Toro 78499 Operator's Manual

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Form No. 3329–570 Rev A

62 inch Triple Bagger and Finishing Kit

200 Series Z Master

Model No. 78456—Serial No. 230000001 and Up Model No. 78499

Operator ’s Manual

English (EN)

Contents

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 Grass Deflector Bracket 7. . . . . . . .

Removing the Mower 8. . . . . . . . . . . . . . . . . . . . . .

Preparing the Mower 9. . . . . . . . . . . . . . . . . . . . . .

Removing the Existing Blades 9. . . . . . . . . . . . . . .

Removing the Cutting Chamber Brackets 9. . . . . .

Installing the Center Rear Baffle 10. . . . . . . . . . . . .

Grinding the Welds 11. . . . . . . . . . . . . . . . . . . . . . . .

Installing the Left Rear Baffle 11. . . . . . . . . . . . . . .

Installing the Rear Tunnel Baffle 12. . . . . . . . . . . . .

Installing the Right Rear Baffle 13. . . . . . . . . . . . . .

Installing the Front Tunnel Baffle 14. . . . . . . . . . . .

Installing the Blade Stiffener 16. . . . . . . . . . . . . . . .

Removing the Existing Mower Pulley and Right Rear

Gage Wheel 16. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Pulley Assembly 17. . . . . . . . . . . . . . .

Installing the Mounting Plates 17. . . . . . . . . . . . . . .

Installing the Gage Wheel 18. . . . . . . . . . . . . . . . . .

Installing the Mower and PTO Drive Belts 19. . . . .

Removing the Drive Wheels and Bumper Guard 20.

Installing the Bagger Brackets 21. . . . . . . . . . . . . . .

Installing the Blower Assembly 22. . . . . . . . . . . . . .

Installing the Bagger Belt and Idler Spring 23. . . . .

Installing the Bagger Tube Support and Elbow 25. .

Installing the Hood Assembly and Bags 25. . . . . . . .

Installing the Bagger Tube 27. . . . . . . . . . . . . . . . . .

Installing the Weights 28. . . . . . . . . . . . . . . . . . . . . .

Adjusting the Parking Brake 29. . . . . . . . . . . . . . . .

Using the Grass Deflector 30. . . . . . . . . . . . . . . . . .

Installing the Grass Deflector 30. . . . . . . . . . . . . . . .

Operation 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emptying the Grass Bags 31. . . . . . . . . . . . . . . . . . .

Clearing Obstructions From the Bagger System 32.

Operating and Bagging Tips 33. . . . . . . . . . . . . . . . .

Maintenance 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Maintenance Schedule 34. . . . . . . . .

Cleaning the Hood Screen 34. . . . . . . . . . . . . . . . . .

Cleaning the Bagger 34. . . . . . . . . . . . . . . . . . . . . . .

Checking and Adjusting the Bagger Belt Tension 35

Checking and Adjusting the Blower Latch 36. . . . . .

Page

Replacing the Blower Belt 37. . . . . . . . . . . . . . . . . .

Greasing the Blower 37. . . . . . . . . . . . . . . . . . . . . . .

Checking the Blower Liner 38. . . . . . . . . . . . . . . . .

Replacing the Blower Liner 38. . . . . . . . . . . . . . . . .

Inspecting the Bagger 39. . . . . . . . . . . . . . . . . . . . . .

Inspecting the Mower Blades and Baffles 39. . . . . .

Installing Mower Blades 39. . . . . . . . . . . . . . . . . . . .

Storage 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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.

 2003 by The Toro Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196

Printed in the USA

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.

• 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.

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.

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.

• 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.

• 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, shut off the engine before leaving the operator’s position for any reason including emptying the grass catcher or unclogging the chute.

