Operator’s Manual
Original Instructions (EN)
Register your product at www.Toro.com
Form No. 3353–268 Rev A
DFS Vac Collection System
2005 and after 500 Series Z Master
Model No. 78513—Serial No. 250000001 and Up
2
W 2005 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
Contact us at www.Toro.com
All Rights Reserved
Printed in the USA
Contents
Page
Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 3. . . . . . . . . . . . . . . .
Setup 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Bagger Mounting Bracket onto an Air
Cooled Machine 6. . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Bagger Mounting Bracket onto a Liquid
Cooled Machine 7. . . . . . . . . . . . . . . . . . . . . . . . .
Tightening all Mounting Bolts 9. . . . . . . . . . . . . . .
Removing the Mower Belt and the Right Rear Idler
Pulley 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Drive Pulley Assembly 10. . . . . . . . . .
Installing the Bagger 11. . . . . . . . . . . . . . . . . . . . . .
Installing the Bagger Tensioner Pulley and Belt 12.
Adjusting the Bagger Belt 14. . . . . . . . . . . . . . . . . .
Installing and Adjusting the Mower Belt 15. . . . . . .
Installing the Weights 16. . . . . . . . . . . . . . . . . . . . . .
Installing the Boot and Discharge Tubes 18. . . . . . .
Installing the Bagger Dump Handle 19. . . . . . . . . . .
Installing the Bagger Dump Lever Stop Bolt 19. . . .
Adjusting the Bagger Dump Lever 20. . . . . . . . . . . .
Checking the Tire Pressure 21. . . . . . . . . . . . . . . . . .
Operation 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Positioning the Adjustable Baffle 22. . . . . . . . . . . . .
Opening the Bagger 22. . . . . . . . . . . . . . . . . . . . . . .
Holding the Bagger Door Open 23. . . . . . . . . . . . . .
Clearing Obstructions From the Bagger System 23.
Removing the Discharge Tubes 23. . . . . . . . . . . . . .
Removing the Bagger 23. . . . . . . . . . . . . . . . . . . . . .
Replacing the Grass Deflector 24. . . . . . . . . . . . . . .
Operating and Bagging Tips 24. . . . . . . . . . . . . . . . .
Maintenance 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Maintenance Schedule 26. . . . . . . . .
Cleaning the Screens 26. . . . . . . . . . . . . . . . . . . . . .
Cleaning the Bagger 26. . . . . . . . . . . . . . . . . . . . . . .
Checking the Bagger Belt 26. . . . . . . . . . . . . . . . . . .
Greasing the Idler Arm 26. . . . . . . . . . . . . . . . . . . . .
Greasing the Fan Shaft Bearings 27. . . . . . . . . . . . .
Inspecting the Bagger 27. . . . . . . . . . . . . . . . . . . . . .
Inspecting the Mower Blades 27. . . . . . . . . . . . . . . .
Storage 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
1
m–6984
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.
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.
3
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.
• Follow the manufacturer’s recommendations for adding
or removing wheel weights or counterweights to
improve stability.
• 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,
removed or altered, unless using a grass catcher.
• Keep hands and feet away from moving parts. Do not
make adjustments with the engine running.
• Stop on level ground, disengage drives, 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.
• Stop the engine before removing the grass catcher or
unclogging the chute.
• 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.
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.
