Form No. 3443-711 Rev A Bagger Kit Z Master® 4000 Series Riding Mower Model No. 78463—Serial No. 400000000 and Up Register at www.Toro.com.
WARNING CALIFORNIA Proposition 65 Warning Use of this product may cause exposure to chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. 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. Visit www.Toro.
Contents This manual uses 2 words to highlight information. Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention. Safety ....................................................................... 4 Safety and Instructional Decals .......................... 5 Setup ........................................................................ 7 1 Preparing the Machine.....................................
Safety • 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.
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 missing. decal133-8061 133-8061 decal126-9451 126-9451 1. Thrown objects hazard—Do not run the blower without the entire collection system installed and latched. 2. Warning–Read the Operator’s manualabout counterbalance weight installation. 3.
decal106-5517 106-5517 1. Warning—do not touch the hot surface. decal126-9595 126-9595 1. Rotation indicator 2. Impeller/Rotating Blades hazard-Keep hands away from moving parts. Keep all safety devices in place and working. Do not reach into the blower unless the rotation indicator has stopped. Disengage the PTO, shut off the engine, remove the key, and wait for all moving parts to stop.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 1 2 3 4 5 6 7 8 9 10 11 12 Description Use Qty.
Procedure 13 14 15 Description Qty. Use Upper tube Lower tube Bolt (#10 x 3/4 inch) Locknut (#10) Washer (7/32 inch) 1 1 3 3 3 Install the discharge tubes. No parts required – Adjust the parking brake. No parts required – Check the tire pressure (for machine with pneumatic tires only). Note: Determine the left and right sides of the machine from the normal operating position.
1 Preparing the Machine No Parts Required Procedure 1. Park the machine on a level surface. 2. Move the motion-control levers to the NEUTRAL-LOCK position. 3. Engage the parking brake. 4. Shut off the engine and remove the key. g037289 Figure 4 2 Installing the ROPS Pivot Shoulder Bolts Parts needed for this procedure: 2 Shoulder bolt 2 Wave washer 2 Locknut (1/2 inch) Procedure 1. 2. Secure the shoulder bolt to the roll bar using a wave washer and locknut (1/2 inch) as shown in Figure 5.
3 4 Installing the Weights Installing the Bagger Supports and Brackets Parts needed for this procedure: 2 Weight 4 Carriage bolt (3/8 x 1 inch) 2 Lower support 4 Flange nut (3/8 inch) 1 Upper support 1 Left, upper bracket 1 Right, upper bracket 2 Backer plate 4 Carriage bolt (5/16 x 2-1/4 inches) 8 Flange nut (5/16 inch) 4 Plain washer 4 Hex-head bolt (5/16 x 3-1/4 inches) 2 Flange-head bolt (3/8 x 1-1/4 inches) 4 Locknut (3/8 inch) 2 Flange-head bolt (5/16 x 1 inch) Parts
2. Remove the 2 torx-head bolts and 2 nuts from the left, rear guard (Figure 8). 4. Note: Perform the step above on 1 side of the machine, then the other. Loosely secure the lower support to the engine plate using 2 carriage bolts (5/16 x 2-1/4 inches), 1 backer plate, and 2 flange nuts (5/16 inch) as shown in Figure 10. Note: Perform the step above on 1 side of the machine, then the other. g341515 Figure 8 1. Left, rear guard 3. Torx-head bolt 2. Nut 3.
2. 5 Insert the lock pin through the bagger frame and cross brace (Figure 12). Note: You may need to loosen the hardware to align the lock pin to the hole. Installing the Bagger Frame Parts needed for this procedure: 1 Bag support 2 Lock-pin assembly Procedure 1. Arrange the bagger frame around the pivot pins on the support bracket and rotate it forward (Figure 11). g038187 Figure 12 1. Hairpin cotter g341549 Figure 11 1. Pivot pin 2. Bagger frame 12 2. Lock pin 3.
6 7 Installing the Bags Installing the Hitch Cover Parts needed for this procedure: Parts needed for this procedure: 2 Bags 1 Procedure 1. Hitch cover Procedure Hook the bag to the bagger frame (Figure 13). 1. Apply a lubricant to the nipple on the hitch cover. 2. Align the hitch cover over the hitch and press it into place (Figure 14). g341572 Figure 14 1. Hitch cover 2. Nipple g341571 Figure 13 1. Bagger frame 2. 2. Bag Close and latch the hood assembly. 13 3.