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

1-653554

80-8040

88-8950

106-0871

98-4387

1. Warning—wear hearing protection.

93-1122

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 2

3 4

Center rear baffle Bolt, 5/16 x 5/8 inch Flange nut, 5/16 inch

Left rear baffle Bolt, 1/4 x 5/8 inch Flange nut, 1/4 inch

Tunnel baffle—rear Bolt, 5/16 x 5/8 inch Flange nut, 5/16 inch Bolt, 1/4 x 5/8 inch Lock nut, 1/4 inch

Right rear baffle Bolt, 1/4 x 5/8 inch Flange nut, 1/4 inch

Tunnel baffle—front Carriage bolt, 5/16 x 5/8 inch Flange nut, 5/16 inch

1 5 5

1 3 3

1 2 2 1 1

1 2 2

1 3 3

Installing the center rear baffle

Installing the left rear baffle

Installing the rear tunnel baffle

Installing the right rear baffle

Installing the front tunnel baffle

6 7 8

9 10

Blade stiffener 3 Installing the blade stiffeners

No parts needed

Pulley assembly 1

Mounting plate Bolt, 3/8 x 1–1/4 inch Flange nuts, 3/8 inch Template

Roller bushing Bolt, 3/8 x 4–1/4 inch

2 4 4 1

1 1

Removing the existing mower pulley assembly and the right rear gage wheel

Installing the pulley assembly, belt and cover

Installing the mounting plates

Installing the gage wheel

Step UseQty.Description

11 12

13 14

No parts needed

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

Blower assembly 1 Installing the blower assembly

Blower belt cover Bagger Belt Idler spring Pulley cover

1 1

1 10 10

Installing the mower and PTO drive belts

Removing the drive wheels and rear bumper guard

Installing the bagger brackets

Installing the bagger belt and idler spring

16 17 18

Hood assembly Bag Clevis pin Hairpin cotter

Bagger tube support Elbow Bolt, 1/4 x 1–1/2 inch Nut, 1/4 inch Flat washer, 1/4 inch

Bagger tube Clamp Knob Blower adapter

Installing the hood assembly and bags

Installing the bagger tube support and elbow

Installing the bagger tube

Step UseQty.Description

Caster weight U–bolt Nut, 1/2 inch Lock washer, 1/2 inch

Plate Top weight Bolt, 1/2 x 3 inch Plate

No parts needed Adjusting the parking brake

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.

2 2 4 4

Installing the weights

2 2 2 2

Removing the Grass Deflector Bracket

Note: This section is only for mowers with grass deflector bracket welded to the mower (Fig. 2).

1. Remove the grass deflector bracket from the mower as

shown in Figure 2. This will avoid any interference with the rear tunnel baffle.

2. If you have a mower like the one shown in Figure 2,

contact an Authorized Service Dealer for a discharge chute kit. This kit will allow you to install the bagger and blower.

m–6169

Figure 2

1. Mower 2. Remove grass deflector bracket

Removing the Mower

Note: If the mower is removed from the bottom bolts attaching the chains to the mower, the mower will not need to be leveled.

1. Remove the PTO drive belt from the rear idler arm

(Figures 3 and 5).

M–4417

Figure 3

1. Center bolt, spring loaded idler

2. Alignment hole

2. Remove the PTO drive belt from the center mower pulley (Fig. 5).

3. Remove PTO drive belt from the front fixed idler pulley assembly (Figures 4 and 5).

m–6763

Figure 4

1. Center mower pulley

2. PTO Drive belt

3. Fixed idler pulley assembly

m–4451

Figure 5

Top View

1. Center mower pulley

2. PTO Drive belt

3. Fixed idler pulley assembly

4. Rear idler pulley

4. Loosen two nuts securing idler plate and move the idler

arm to relieve belt tension on the idler pulley (Fig. 29).

5. Remove the mower belt from the right side pulley.

M–4312

Figure 6

Top View

1. Mower Belt

2. Idler Arm

3. Idler nuts

4. Idler adjusting nut

5. Right side pulley

6. Idler pulley

6. Raise the mower with the height–of–cut lever.

7. Place wood blocks under the mower and lower the

mower onto the wood blocks.