104-8569
106-3339
4
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 Description Qty. Use
1
Bagger mounting bracket
Side bracket—right
Side bracket—left
Long frame spacer—only two are
needed for air cooled machines
Short frame spacer
Bolt, 3/8 x 1–1/2 inch
Bolt, 3/8 x 1–1/4 inch
Flange Nut, 3/8 inch
Stiffener bracket
Bolts, 3/8 x 3/4 inch
Curved washer
1
1
1
4
2
12
4
26
2
8
8
Installing bagger mounting brackets
onto the machine
2
No parts needed Tightening all mounting bolts
3
No parts needed
Removing the mower belt and the right
rear idler pulley
4
Pulley assembly
Bolt, 1/2 x 1–1/4 inch
Lock nut,1/2 inch
Washer, 1/2 inch
1
4
4
4
Installing the drive pulley assembly
5
Bagger
Clevis pin
Hairpin cotter
1
2
2
Installing the bagger
6
Bagger tensioner pulley
Bolt, 3/8 x 2 inch
Lock Nut, 3/8 inch
Washer, 3/8 inch
Bagger belt
1
1
1
1
1
Installing the bagger tensioner pulley
and the bagger belt
7
No parts needed Adjusting the bagger belt
8
No parts needed Adjusting the mower belt tension
5
Step UseQty.Description
9
Caster weight
U–bolt
Nut, 1/2 inch
Lock washer, 1/2 inch
Plate
Top weight
Bolt, 1/2 x 3 inch
2
2
4
4
2
4
2
Installing the weights
10
Boot
Middle Tube
Upper Tube
Clamp
1
1
1
1
Installing the boot and the discharge
tubes
11
Bagger dump lever
Washer, 13/16 inch
Cotter pin
1
2
1
Installing the bagger dump lever
12
Bolt, 1/2 x 1–3/4 inch
Jam nut, 1/2 inch
Long clevis (liquid cooled only)
1
2
1
Installing the bagger dump lever stop
bolt
13
No parts needed Adjusting the bagger dump lever
14
No parts needed Checking the tire pressure
6
1
Step
Parts needed for this step:
• 1 Bagger mounting bracket
• 1 Side bracket—right
• 1 Side bracket—left
• 4 Long frame spacer—only two are needed for air
cooled machines
• 2 Short frame spacer
• 12 Bolt, 3/8 x 1–1/2 inch
• 4 Bolt, 3/8 x 1–1/4 inch
• 26 Flange Nut, 3/8 inch
• 2 Stiffener bracket
• 8 Bolts, 3/8 x 3/4 inch
• 8 Curved washer
If you have a liquid cooled machine, go to page 7 for
Installing the Bagger Mounting Bracket onto a Liquid
Cooled Machine.
If you have an air cooled machine, use the following
instructions for Installing the Bagger Mounting Bracket
onto an Air Cooled Machine.
Installing the Bagger Mounting
Bracket onto an Air Cooled
Machine
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 9, for the
correct procedure to tighten the bolts.
Installing the Bagger Mounting Bracket to
the Side Brackets (Air Cooled)
Important When installing the bagger bracket for an
air cooled machine, use only 2 long frame spacers; 1 per
each side (Fig. 2).
1. Install the side brackets to the bagger mounting bracket
(Fig. 2).
2. In the top two holes, install 2 bolts (3/8 x 1–1/2 inch),
2 flange nuts (3/8 inch) one long frame spacer, and one
short frame spacer (Fig. 2).
Note: Make sure the long frame spacers are installed as
shown in figure 2.
3. In the bottom hole, install a bolt (3/8 x 1–1/4 inch) and
a flange nut (3/8 inch) (Fig. 2).
4. Install a bracket stiffener to the side bracket and bagger
mounting bracket. Use 4 bolts (3/8 x 3/4 inch) and
4 flange nuts (3/8 inch) (Fig. 2).
5. Repeat the previous steps for the opposite side (Fig. 2).
6
4
1
9
8
3
3
4
7
3
6
2
10
5
m–8040
Figure 2
1. Bagger mounting bracket
2. Bolt, 3/8 x 1–1/4 inch
3. Flange nut, 3/8 inch
4. Bracket stiffener
5. Left side bracket
6. Bolt, 3/8 x 3/4 inch
7. Long frame spacer
8. Bolt, 3/8 x 1–1/2 inch
9. Short frame spacer
10. Right side bracket
Installing the Side Brackets to an Air
Cooled Machine
Important Do not tighten any bolts until both side
brackets and bagger mounting bracket are fit loose on the
machine.
Important Install one side at a time.
1. Remove the bolts, nuts and washers holding the rollbar
to one side of the machine. Discard the bolts, nuts and
washers (Fig. 3).
2. Install the bagger side plate and the roll bar section to
the side of the machine using 4 bolts
(3/8 x 1–1/2 inch), 4 curved washer (3/8 inch) and 4
flange nuts (3/8 inch) (Fig. 3).
7
3. Repeat the previous step on the opposite side of the
machine.
Note: Make sure the curved washers are installed as shown
in Figure 3.
3
2
m–8044
5
3
2
1
4
Figure 3
1. Side bracket
2. Curved washer, 3/8 inch
3. Bolt, 3/8 x 1–1/2 inch
4. Flange nut, 3/8 inch
5. ROPS
Installing the Bagger Mounting Bracket
onto an Air Cooled Machine
Important When installing the bagger onto an air
cooled machine, use the air cooled spacer (Fig. 4).
