uppertube1

Lowertube1

Bolt(#10x3/4inch)

3

Locknut(#10)

3

13

Washer(7/32inch)

3

Installthedischargetubes.

14

Nopartsrequired

–

Adjusttheparkingbrake.

15

Nopartsrequired

–

Checkthetirepressure(formachine

withpneumatictiresonly).

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

8

1

PreparingtheMachine

NoPartsRequired

Procedure

1.Parkthemachineonalevelsurface.

2.Movethemotion-controlleverstotheNEUTRAL-LOCKposition.

3.Engagetheparkingbrake.

4.Shutofftheengineandremovethekey.

g037289

Figure4

2

InstallingtheROPSPivot

ShoulderBolts

Partsneededforthisprocedure:

2

Shoulderbolt

2Wavewasher

2

Locknut(1/2inch)

Procedure

1.Securetheshoulderbolttotherollbarusinga

wavewasherandlocknut(1/2inch)asshown

inFigure5.

2.Repeatthisprocedureontheotherside.

g341473

Figure5

1.Locknut(1/2inch)3.Shoulderbolt

2.Wavewasher

9

3

InstallingtheWeights

Partsneededforthisprocedure:

2Weight

4

Carriagebolt(3/8x1inch)

4

Flangenut(3/8inch)

Procedure

1.Securetheweighttothecasterarmusing2

carriagebolts(3/8x1inch)and2angenuts

(3/8inch)asshowninFigure6.

2.Repeatthisprocedureontheotherside.

g341474

Figure6

1.Carriagebolt(3/8x1inch)3.Flangenut(3/8inch)

2.Weight

4

InstallingtheBagger

SupportsandBrackets

Partsneededforthisprocedure:

2Lowersupport

1Uppersupport

1

Left,upperbracket

1Right,upperbracket

2Backerplate

4

Carriagebolt(5/16x2-1/4inches)

8

Flangenut(5/16inch)

4Plainwasher

4

Hex-headbolt(5/16x3-1/4inches)

2

Flange-headbolt(3/8x1-1/4inches)

4

Locknut(3/8inch)

2

Flange-headbolt(5/16x1inch)

Procedure

1.Looselysecuretheuppersupporttotherear

engineguardusing2ange-headbolts(5/16x

1inch)and2angenuts(5/16inch)asshown

inFigure7.

g341518

Figure7

1.Flangenut(5/16inch)3.Flange-headbolt(5/16x

1inch)

2.Uppersupport

10

2.Removethe2torx-headboltsand2nutsfrom

theleft,rearguard(Figure8).

Note:Performthestepaboveon1sideofthe

machine,thentheother.

g341515

Figure8

1.Left,rearguard

3.Torx-headbolt

2.Nut

3.Looselysecuretheleft,upperbrackettotheleft,

rearguardanduppersupportusing2hex-head

bolts(5/16x3-1/4inches),2plainwashers,2

angenuts(5/16inch),1ange-headbolt(3/8x

1-1/4inches),and1locknut(3/8inch)asshown

inFigure9.

Note:Performthestepaboveon1sideofthe

machine,thentheother.

g341516

Figure9

1.Left,rearguard5.Flange-headbolt(3/8x

1-1/4inches)

2.Flangenut(5/16inch)6.Left,upperbracket

3.Locknut(3/8inch)

7.Plainwasher

4.Uppersupport

8.Hex-headbolt(5/16x

3-1/4inches)

4.Looselysecurethelowersupporttotheengine

plateusing2carriagebolts(5/16x2-1/4inches),

1backerplate,and2angenuts(5/16inch)as

showninFigure10.

Note:Performthestepaboveon1sideofthe

machine,thentheother.

g341517

Figure10

1.Backerplate3.Lowersupport

2.Carriagebolt(5/16x2-1/4

inches)

4.Flangenut(5/16inch)

5.Tightallthefasteners.

11

5

InstallingtheBaggerFrame

Partsneededforthisprocedure:

1Bagsupport

2Lock-pinassembly

Procedure

1.Arrangethebaggerframearoundthepivotpins

onthesupportbracketandrotateitforward

(Figure11).

g341549

Figure11

1.Pivotpin

2.Baggerframe

2.Insertthelockpinthroughthebaggerframeand

crossbrace(Figure12).