Note: If the mower is removed from the bottom bolts attaching the chains to the mower, the mower will not need to be leveled.

8. Remove the four bolts at the bottom of the chains that

are attached to the mower (Fig. 7).

9. Remove the nuts and bolts holding the push arm pins

(Fig. 7).

Note: The gage wheels may need to be removed to allow the push arm pins to be removed (Fig. 7).

10.Remove the push arm pins (Fig. 7).

Removing the Existing Blades

Note: In most mowing conditions, improved bagging performance can be achieved by using bagging blades (high lift). Contact an Authorized Service Dealer for the proper blades for different mowing conditions.

11. Raise the height of cut lever and slide the mower out

from under the machine (Fig. 7).

4 7 5

M–4450

Figure 7

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

1. Remove the existing blades from the spindles. Keep the

blade bolts for installing blades.

Warning

Contact with sharp blade can cause serious personal injury.

• Wear gloves or wrap sharp edges of the

blade with a rag.

Removing the Cutting Chamber Brackets

Note: This section is only for mowers with brackets welded to the cutting chamber (Fig. 8).

1. Remove the three cutting chamber brackets from the

mower (Fig. 8).

2. Grind the welds flat on rear part of the cutting

chambers. This will allow the correct fit for the cutting chamber baffles.

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.

Warning

Contact with sharp blade can cause serious personal injury.

• Wear gloves or wrap sharp edges of the blade

with a rag.

m–6159

Figure 8

1. Cutting chamber 2. Cutting chamber stiffener

Step

Parts needed for this step:

• 1 Center cutting chamber baffle

• 5 Bolts, 5/16 x 5/8 inch

• 5 Flange nuts, 5/16 inch

Installing the Center Rear Baffle

A right angle drill will be needed to perform this installation.

Note: If present, use existing holes for installing this baffle. Make sure the existing holes match the holes in the baffle.

1. Place the center rear baffle behind the rear cutting blade

chamber (Fig. 11).

2. Align the center rear baffle so the baffle flange is

3–5/8 in. (92 mm) from the top of the cutting chamber (Figures 9 and 11).

Important Make sure the baffle flange is 3–5/8 inch

(92 mm) from the top of the cutting chamber at all locations (Figures 9 and 13).

m–6774

Figure 10

1. Baffle flange 2. Baffle to top of cutting chamber, 3–5/8 in.

3. Clamp the center baffle in place, tightly against the

cutting chamber.

4. Using the baffle as a template, mark, center punch and

drill 1/8 inch pilot holes at the 5 locations (Fig. 11).

5. Drill 11/32 inch dia. holes through the pilot holes

(Fig. 11).

Install the center baffle with 5 bolts (5/16 x 5/8 inch) and 5 flange nuts (5/16 inch) (Fig. 11).

Important Make sure the bolt heads are installed on the

inside of the cutting chamber. See figure 11.

154 32

1. Baffle flange

2. Blade

3. Spindle

Figure 9

4. Blade clearance, 1/2 ±1/16 in.

5. Baffle to top of cutting chamber, 3–5/8 in.

m–5942

1. Center Baffle

2. Hole to drill

3. Center cutting blade chamber

Figure 11

4. Flange nuts, 5/16 inch

5. Bolt, 5/16 x 5/8 inch

m–6775

Step

Parts needed for this step:

• 1 Left rear baffle

• 3 Bolts, 1/4 x 5/8 inch

• 3 Flange nuts, 1/4 inch

2. Align the left rear baffle within 3/16 inch and flush with

the bottom of the center baffle (Fig. 13).

3. Position the left rear baffle so the baffle flange is

3–5/8 in. (92 mm) from the top of the cutting chamber (Fig. 9).

Important Make sure the baffle flange is 3–5/8 inch

(92 mm) from the top of the cutting chamber at all locations (Fig. 9).

Note: If 3–5/8 inch (92 mm) can not be achieved, the

bottom welds have to be ground down. Refer to Grinding the Welds on page 11.