1. Install the bagger mounting bracket to the rear frame of
the machine (Fig. 4).
2. In the top two holes, install 2 bolts (3/8 x 1–3/4 inch),
2 flange nuts (3/8 in.) and the air cooled frame spacer
(Fig. 4).
3. In the bottom two holes, install 2 bolts (3/8 x
1–1/4 inch) and 2 flange nuts (3/8 in.) (Fig. 4).
6
1
5
3
3
3
2
6
2
4
m–8041
Figure 4
1. Bagger mounting bracket
2. Bolt, 3/8 x 1–1/4 inch
3. Flange nut, 3/8 inch
4. Bumper
5. Air cooled frame spacer
6. Bolt, 3/8 x 1–3/4 inch
Installing the Bagger Mounting
Bracket onto a Liquid Cooled
Machine
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 9, for the
correct procedure to tighten the bolts.
Installing the Bagger Mounting Bracket to
the Side Brackets (Liquid Cooled)
Important When installing the bagger onto a liquid
cooled machine, the rear bumper plate must be removed.
Use 4 long frame spacers for this installation, 2 per each
side (Fig. 5).
1. Install the side brackets to the bagger mounting bracket
(Fig. 5).
2. In the top two holes, install 2 bolts (3/8 x 1–1/2 inch),
2 flange nuts (3/8 in.), 2 long frame spacers, and one
short frame spacer (Fig. 5).
Note: Make sure the long frame spacers are installed as
shown in figure 5.
8
3. In the bottom hole, install a bolt (3/8 x 1–1/4 inch) and
a flange nut (3/8 in.) (Fig. 5).
4. Install a bracket stiffener to the side bracket and bagger
mounting bracket. Use 4 bolts (3/8 x 3/4 inch) and
4 flange nuts (3/8 in.) (Fig. 5).
5. Repeat the previous steps for the opposite side (Fig. 5).
6
4
1
9
8
3
3
4
7
3
6
2
10
5
7
m–8042
Figure 5
1. Bagger mounting bracket
2. Bolt, 3/8 x 1–1/4 inch
3. Flange nut, 3/8 inch
4. Bracket stiffener
5. Left side bracket
6. Bolt, 3/8 x 3/4 inch
7. Long frame spacer
8. Bolt, 3/8 x 1–1/2 inch
9. Short frame spacer
10. Right side bracket
Installing the Side Brackets to a Liquid
Cooled Machine
Important Do not tighten any bolts until both side
brackets and bagger mounting bracket are fit loose on the
machine.
Important Install one side at a time.
1. Remove the bolts, nuts and washers holding the rollbar
to one side of the machine. Discard the bolts, nuts and
washers (Fig. 6).
2. Install the bagger side plate and the roll bar section to
the side of the machine using 4 bolts
(3/8 x 1–1/2 inch), 4 curved washer (3/8 inch) and 4
flange nuts (3/8 inch) (Fig. 6).
3. Repeat the previous step on the opposite side of the
machine.
Note: Make sure the curved washers are installed as shown
in Figure 6.
3
2
m–8044
5
3
2
1
4
Figure 6
1. Side bracket
2. Curved washer, 3/8 inch
3. Bolt, 3/8 x 1–1/2 inch
4. Flange nut, 3/8 inch
5. ROPS
Installing the Bagger Mounting Bracket
onto a Liquid Cooled Machine
1. Install the bagger mounting bracket to the rear frame of
the machine (Fig. 7).
2. In the top two holes, install 2 bolts (3/8 x 1–3/4 inch)
and 2 flange nuts (3/8 inch) (Fig. 7).
3. In the bottom two holes, install 2 bolts (3/8 x
1–1/4 inch) and 2 flange nuts (3/8 inch) (Fig. 7).
m–8043
5
1
3
3
2 5
2
4
Figure 7
1. Bagger mounting bracket
2. Bolt, 3/8 x 1–1/4 inch
3. Flange nut, 3/8 inch
4. Bumper
5. Bolt, 3/8 x 1–3/4 inch
9
2
Step
No parts needed for this step.
Tightening all Mounting Bolts
The following steps are the correct sequence to tighten the
side brackets and the bagger mounting bracket.
All 3/8 inch mounting bolts need to be torqued to 35 ft–lb
(48 Nwm).
1. Tighten the bagger mounting bracket to the rear frame
first (Figures 4 or 7).