Note:Youmayneedtoloosenthehardwareto

alignthelockpintothehole.

g038187

Figure12

1.Hairpincotter2.Lockpin

3.Usethehairpincottertosecurethelockpin

(Figure12).

4.Tightenallloosehardware.

12

6

InstallingtheBags

Partsneededforthisprocedure:

2Bags

Procedure

1.Hookthebagtothebaggerframe(Figure13).

g341571

Figure13

1.Baggerframe

2.Bag

2.Closeandlatchthehoodassembly.

7

InstallingtheHitchCover

Partsneededforthisprocedure:

1Hitchcover

Procedure

1.Applyalubricanttothenippleonthehitchcover.

2.Alignthehitchcoveroverthehitchandpressit

intoplace(Figure14).

g341572

Figure14

1.Hitchcover3.Hitch

2.Nipple

13

8

RemovingtheExisting

BeltCover,Bracket,and

DischargeChute

NoPartsRequired

Procedure

Note:Cleantheareaaroundthebeltcoverbefore

removingit.

1.Lowerthemowerdecktothelowestheight-of-cut

position.

2.Removetherightbeltcover(Figure15).

g038092

Figure15

3.Removetherightbelt-coverbracket,2washers

(60-inchmowerdeckonly),and2angenuts

fromthemowerdeck(Figure16).

Note:Retainthehardwarethatyouremoved

duringthisproceduresothatitisavailablefor

changeover.

g038093

Figure16

1.Rightbelt-coverbracket3.Flangenuts

2.Washers-onlyon152cm

(60inch)mowerdeck

4.Removethelocknut,bolt,spring,andspacer

holdingthedeectortothepivotbrackets

(Figure17).

g015594

Figure17

1.Bolt

5.Springinstalled

2.Spacer6.Grassdeector

3.Locknut

7.J-hookendofspring

4.Spring

5.Removethegrassdeector(Figure17).

Note:Retainthehardwarethatyouremoved

duringthisproceduresothatitisavailablefor

changeover.

14

9

InstallingtheBlower-Pulley

AssemblyandBelt-Cover

Bracket

Partsneededforthisprocedure:

1Blowerpulley

1Pulleymount

3

Locknut(3/8inch)

1Belt-coverbracket

1

Speednut

2

Carriagebolt(1/4x3/4inch)

2

Locknut(1/4inch)

Procedure

1.Usea3/8-inchratchetinthesquareholeinthe

idlerarmtoremovetensionontheidlerspring

(Figure18).

g334846

Figure18

1.Spring4.Spring-loadedidler

assembly

2.Clutchpulley

5.Ratchet

3.Mowerbelt

6.Squareholeintheidler

armfortheratchet

2.Removethebeltfromtherightmower-deck

pulley.

15

3.Useawrench(1-1/2inches)toholdthespindle

shaft,asyouremovethehexnut(3/4inch)and

washerfromthespindleshaft(Figure19).

Note:Retainthehexnut(3/4inch)andwasher.

g341576

Figure19

1.Hexnut(3/4inch)3.Rightspindleshaft

2.Washer

4.Insertthethreadedstudsonpulleymount

throughtheholesinthedeckpulley(Figure20).

5.Securethedeckpulleytothespindleshaftusing

thepreviouslyremovedhexnut(3/4inch)and

washer(Figure20).

6.Torquethehexnut(3/4inch)to176to217N∙m

(130to160ft-lb).

7.Arrangetheblowerpulleyontothethreaded

studsandlooselyinstallthe3locknuts(3/8inch)

asshowninFigure20.

8.Rotatetheblowerpulleyclockwiseuntilitstops.

9.Torquethe3locknuts(3/8inch)to18N∙m(13

ft-lb).

g341574

Figure20

1.Locknut(3/8inch)

5.Existingdeckpulley

2.Blowerpulley6.Pulleymount

3.Hexnut(3/4inch)7.Rightspindleshaft

4.Washer

16

10.Ensurethatthebladeboltistorquedto75to81

N∙m(55to60ft-lb).