4. Clamp the baffle in place.

5. Using the baffle as a template, drill three, 9/32 inch

diameter, holes into the left cutting chamber (Fig. 14).

Grinding the Welds

Note: If 3–5/8 inch (92 mm) can not be achieved when installing the left and right rear baffles, the bottom welds need to be ground down.

1. Grind the welds flat on rear part of the mower. This will

allow the correct fit for the left and right rear baffles (Fig. 12).

m–5877

Figure 12

1. Grind welds flat

Installing the Left Rear Baffle

1. Place the left rear baffle behind the left cutting chamber

(Fig. 13). The tabs will mount on the outside of the mower.

6. Install the left baffle with 3 bolts (1/4 x 5/8 inch) and 3

flange nuts (1/4 inch) (Fig. 14).

Important Make sure the bolt heads are installed on the

inside of the cutting chamber. See figure 14.

1. Center Baffle

2. Left baffle

3. Flush with bottom of center baffle

4. Left cutting chamber

Figure 13

5. Baffle flange to top of cutting chamber, 3–5/8 in. (92 mm)

6. 0 to 3/16 inch gap

m–5874

m–6773

Step

1. Left rear baffle

2. Left side of mower

3. Bolt, 1/4 x 5/8 inch

4. Flange nut, 1/4 inch

Figure 14

5. Hole to drill

6. Rear center baffle

7. Cutting chamber

8. Tab

Parts needed for this step:

• 1 Tunnel baffle—rear

• 2 Bolts, 5/16 x 5/8 inch

4 2

• 2 Flange nuts, 5/16 inch

Installing the Rear Tunnel Baffle

1. Place the rear tunnel baffle against the rear wall of the

discharge tunnel (Fig. 16).

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. 16).

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 in Figures 15, 16, and 17.

5. Remove the clamp.

6. Drill two, 11/32 inch diameter, holes through the pilot

holes along the tunnel (Figures 15 and 16).

m–6768

Figure 15

1. Rear tunnel baffle

2. Mounting bracket

3. Flush edge with outside of mounting bracket

4. Drill an 11/32 inch hole here

Step

m–6767

Figure 16

1. Rear tunnel baffle 2. Drill an 11/32 inch hole

7. Drill a, 9/32 inch diameter, hole through the side of the

right cutting chamber (Fig. 17).

8. Install the rear tunnel baffle to the mower with

2 carriage bolts (5/16 x 5/8 inch) and 2 flange nuts (5/16 inch) (Fig. 17).

Important Make sure the bolt heads are installed on the

inside of the cutting chamber.

here

Parts needed for this step:

• 1 Right rear baffle

• 3 Bolts, 1/4 x 5/8 inch

• 3 Flange nuts, 1/4 inch

Installing the Right Rear Baffle

1. Place the right baffle behind the right cutting chamber

(Fig. 18). The tabs will mount on the outside of the mower.

2. Align the right baffle against and flush with the bottom

of the center baffle (Fig. 18).

3. Position the left rear baffle so the baffle flange is

3–5/8 in. (92 mm) from the top of the cutting chamber (Fig. 9).

Important Make sure the baffle flange is 3–5/8 inch

(92 mm) from the top of the cutting chamber at all locations (Fig. 9).

m–6769

1. Rear tunnel baffle

2. Bolt, 5/16 x 5/8 inch

3. Flange nut, 5/16 inch

Figure 17

4. Tunnel rear wall

5. Drill a 9/32 inch hole here

6. Side of cutting chamber

Note: If 3–5/8 inch (92 mm) can not be achieved, the bottom welds have to be ground down. Refer to Grinding the Welds on page 11.

4. Clamp the baffle in place.

5. Using the baffle as a template, drill three, 9/32 inch

diameter, holes into the right cutting blade chamber (Fig. 19).

6. Install the right baffle with 2 bolts (1/4 x 5/8 inch) and

2 flange nuts (1/4 inch) (Fig. 19).

Important Make sure the bolt heads are installed on the

inside of the cutting chamber.