2. Tighten the bagger mounting bracket to the side
brackets (Figures 4 or 7).
3. Tighten the bracket stiffeners to both the side plates and
the bagger mounting bracket (Figures 2 or 5).
4. Tighten the side brackets to the side of the mower
(Fig. 3 or 6).
5. Lower the machine onto the drive wheels.
3
Step
No parts needed for this step.
Removing the Mower Belt and
the Right Rear Idler Pulley
1. Loosen the idler plate bolts and loosen the mower idler
plate (Fig. 8).
2
m–6826
1
3
4
Figure 8
1. Mower idler plate
2. Square hole
3. Ratchet or breaker bar
4. Idler plate bolt
10
2. Remove the mower belt from the mower and the rear
fixed idler pulley (Fig. 9).
2
m–6825
3
4
4
1
6
5
Figure 9
1. Clutch
2. Mower belt
3. Right rear fixed idler
pulley
4. Belt guide
5. Mower spindle pulley
6. Mower idler pulley
3. Remove the fixed idler pulley from the right rear frame
of the machine (Fig. 10).
3
m–7055
6
4
5
6
1
2
Figure 10
1. Fixed idler pulley
2. Right rear of the machine
3. Bolt
4. Nut
5. Spacer
6. Washer
4
Step
Parts needed for this step:
• 1 Pulley assembly
• 4 Bolt, 1/2 x 1–1/4 inch
• 4 Lock nut, 1/2 inch
• 4 Washer, 1/2 inch
• 1 Template
Installing the Drive Pulley
Assembly
1. Install the mower belt onto the drive pulley assembly
(Figures 12 and 19).
Note: Make sure the cut–out in the pulley plate is on the
left–hand side of the machine (Fig. 11). This cut–out allows
room for the mower spring loaded idler pulley.
7
1
3
5
4
6
2
m–8045
Figure 11
1. Rear frame
2. Drive pulley assembly
3. Bolt, 1/2 x 1–1/4 inch
4. Nut, 1/2 inch
5. Washer, 1/2 inch
6. Cut–out
7. Pulley plate
11
2. Install the pulley assembly under the rear frame, and
loosely install 4 bolts (1/2 x 1–1/4 inch), 4 washers
(1/2 in.) and 4 locknuts (1/2 inch) (Fig. 11). Do not
tighten bolts now.
Positioning the Drive Pulley Assembly on
an Air Cooled Machine
1. Push the drive pulley assembly all the way forward and
then rearward a 1/4 inch (6 mm) (Fig. 11).
Note: The bolt head on the drive pulley assembly, should
be approximately centered horizontally, in the frame slot
(Fig. 12). View this from the right–hand side of the
machine.
2. Tighten the 4 bolts (1/2 x 1–1/4 inch), 4 washers
(1/2 in.) and 4 locknuts (1/2 inch) (Fig. 11).
Important A final adjustment may be needed when
installing the bagger belt.
Positioning the Drive Pulley Assembly on
a Liquid Cooled Machine
1. Push the drive pulley assembly all the way rearward and
then forward a 1/4 inch (6 mm) (Fig. 11).
Note: The bolt head on the drive pulley assembly, should
be approximately a 1/4 inch (6mm) rearward of the center
in the frame slot (Fig. 12). View this from the right–hand
side of the machine.
2
1
3
5
4
6
m–5861
Figure 12
1. Drive pulley assembly
2. Bolt head—air cooled
machine only
3. Mower drive belt
4. Bolt head—liquid cooled
machine only
5. Frame slot
6. 1/4 inch—liquid cooled
2. Tighten the 4 bolts (1/2 x 1–1/4 inch), 4 washers
(1/2 in.) and 4 locknuts (1/2 inch) (Fig. 11).
Important A final adjustment may be needed when
installing the bagger belt.
5
Step
Parts needed for this step:
• 1 Bagger
• 2 Clevis pin
• 2 Hairpin cotter
Installing the Bagger
1. Install the bagger onto the bagger mounting bracket
(Fig. 13).
2. Install clevis pins into the bagger and bagger bracket.
Secure with hairpin cotters (Fig. 13).
m–8046
2
4
1
3
Figure 13
1. Bagger
2. Bagger mounting bracket
3. Hairpin cotter
4. Clevis pin
Installing Bagger onto a Liquid Cooled
Machine
Note: The following instructions are for liquid cooled
machines only.
