Toro 78491 Operator's Manual
Bagger
200 Series Z Master
Model No. 78491—Serial No. 220000001 and Up
Form No. 3327–888
Operator ’s Manual
Domestic English (EN)
Contents
Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 3. . . . . . . . . . . . . . . .
Setup 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Drive Wheels 5. . . . . . . . . . . . . . . .
Installing the Bagger Mounting Bracket and the Side
Brackets 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Bagger Mounting Bracket onto an Air
Cooled Machine 5. . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Bagger Mounting Bracket onto a Liquid
Cooled Machine 6. . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Side Brackets to the Machine 7. . . . .
Tightening all Mounting Bolts 8. . . . . . . . . . . . . . .
Drilling Holes for the Drive Pulley Assembly 8. . .
Installing the Drive Pulley Assembly 9. . . . . . . . . .
Installing the Bagger 10. . . . . . . . . . . . . . . . . . . . . .
Installing the Bagger Tensioner Pulley and Belt 11.
Adjusting the Bagger Belt 12. . . . . . . . . . . . . . . . . .
Adjusting the PTO Drive Belt 12. . . . . . . . . . . . . . .
Installing the Weights 13. . . . . . . . . . . . . . . . . . . . . .
Installing the Boot and Discharge Tubes 14. . . . . . .
Checking the Tire Pressure 15. . . . . . . . . . . . . . . . . .
Operation 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Opening the Bagger 15. . . . . . . . . . . . . . . . . . . . . . .
Holding the Bagger Door Open 16. . . . . . . . . . . . . .
Clearing Obstructions From the Bagger System 16.
Removing the Discharge Tubes 16. . . . . . . . . . . . . .
Removing the Bagger 17. . . . . . . . . . . . . . . . . . . . . .
Replacing the Grass Deflector Spring 17. . . . . . . . .
Operating and Bagging Tips 18. . . . . . . . . . . . . . . . .
Maintenance 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Maintenance Schedule 19. . . . . . . . .
Cleaning the Screens 19. . . . . . . . . . . . . . . . . . . . . .
Cleaning the Bagger 19. . . . . . . . . . . . . . . . . . . . . . .
Checking the Bagger Belt 19. . . . . . . . . . . . . . . . . . .
Greasing the Idler Arm 19. . . . . . . . . . . . . . . . . . . . .
Inspecting the Bagger 19. . . . . . . . . . . . . . . . . . . . . .
Inspecting the Mower Blades and Baffles 20. . . . . .
Storage 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction
damage. Although Toro designs and produces safe
products, you are responsible for operating the product
properly and safely.
Page
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–5992
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.
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.
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
2002 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
All Rights Reserved
Printed in the USA
2
Safety
• Use care when loading or unloading the machine into a
trailer or truck
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.
• Never operate with the discharge deflector raised,
removed or 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, 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
3
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.
Description Qty. Use
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 in.
Bolt, 3/8 x 1–1/4 in.
Flange Nut, 3/8 in.
Stiffener bracket
Bolts, 3/8 x 3/4 in.
Air cooled frame spacer
Bolt, 3/8 x 1–3/4 in.
Bolt, 3/8 x 1–1/4 in.
Flange Nut, 3/8 in.
Bolt, 3/8 x 1 in.
Flange Nut, 3/8 in.
Curved washer
1
1
1
4
2
4
2
14
2
8
1
2
2
4
6
6
6
Installing bagger mounting bracket and the side
brackets
Installing bagger mounting bracket to the
machine
Installing the side brackets
Pulley assembly
Bolt, 1/2 x 1–1/4 in.
Lock nut,1/2 in.
Washer, 1/2 in.
Template
Bagger
Clevis pin
Hairpin cotter
Bagger tensioner pulley
Bolt, 3/8 x 2 in.
Lock Nut, 3/8 in.
Washer, 3/8 in.
Bagger belt 1 Installing the bagger belt
1
4
4
4
1
1
2
2
1
1
1
1
Installing the pulley drive assembly
Installing the bagger
Installing the bagger tensioner pulley
4
Description UseQty.
Caster weight
U–bolt
Nut, 1/2 in.
Lock washer, 1/2 in.
Plate
Top weight
Bolt, 1/2 x 3 in.— for two top weights
Bolt, 1/2 x 4 in.— for three top weights
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.
Installing the Bagger Mounting
Bracket and the Side Brackets
2
2
4
4
2
6
2
2
Installing the caster weights
Installing the top weights
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 8, 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).
If you have a liquid cooled machine, go to page 6 for
Installing the Bagger Mounting Bracket onto a Liquid
Cooled Machine.
If you have an air cooled machine, use instructions below
for Installing the Bagger Mounting Bracket onto a Air
Cooled Machine.
2. In the top two holes, install 2 bolts (3/8 x 1–1/2 in.),
2 flange nuts (3/8 in.) 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 in.) and a
flange nut (3/8 in.) (Fig. 2).
4. Install a bracket stiffener to the side bracket and bagger
mounting bracket. Use 4 bolts (3/8 x 3/4 in.) and 4
flange nuts (3/8 in.) (Fig. 2).