7. Install the right rear baffle to the rear tunnel baffle with

a bolt (1/4 x 5/8 inch) and a flange nut (1/4 inch) (Fig. 19).

1. Center Baffle

2. Right baffle

Figure 18

m–6813

3. Flush with center baffle

4. Right cutting chamber

Step

Parts needed for this step:

• 1 Tunnel baffle—front

• 3 Carriage bolts, 5/16 x 5/8 inch

• 3 Flange nuts, 5/16 inch

Installing the Front Tunnel Baffle

1. Remove the existing right front blowout baffle. Save

baffle and hardware for use when bagging baffles are removed.

2. Place the front tunnel baffle against the the front wall of

the discharge tunnel. (Fig. 20).

3. Align the front tunnel baffle flush with the outside of

the mounting bracket (Figures 20 and 21).

1. Right baffle

2. Right side of mower

3. Bolt, 1/4 x 5/8 inch

Figure 19

4. Flange nut, 1/4 inch

5. Holes to drill

6. Rear tunnel baffle

m–6770

Figure 20

1. Front tunnel baffle

2. Flush edge with mounting bracket

m–6764

3. Front tunnel wall

Bottom View

m-5958

Figure 21

1. Front tunnel baffle

2. Mounting bracket

3. Flush edge with mounting bracket

4. Grass deflector

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 3 locations (Fig. 22).

6. Remove the clamp.

7. Remove the baffle and drill two, 11/32 inch diameter,

through the pilot holes in the top of the mower (Fig. 22).

1. Front tunnel baffle

2. Carriage Bolt, 5/16 x 5/8 inch

3. Nut, 5/16 inch

Figure 22

m–6765

4. Hole to drill

5. Front wall

6. Mounting bracket

8. Drill one, 11/32 inch diameter, hole through the pilot

hole in the side of the discharge tunnel (Fig. 22).

9. Install the front tunnel baffle with 3 carriage bolts

(5/16 x 5/8 inch) and 3 flange nuts (5/16 inch) (Fig. 22).

Step

Parts needed for this step:

• 3 Blade stiffeners

Installing the Blade Stiffener

1. Install the blade onto the spindle shaft (Fig. 23).

Important The sail, or the curved part of the blade,

must be pointing upward toward the inside of the mower to ensure proper cutting.

2. Install the blade stiffener, the spring disk and the blade bolt (Fig. 23). Torque the blade bolt to 85–110 ft-lb

(115–150 Nm).

3. Rotate the blades to ensure there is clearance between the blade tips and the baffles.

No Parts needed for this step.

Removing the Existing Mower Pulley and Right Rear Gage Wheel

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. 25). Save the nut and washer.

4. Remove the existing pulley assembly.

5. Remove the existing gage wheel from the right rear of

the mower (Fig. 24).

4. If contact is made, do not use the mower. Check and make sure the baffles are installed properly.

Important Do not use the mower if blades contact the

baffles.

3 5 4

1. Sail Area of Blade

2. Blade

3. Spring Disk

Figure 23

4. Blade Bolt

5. Cone Towards Bolt Head

6. Stiffener

m–6728

6. Remove the gage wheel from the stud by removing the

nut and washer (Fig. 24).

1. Gage wheel

2. Stud

3. Spring disk

Figure 24

4. Flange nut

5. Nut and washer—retain

m–4161

Step

Parts needed for this step:

• 1 Pulley assembly

Installing the Pulley Assembly

1. Install new pulley assembly onto the spindle. Install it

so the large pulley is on the bottom (Fig. 25).

2. Install the washer and nut (Fig. 25).

Important Tighten the nut to 115 ft–lb ± 15 ft–lb

torque.

3. Grease the spindle to fill bearings with grease.

1 2

3 4

Parts needed for this step:

• 2 Mounting plates

• 1 T emplate

• 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. 57).