4. 8 Remove the locknut, bolt, spring, and spacer holding the deflector to the pivot brackets (Figure 17). Removing the Existing Belt Cover, Bracket, and Discharge Chute No Parts Required Procedure Note: Clean the area around the belt cover before removing it. 1. Lower the mower deck to the lowest height-of-cut position. 2. Remove the right belt cover (Figure 15). g015594 Figure 17 1. Bolt 5. Spring installed 2. Spacer 6. Grass deflector 3. Locknut 7. J-hook end of spring 4. Spring 5.
9 Installing the Blower-Pulley Assembly and Belt-Cover Bracket Parts needed for this procedure: 1 Blower pulley 1 Pulley mount 3 Locknut (3/8 inch) 1 Belt-cover bracket 1 Speed nut 2 Carriage bolt (1/4 x 3/4 inch) 2 Locknut (1/4 inch) Procedure 1. g334846 Figure 18 Use a 3/8-inch ratchet in the square hole in the idler arm to remove tension on the idler spring (Figure 18). 1. Spring 4. Spring-loaded idler assembly 2. Clutch pulley 5. Ratchet 3. Mower belt 6.
3. Use a wrench (1-1/2 inches) to hold the spindle shaft, as you remove the hex nut (3/4 inch) and washer from the spindle shaft (Figure 19). Note: Retain the hex nut (3/4 inch) and washer. g341576 Figure 19 1. Hex nut (3/4 inch) 3. Right spindle shaft g341574 Figure 20 2. Washer 1. Locknut (3/8 inch) 4. Insert the threaded studs on pulley mount through the holes in the deck pulley (Figure 20). 5.
10. Ensure that the blade bolt is torqued to 75 to 81 N∙m (55 to 60 ft-lb). 11. Install the mower belt around the lower pulley of the double pulley (Figure 21). g341575 Figure 21 1. Lower pulley 2. Mower belt 12. Install the belt-cover bracket to the mower deck using 2 carriage bolts (1/4 x 3/4 inch) and 2 locknuts (1/4 inch) as shown in Figure 22. 13. Install the speed nut onto the belt-cover bracket (Figure 22). g038112 Figure 22 1. Carriage bolt (1/4 x 3/4 inch) 3. Speed nut 2.
10 Installing the Baffle Parts needed for this procedure: 1 Baffle 1 Carriage bolt (5/16 x 7/8 inch) 1 Flange nut (5/16 inch) 2 Carriage bolt (3/8 x 7/8 inch) 2 Flange nut (3/8 inch) Procedure 1. Remove the 2 existing flange nuts (3/8 inch) and 2 carriage bolts (3/8 x 7/8 inch) from the mower deck (Figure 23). Note: Retain the hardware that you removed during this procedure so that it is available for changeover. g341587 Figure 24 1. Flange nut (3/8 inch) 4. Flange nut (5/16 inch) 2.
11 Installing the Blower Assembly Parts needed for this procedure: 1 Blower assembly 1 Pivot pin 1 Roll pin Procedure g341589 Verify that the pivot pin is secured on the blower assembly in the correct location (Figure 25 or Figure 26). Figure 26 • If you have a 48-inch or 52-inch mower deck, there is only a single hole to install the pivot pin (Figure 25). 1. Blower assembly 3. Roll pin 2. Rear hole 4. Pivot pin 1.
3. Move the latch pin from the locking position to the open position (Figure 28). 12 Installing the Blower Belt, Spring, and Blower-Belt Cover Parts needed for this procedure: 1 Blower-belt cover 1 Cover knob Procedure 1. Arrange the blower belt around the drive pulley as shown in Figure 29. g018370 Figure 28 1. Blower assembly 5. Idler-pivot bracket 2. Latch pin (locking position) 6. Idler pulley 3. Latch pin (open position) 7. Belt (beneath the idler pulley) 4. Chute bracket 4.
g341601 Figure 31 1. Cover knob g018371 Figure 30 Installing the tension spring and aligning the belt 1. Blower assembly 6. Spring 2. Latch pin (locking position) 7. Idler-spring post 3. Chute bracket 8. Spring (hook end) 4. Idler-pivot bracket 9. Belt (aligned to the idler pulley) 5. Fixed spring post 3. Move the idler-pivot bracket toward the fixed spring post and install the spring by aligning the spring hook onto the idler-spring post (Figure 30).
Note: The hopper seal must protrude outward 13 from the bagger hood. Installing the Discharge Tubes Parts needed for this procedure: 1 Upper tube 1 Lower tube 3 Bolt (#10 x 3/4 inch) 3 Locknut (#10) 3 Washer (7/32 inch) g007027 Figure 33 1. Dimple Procedure 5. 1. Lower the machine deck to the lowest height-of-cut position. 2. Remove the bags for viewing the tube under the hood. 3.