5
5. Repeat the previous steps for the opposite side (Fig. 2).
6
4
5
3
3
5
4
3
7
4
3
10
3
1
9
8
2
6
m–5978
Figure 2
1. Bagger mounting bracket
2. Bolt, 3/8 x 1–1/4 in.
3. Flange nut, 3/8 in.
4. Bracket stiffener
5. Left side bracket
6. Bolt, 3/8 x 3/4 in.
7. Long frame spacer
8. Bolt, 3/8 x 1–1/2 in.
9. Short frame spacer
10. Right side bracket
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. 3).
1. Install the bagger mounting bracket to the rear frame of
the machine (Fig. 3).
2. In the top two holes, install 2 bolts (3/8 x 1–3/4 in.),
2 flange nuts (3/8 in.) and the air cooled frame spacer
(Fig. 3).
3. In the bottom two holes, install 2 bolts (3/8 x 1–1/4 in.)
and 2 flange nuts (3/8 in.) (Fig. 3).
1
3
6
2
6
2
m–5863
Figure 3
1. Bagger mounting bracket
2. Bolt, 3/8 x 1–1/4 in.
3. Flange nut, 3/8 in.
4. Bumper
5. Air cooled frame spacer
6. Bolt, 3/8 x 1–3/4 in.
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 8, 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. 4).
1. Install the side brackets to the bagger mounting bracket
(Fig. 4).
2. In the top two holes, install 2 bolts (3/8 x 1–1/2 in.),
2 flange nuts (3/8 in.), 2 long frame spacers, and one
short frame spacer (Fig. 4).
Note: Make sure the long frame spacers are installed as
shown in figure 4.
6
3. In the bottom hole, install a bolt (3/8 x 1–1/4 in.) and a
flange nut (3/8 in.) (Fig. 4).
4
3
4. Install a bracket stiffener to the side bracket and bagger
mounting bracket. Use 4 bolts (3/8 x 3/4 in.) and 4
flange nuts (3/8 in.) (Fig. 4).
5. Repeat the previous steps for the opposite side (Fig. 4).
6
5
4
10
3
4
3
7
3
7
1
9
6
8
2
m–5979
Figure 4
1. Bagger mounting bracket
2. Bolt, 3/8 x 1–1/4 in.
3. Flange nut, 3/8 in.
4. Bracket stiffener
5. Left side bracket
6. Bolt, 3/8 x 3/4 in.
7. Long frame spacer
8. Bolt, 3/8 x 1–1/2 in.
9. Short frame spacer
10. Right side bracket
1
3
5
2
5
2
m–5864
Figure 5
1. Bagger mounting bracket
2. Bolt, 3/8 x 1–1/4 in.
3. Flange nut, 3/8 in.
4. Bumper
5. Bolt, 3/8 x 1–3/4 in.
Installing the Side Brackets to
the Machine
The following instructions are for both air cooled and
liquid cooled.
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 8, for the
correct procedure to tighten the bolts.
Installing the Bagger Mounting Bracket
onto a Liquid Cooled Machine
1. Install the bagger mounting bracket to the rear frame of
the machine (Fig. 5).
2. In the top two holes, install 2 bolts (3/8 x 1–3/4 in.) and
2 flange nuts (3/8 in.) (Fig. 5).
3. In the bottom two holes, install 2 bolts (3/8 x 1–1/4 in.)
and 2 flange nuts (3/8 in.) (Fig. 5).
Note: Hydraulic lines may need to be adjusted when
installing the side brackets onto the machine. This will
allow for fastener clearance.
1. Install the side plates to the side of the mower using 6
bolts (3/8 x 1 in.), 6 curved washers (3/8 in.), and 6
flange nuts (3/8 in.) (Fig. 6).
Note: Make sure the curved washers are installed as shown
in figure 6.
7
4
2 3
12
m–3746
1
32
m–5875
Figure 6
1. Side bracket
2. Curved washer, 3/8 in.
3. Bolt, 3/8 x 1 in.
4. Flange nut, 3/8 in.
Tightening all Mounting Bolts
The following steps are the correct sequence to tighten the
side brackets and the bagger mounting bracket.
All 3/8 in. mounting bolts need to be torqued to 35 ft.–lb.
(48 Nm).
1. Tighten the bagger mounting bracket to the rear frame
first (Figures 3 or 5).
2. Tighten the bagger mounting bracket to the side
brackets (Figures 3 or 5).
3. Tighten the bracket stiffeners to both the side plates and
the bagger mounting bracket (Figures 2 or 4).
4. Tighten the side brackets to the side of the mower
(Fig. 6).
5. Install the drive wheels.
Figure 7
1. Rear Idler pulley—remove 2. Adjustment slot
2. Place a wooden block under the spring loaded idler, to
hold it above the rear frame (Fig. 19). This will prevent
the pulley from interfering with the template.
3. Position the template under the rear frame so the sides
are flush with the frame and is fully against the back of
the frame (Figures 8 and 9).
1
3
6. Lower the machine onto the drive wheels.
Drilling Holes for the Drive
Pulley Assembly
Use the metal template, included with the bagger, to locate
the drive pulley assembly holes.
1. Remove the existing right idler pulley on rear of
traction unit (Fig. 7). This pulley is used for the PTO
drive belt.
Note: Save the idler pulley. Replace if the bagger and drive
pulley assembly are removed.
2
Figure 8
1. Rear frame
2. Template
3. Drill 17/32 in. holes here
4. Clamp the template in place. Using the template, drill
four 1/8 in. pilot holes into the rear frame (Figures 8
and 9).
8
m–5890
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