1. Loosen bolts that hold the engine shroud.
2. Move the engine shroud forward as far as possible.
3. Tighten bolts that hold the engine shroud.
12
4. Remove the cable guide and bolt from the frame of the
bagger (Fig. 14).
5. Install the cable guide, bolt, and nut with the cable
behind the cable guide (Fig. 14).
Note: Make sure the cable guide can rotate.
6. Locate template number 1 in the back of this manual.
Cut out template number 1 as indicated on the template
(Fig. 14).
7. Position the template on the right–hand side of the
engine shroud (Fig. 14).
8. Line up the mark on the template where the bagger
dump lever hits the engine shroud and the template
bottom is flush with the bottom of shroud (Fig. 14).
9. Tape the template to the engine shroud. Mark the outer
edge of the template. (Fig. 14).
10. Cut the engine shroud at the marked line. This will
prevent damage to the engine shroud while using the
bagger dump lever (Fig. 14).
Note: Make sure to follow the template outline. Do not
create any sharp corners.
4
1
3
6
2
7
5
m–8048
Figure 14
1. Bagger dump lever
2. Engine shroud
3. Template
4. Cable guide
5. Mark on template
6. Template bottom
7. Shroud bottom
6
Step
Parts needed for this step:
• 1 Bagger tensioner pulley
• 1 Bolt, 3/8 x 2 inch
• 1 Lock Nut, 3/8 inch
• 1 Washer, 3/8 inch
• 1 Bagger belt
Installing the Bagger Tensioner
Pulley and Belt
1. Remove the four bolts in the skid plate (Fig. 15).
2. Remove the skid plate (Fig. 15). This will make it easier
to install the bagger belt.
2
1
m–6984
Figure 15
1. Bolts 2. Skid plate
3. Install the bagger tensioner pulley onto the idler arm
with a bolt (3/8 x 2 inch), washer (3/8 inch), and lock
nut (3/8 inch) (Fig. 16).
13
6
4
2
5
1
M–6908
3
Figure 16
1. Bolt, 3/8 x 2 inch
2. Idler arm
3. Lock nut, 3/8 inch
4. Washer, 3/8 inch
5. Bagger tensioner pulley
6. Bagger
4. Install the bagger belt onto the drive pulley
(Fig. 18 and 19).
5. Route the bagger belt onto the bagger pulley
(Figures 17 and 18).
1
2
m–5887
3
6
4
5
Figure 17
1. Tensioner spring
2. Eye bolt
3. Bagger tensioner pulley
4. Bagger pulley
5. Belt
6. Shortest space between
belt strands, 1 inch
±1/8 inch
Note: There should be a 1/4 twist in the belt when it is
installed onto the bagger tensioner pulley
6. Install the spring onto the idler arm (Fig. 17).
7. Install the tensioner spring onto the eyebolt attached to
the bagger (Fig. 17 and 20).
8. Adjust the bagger belt for proper tension. Refer to
Adjusting the Bagger Belt on page 14.
9. Adjust the Mower belt tension. Refer to Adjusting the
Mower Belt Tension on page 15.
10. Install the skid plate (Fig. 15).
m–5773
3
2
1
4
Figure 18
1. Drive pulley
2. Bagger tensioner pulley
3. Bagger pulley
4. 1/4 twist
m–5892
2
3
1
5
4
Figure 19
1. Drive pulley assembly
2. Mower belt
3. Bagger belt
4. Mounting bolts
5. Back of machine
14
7
Step
No parts needed for this step
Adjusting the Bagger Belt
1. Check the belt tension (Fig 20).
2. Measure the gap, at the bagger tensioner pulley,
between the tight and slack side of the belt when the
bagger tensioner pulley and spring are installed
(Fig. 20).
1
2
m–5887
3
6
4
5
Figure 20
1. Tensioner spring
2. Eye bolt
3. Bagger tensioner pulley
4. Bagger pulley
5. Belt
6. Shortest space between
belt strands, 1 inch
±1/8 inch
3. There must be a gap of 1 inch ± 1/8 inch (26mm ±
3 mm) between the belt strands (Fig 20).
4. If the gap is not correct, remove the tensioner spring
from the eyebolt and remove the tension on the mower
spring loaded idler (Fig 23).
5. If the gap measurement is too large:
A. Loosen the 4 mounting bolts holding the drive
pulley assembly (Fig 19).
B. Pull the pulley assembly rearward slightly
[1/8–3/16 inch (3–5 mm)] from the original set–up
position (Fig 19).