Note: There is a latch on the top and bottom diameter) where the upper and lower tubes join together (Figure 36). of the blower housing. g003449 g037981 Figure 35 1. Blower assembly Figure 36 3. Latch (twin bagger shown) 2. Lower tube 1. Bagger hood 4. Blower assembly 2. Upper tube 5. Drill holes (7/32 inch) 3. Lower tube 7. Ensure that the machine deck is in the lowest height-of-cut position. 8. Verify that the dimple from Figure 33 is still in place. 9.
11. Join the upper and lower tubes with 3 bolts (#10 x 3/4 inch), flat washers, and locknuts as shown in Figure 37. 15 Checking the Tire Pressure For Machines with Pneumatic Tires Only No Parts Required Procedure Increase the tire pressure due to the additional weight. Note: This is not applicable with semi-pneumatic tires. Maintain the air pressure in the rear tires at 90 kPa (13 psi). Uneven tire pressure can cause uneven cut.
Emptying the Grass Bags Operation Note: Determine the left and right sides of the machine from the normal operating position. WARNING Debris, such as leaves, grass, or brush can catch fire. A fire in the engine area can cause personal injury and property damage. • Keep the engine and muffler area free of debris accumulation. • Take care when opening the bagger cover to keep debris from falling onto the engine and muffler area. • Allow the machine to cool before storing it.
8. Lower the bagger hood over the bags. 9. Latch the bagger hood. Removing the Bagger WARNING Clearing Obstructions from the Bagger System Components around the engine are hot if the machine has been running. Touching hot components can cause burns. • Do not touch the engine hot components. WARNING • Allow engine to cool before removing the bagger. When the bagger is in operation, the blower is rotating and can cut off or injure hands and fingers. 1. Disengage the PTO. 2.
Operating Tips CAUTION As the bagger fills, extra weight is added to the back of the machine. If you stop and start the machine suddenly on hills, you may lose steering control or the machine may tip. Tips for Bagging Remembering the Size • Do not start or stop suddenly when going uphill or downhill. Avoid uphill starts. Remember that the machine is longer and wider with this attachment installed. By turning too sharply in confined places you may damage the attachment.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 8 hours • Inspect the blower belt. • Inspect the bagger. After the first 10 hours • Inspect the bagger. 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.
Inspecting the Bagger Attachment Inspecting the Blower Belt Service Interval: After the first 8 hours Every 25 hours Service Interval: After the first 10 hours Check belts for cracks, frayed edges, burn marks, or any other damage. Replace any belts that are damaged. Before storage Inspect the bagger attachment after the first 10 hours of operation, and monthly thereafter. 1. Check the chute, discharge tube, and the bagger top. Replace these parts if they are cracked or broken. 2.
Inspecting the Bagger Service Interval: Every 100 hours After the first 8 hours g038292 Figure 41 1. Spring-loaded idler pulley 9. 2. Spring 1. Disengage the PTO, move the motion-control levers to the NEUTRAL-LOCK position, and engeage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Check the upper tube, lower tube, bagger hood, and the blower assembly. Replace these parts if they are cracked or broken. 4.
Replacing the Grass Deflector Storage WARNING An uncovered discharge opening could allow the machine to throw objects toward you or bystanders, resulting in serious injury. Also, contact with the blade could occur. • Never operate the machine without a grass deflector, a mulch plate, or a bagger system installed. • Ensure that the grass deflector is in the down position. 1. Place one end of the spring behind the deck edge and the other end on the grass deflector (Figure 43). g015594 Figure 43 1.
Troubleshooting Problem There is abnormal vibration. There is reduced bagging performance. Possible Cause 1. The cutting blade(s) is/are bent or unbalanced. 1. Install new cutting blade(s). 2. The blade mounting bolt is loose. 3. The blower pulley or pulley assembly is loose. 4. The blower belt is worn. 5. The blower fan blade(s) is/are bent or unbalanced. 2. Tighten the blade mounting bolt. 3. Tighten the appropriate pulley. 1. Always operate the bagger at full throttle. 2.
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California Proposition 65 Warning Information What is this warning? You may see a product for sale that has a warning label like the following: WARNING: Cancer and Reproductive Harm—www.p65Warnings.ca.gov. What is Prop 65? Prop 65 applies to any company operating in California, selling products in California, or manufacturing products that may be sold in or brought into California.