2. Remove the existing right rear gage wheel (Fig. 57).

1. Nut

2. Washer

3. Pulley Assembly

4. Blade spindle

Figure 25

5. Mower

6. Lower pulley

7. Upper pulley

m–6793

3. Position the template onto the the mounting bracket and align with the top and sides of the mounting bracket. (Fig. 26).

4. Clamp the template to the mounting bracket (Fig. 26).

5. Mark and center punch the 4 holes and remove the

template (Fig. 26).

6. Drill 1/8 inch pilot holes at the 4 marked locations and then drill 7/16 or 1/2 inch diameter holes.

7. File the metal burrs from the drilled holes.

holes

m–6752

1. Template

2. Mounting bracket

Figure 26

3. Mark and center punch

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. 27).

Step

Parts needed for this step:

Figure 27

1. Mounting plate

2. Bolt, 3/8 x 1–1/4 inch

3. Flange nut, 3/8 inch

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.

4. Mounting bracket

5. Drill 7/16 inch holes

m–6785

• 1 Bolt, 3/8 x 4–1/4

• 1 Roller bushing

Installing the Gage Wheel

1. Install the gage wheel to the new mounting plate with a

new bolt (3/8 x 4–1/4 inches), new roller bushing, existing flat washer, and existing nut (Fig. 29).

Note: The roller bushing and bolt replace the existing gage wheel stud (3/8 x 4–1/4 inches).

Figure 28

4. Gage wheel

5. Flat washer

6. Nut

m–6784

1. Mounting plate

2. Bolt, 3/8 x 4–1/4 inch

3. Roller bushing

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 and right side spindle pulleys (Fig. 29).

2. Using a socket and torque wrench, rotate the idler

adjusting nut until the torque is 25–30 ft–lb (34–41 Nm). Tighten the two idler nuts.

m–4451

1. Clutch

2. Clutch retaining strap

3. Clutch terminal

4. PTO belt

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 31).

Note: Check position of center bolt in Low Height of Cut. The center bolt must be at or below the top alignment hole. Check position of center bolt in a High Height of Cut. The center bolt must be at or above the lower adjustment hole (Fig 31).

M–4373

Figure 30

5. Machine frame

6. 1/4 inch Belt Twist

7. 1/8 inch Belt Twist

M–4312

Figure 29

Top View

1. Deck Belt

2. Idler Arm

3. Idler nuts

4. Idler adjusting nut

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 4 and 30).

Important Check the amount of twist in belt between

pulleys. Make sure it is only what is specified in figure 30.

Figure 31

1. Center bolt, spring loaded idler

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.

2. Alignment hole

M–4417

Step

Figure 32

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 31). Adjust, if necessary, and tighten all hardware securely.

5. Rotate the belt guide, on rear of the mower, so it is

1/8–1/4 inch (3–7 mm) away from the vertical side of the PTO belt (Fig. 33).

No parts needed for this step.

m–3746

Removing the Drive Wheels and Bumper Guard

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. Remove the existing rear bumper guard (Fig. 34).

1. Belt guide

2. PTO Drive belt

Figure 33

3. 1/8–1/4 inch (3–7 mm)

M–4374

m–6794

Figure 34

1. Rear bumper guard

2. Bolt

2. Loosen the drive wheel lugs or nuts.

3. Raise the rear of the machine and support with jack

stands.

4. Remove the drive wheels.

3. Nut

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 22, 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. 35).

2. Repeat the previous step for the opposite side.

1. Bagger bracket—left side shown

2. Bolt, 3/8 x 1 inch

3. Flange nut, 3/8 inch

Figure 35

4. Machine side frame

5. Existing hole

6. Belleville washer, 3/8 inch

m–6742

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 36.

1. Remove the existing two bolts in the bottom of the rear frame (Fig. 36).

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. 36).

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. 36).

1. Bagger mounting bracket

2. Bolt, 3/8 x 1 inch

3. Flange nut, 3/8 inch

4. Belleville washer, 3/8 inch

Figure 36

5. Rear frame

6. Existing bolts located here

Step

Parts needed for this step:

• 1 Blower assembly

Installing the Blower Assembly

m–6743

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. Stop the engine, remove the key, and wait for all

moving parts to stop before leaving the operating position.