11.Installthemowerbeltaroundthelowerpulleyof

thedoublepulley(Figure21).

g341575

Figure21

1.Lowerpulley2.Mowerbelt

12.Installthebelt-coverbrackettothemowerdeck

using2carriagebolts(1/4x3/4inch)and2

locknuts(1/4inch)asshowninFigure22.

13.Installthespeednutontothebelt-coverbracket

(Figure22).

g038112

Figure22

1.Carriagebolt(1/4x3/4

inch)

3.Speednut

2.Belt-coverbracket

4.Locknut(1/4inch)

14.Installthemowerdeckbeltaroundthe

spring-loadedidlerpulley(Figure18).

17

10

InstallingtheBafe

Partsneededforthisprocedure:

1

Bafe

1

Carriagebolt(5/16x7/8inch)

1

Flangenut(5/16inch)

2

Carriagebolt(3/8x7/8inch)

2

Flangenut(3/8inch)

Procedure

1.Removethe2existingangenuts(3/8inch)and

2carriagebolts(3/8x7/8inch)fromthemower

deck(Figure23).

Note:Retainthehardwarethatyouremoved

duringthisproceduresothatitisavailablefor

changeover.

g038113

Figure23

1.Flangenut(3/8inch)2.Carriagebolt(3/8x7/8

inch)

2.Installthebafeusingthecarriagebolt(5/16x

7/8inch),angenut(5/16inch),2carriagebolts

(3/8x7/8inch),and2angenuts(3/8inch)as

showninFigure24.

g341587

Figure24

1.Flangenut(3/8inch)4.Flangenut(5/16inch)

2.Carriagebolt(3/8x7/8

inch)

5.Carriagebolt(5/16x7/8

inch)

3.Bafe

18

11

InstallingtheBlower

Assembly

Partsneededforthisprocedure:

1Blowerassembly

1Pivotpin

1Rollpin

Procedure

Verifythatthepivotpinissecuredontheblower

assemblyinthecorrectlocation(Figure25orFigure

26).

•Ifyouhavea48-inchor52-inchmowerdeck,

thereisonlyasingleholetoinstallthepivotpin

(Figure25).

g341588

Figure25

1.Blowerassembly3.Pivotpin

2.Rollpin

•Ifyouhavea60-inchmowerdeck,installthepivot

pinintherearhole(Figure26).

g341589

Figure26

1.Blowerassembly3.Rollpin

2.Rearhole4.Pivotpin

1.Alignthepivotpinontheblowerwiththe

pivot-pinholeinthemowerdeck(Figure27).

g038256

Figure27

1.Blowerassembly3.Pivothole

2.Deck4.Blower-pivotpin

2.Lowertheblowerandslidethepivotpinintothe

pivothole(Figure27).

Note:Ensurethatthebeltremainspositioned

intheblowerpulley.

19

3.Movethelatchpinfromthelockingpositionto

theopenposition(Figure28).

g018370

Figure28

1.Blowerassembly5.Idler-pivotbracket

2.Latchpin(lockingposition)

6.Idlerpulley

3.Latchpin(openposition)7.Belt(beneaththeidler

pulley)

4.Chutebracket

4.Closetheblowerassemblyandalignthelatch

pinwiththeholeinthechutebracket(Figure28).

5.Movethelatchpintothelockingposition.

Note:Ensurethatthelatchpinextendsthrough

theholeinthechutebracket.

Note:Ensurethatthelatchrmlyholdsthe

blowerassemblyagainstthemowerdeck,but

youcanreleaseitbyhand.

12

InstallingtheBlowerBelt,

Spring,andBlower-Belt

Cover

Partsneededforthisprocedure:

1Blower-beltcover

1

Coverknob

Procedure

1.Arrangetheblowerbeltaroundthedrivepulley

asshowninFigure29.

g341600

Figure29

1.Blowerpulley4.Drivepulley

2.Idler/pulley5.Idler/tensionpulley

3.Blowerbelt

2.Temporarilyroutethebeltbeneaththeidler

pulley(Figure30).

20

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