C. Tighten the 4 mounting bolts holding the drive
pulley assembly to the machine frame (Fig 19).
6. If the gap measurement is too small:
A. Loosen the 2 nuts on the lower fan shaft pillow
block (Fig. 21).
B. Insert a spacer behind the pillow block (Fig. 21).
C. Tighten the nuts.
D. Check the belt gap and repeat procedure as required.
1
3
2
Figure 21
1. Pillow block
2. Fan shaft
3. Spacer
7. Install the tensioner spring to the eyebolt and apply the
tension on the mower spring loaded idler.
8. Measure the bagger belt tension. There must be a gap of
1 inch ± 1/8 inch (26mm ± 3 mm) between the belt
strands (Fig 20).
9. Repeat this procedure if a gap of 1 inch ± 1/8 inch
(26mm ± 3 mm) was not achieved (Fig 20).
15
8
Step
No parts needed for this step.
Installing and Adjusting the
Mower Belt
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. Raise the mower to the transport position.
4. Ensure the mower belt is installed on all mower pulleys
(Fig 22).
Important Check the amount of twist in the belt
between the pulleys. Make sure it is only what is specified
in Figure 22.
2
m–6825
3
3
3
4
4
1
3
6
5
Figure 22
1. Clutch
2. Mower belt
3. 1/4 turn belt twist
4. Belt guide
5. Mower spindle pulley
6. Mower idler pulley
Important Check and make sure the belt is installed
into both the front and rear belt guides (Fig 23).
5. Check the belt tension. The spring loaded idler center
bolt needs to be near the top alignment hole in left
support plate (Fig 23).
1
2
M–4417
3
1
Figure 23
1. Center bolt
2. Alignment hole
3. Left support plate
4. Spring loaded idler
6. If adjustment is required, loosen the mower idler plate
and adjust it (Fig. 24).
7. Insert a ratchet or breaker bar into the square hole in the
mower idler plate to adjust the tension (Fig. 24).
8. To increase belt tension, rotate the mower idler plate
until resistance is felt and rotation stops. Do not go past
when it stops (Fig. 24).
9. Tighten the idler plate bolts (Fig. 24).
2
m–6826
1
3
4
Figure 24
1. Mower idler plate
2. Square hole
3. Ratchet or breaker bar
4. Idler plate bolt
16
10. Check the distance from the rubber stop and the arm of
the spring loaded idler pulley when the idler plate is
tightened. It needs to be 0 to 1/4 inch (0 to 6 mm) from
the rubber stop (Fig. 25).
m–6825
1
2
3
5
4
6
Figure 25
1. Spring loaded idler pulley
2. Top alignment hole
3. 0 to 1/4 inch gap
(0 to 6 mm)
4. Idler pulley arm
5. Belt
6. Rubber bumper
11. Adjust the belt tension and the idler plate, if necessary,
and tighten all hardware securely (Fig. 24).
9
Step
Parts needed for this step:
• 2 Caster weight
• 2 U–bolt
• 4 Nut, 1/2 inch
• 4 Lock washer, 1/2 inch
• 2 Plate
• Top weight
• 2 Bolt, 1/2 x 3 inch— for two top weights
Installing the Weights
To comply with ANSI/OPEI B71.4–1999 Standard, top
weights must be added to the machine.
Installing the Caster Weights
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.
• Install the front caster weights and top weights.
Caution
1. Place caster weights on the front casters.
2. Install plate, nuts (1/2 inch) and lock washer (1/2 inch)
under the frame and weight (Fig. 26).
3. Repeat for opposite side.
Note: On Z–Master mowers with 52 inch mower decks and
liquid cooled Z–Master mowers with 60 inch mowers
additional weights are required.
17
4
1
m–5882
6
3
1
2
5
Figure 26
1. Front caster weight
2. U–bolt
3. Plate
4. Nut
5. Front caster
6. Lock washer
Installing the Extra Top Weights
1. Install 2 top weights on top of each caster weight and
secure them with a bolt (1/2 x 3 inch) (Fig. 27).
1
3
4
2
m–5882
Figure 27
1. Top weight
2. Bolt, 1/2 x 3 inches
3. Front caster weight
4. Front caster wheel
18
10
Step
Parts needed for this step:
• 1 Boot
• 1 Middle tube
• 1 Upper tube
• 1 Clamp
Installing the Boot and
Discharge Tubes
Note: Remember to replace the L or the straight end of the
spring when in side discharge mode. Refer to Replacing the
Grass Deflector on page 24.
1. Disengage the PTO 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. To relieve the spring tension on the grass deflector,
place the L or the straight end of the spring in front of
the mounting bracket (Fig. 38).
4. Lift the grass deflector all the way back.
5. Position the boot’s front hook into the front slot on the
mounting bracket (Fig. 29).
Note: If the grass deflector interferes with the boot, grind
off part of the grass deflector frame. See Figure 28 for the
correct part to grind off.
m–7056
1
2
Figure 28
1. Grass deflector frame 2. Grind this part off
6. Place the rear hook over the rear of the mounting
bracket (Fig. 29).
7. Install the upper tube into the bagger (Fig. 29).
8. Slide the clamp onto the middle tube (Fig. 29).
9. Align the knob on the middle tube with the notch in the
upper tube. Slide the middle tube into the upper tube
and twist the middle tube 60 degrees (Fig. 29).
10. Tighten the clamp around the upper and middle tube
connection (Fig. 29).
11. Slide the middle tube onto the boot and latch them
together (Fig. 29).
1
10
4
9
8
7
5
2
3
6
11
M–6910
Figure 29
1. Boot
2. Middle tube
3. Knob
4. Upper tube
5. Latch
6. Notch in upper tube
7. Mounting bracket
8. Front slot
9. Rear hook
10. Front hook
11. Clamp
19
11
Step
Parts needed for this step:
• 1 Dump handle
• 2 Washers, 13/16 inch
• 1 Cotter pin
Installing the Bagger Dump
Handle
1. Unfasten the dump handle from the crate.
2. Install a washer onto the bagger dump handle and install
the bagger dump handle into the bagger frame (Fig. 31).
3. Fasten the bagger with a washer ( inch) and a cotter
pin (Fig. 31).
3
2
2
1
4
m–8047
Figure 30
1. Dump handle
2. Washer
3. Cotter pin
4. Bagger frame
12
Step
Parts needed for this step:
• 1 Bolt, 1/2 x 1–3/4 inch
• 2 Jam nuts, 1/2 inch
• 1 Long clevis, liquid cooled machines only
Installing the Bagger Dump
Lever Stop Bolt
1. Move the bagger dump lever rearward to increase the
slack in the bagger cable (Fig. 31).
2. Remove the cotter pin and clevis pin securing the
bagger cable clevis to the bagger dump handle
(Fig. 31).
1
2
3
5
6
m–6985
4
Figure 31
1. Bagger dump lever
2. Bagger cable
3. Bagger cable clevis
4. Bolt, 1/2 x 1–3/4 inch
5. Jam nut, 1/2 inch
6. Stop bracket
3. Thread a jam nut (1/2 inch) all the way onto the bolt
(1/2 x 1–3/4 inch) (Fig. 31).
4. Move the bagger dump lever forward to move the
bottom of the lever away from the stop bracket
(Fig. 31).
5. Insert the bolt into the stop bracket hole and thread
another jam nut (1/2 inch) onto the bolt. Do not tighten.
20
Note: Install the long cable clevis onto the bagger dump
handle if it is for a liquid cooled machine (Fig. 32).
6. Secure the bagger cable clevis to the bagger dump
handle with the clevis pin and cotter pin previously
removed (Fig. 31 or Fig. 32).
3
8
7
4
m–6986
2
5
6
4
1
Figure 32
1. Bagger dump lever
2. Bagger cable
3. Long cable clevis—liquid
cooled machines only
4. Bolt, 1/2 x 1–3/4 inch
5. Jam nut, 1/2 inch
6. Stop bracket
7. Clevis pin
8. Cotter pin
7. Adjust the handle stop, refer to Adjusting the Bagger
Dump Lever, page 20.
13
Step
No parts needed for this step.
Adjusting the Bagger Dump
Lever
The bagger lever needs to be adjusted to remove slack in
the bagger cable.
1. Loosen the nuts on both sides of the stop bracket
(Fig. 33).
2. Adjust the stop bolt until there is no slack in the bagger
cable (Fig. 33).
3. Tighten the nuts on both sides of the stop bracket
(Fig. 33).
1
1 5 25
4
m–6990
3
Figure 33
1. Bagger dump lever
2. Stop bracket
3. Stop bolt
4. Bagger cable
5. Nut
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