3. Raise the grass deflector.

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 Nm).

1. Tighten the bagger mounting bracket to the rear frame

first (Fig. 36).

2. Tighten the bagger mounting bracket to the side

brackets (Fig. 36).

3. Tighten the side brackets to the side of the mower

(Fig. 35).

4. Install the drive wheels and torque to 95 ft-lb

(128 NM).

5. Lower the machine onto the drive wheels.

4. Slide the blower assembly peg into the hole on the

mounting plate (Fig. 37).

Figure 37

1. Mower

2. Blower assembly

3. Blower assembly peg

5. Close the blower assembly. (Fig. 42).

4. Mounting plate hole

5. Mounting plate

m–6747

6. Check if the latch fully engages the front latch peg.

Refer to Checking and Adjusting the Blower Latch on page 36.

Note: There needs to be a little or no gap between the blower assembly and the mounting plate.

Step

6. Install the new belt cover over the pulley assembly and

secure the latches (Fig. 39).

Parts needed for this step:

• 1 Blower belt cover

• 1 Idler spring

• 1 Bagger belt

• 1 Pulley cover

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 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. Slide the spring into the blower eyebolt (Fig. 38).

Figure 39

1. Belt cover 2. Latch

7. Install the bagger belt between the top mower pulley

and the belt cover (Fig. 40).

m–6755

4. Install the spring into the idler arm eyebolt (Fig. 38).

3 1

m–6276

Figure 38

1. Idler spring

2. Blower assembly

3. Idler arm eyebolt

5. Push down on the front latch (colored red) and open the

blower assembly (Fig. 41).

4. Blower eyebolt

5. Idler arm

Figure 40

1. Mower belt cover

2. Blower assembly

3. Top mower pulley

8. Route the bagger belt around the top pulley of the mower pulley assembly (Fig. 41).

9. Feed the belt between the idler pulleys (Fig. 41).

4. Bagger belt

5. Bagger belt—installed

m–6731

10.Route the bagger belt around the spring–loaded idler pulley (Fig. 41). The backside of belt will be touching

the pulley.

11. Route the bagger belt around the fixed idler pulley (Fig. 41).

12.Route the bagger belt around the blower pulley (Fig. 41).

15.Install the belt cover over the pulley assembly and

secure the 3 cover latches into the blower (Fig. 43).

3 2

m–6732

Figure 41

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)

13.Close the blower assembly and ensure the blower front

latch engages onto the front peg (Fig. 42).

1. Blower assembly

2. Blower belt cover

m–6236

Figure 43

3. Latch

m–6732

Figure 42

1. Blower front latch (Red) 2. Front peg

Important Make sure to check the belt and spring

length after the initial 8 hours of use.

14.Adjust the bagger belt tension. Refer to Checking and

Adjusting the Bagger Belt Tension on page 35.

Step

Parts needed for this step:

• 1 Tube support

• 1 Elbow

• 4 Bolts, 1/4 x 1–1/2 inch

• 4 Nuts, 1/4 inch

• 4 Flat washers, 1/4 inch

Installing the Bagger Tube Support and Elbow

1. Position the elbow inside the bagger hood (Fig. 44).

2. Install the elbow and tube support to the bagger hood

with 4 bolts (3/8 x 5/8 inch), 4 washers (3/8 inch), and 4 nuts (3/8 inch) (Fig. 44).

Parts needed for this step:

• 1 Hood assembly

• 3 Bags

• 2 Clevis pins

• 2 Hairpin cotter pins

Installing the Hood Assembly and Bags

Warning

Components around engine will be hot if the machine has been running. Touching hot components can cause burns.

• Do not touch engine components when hot.

• Allow engine to cool before performing

maintenance.

1. Tube support

2. Elbow

3. Bagger hood

1. Install the hood assembly onto the bagger mounting

bracket (Fig. 45).

m–6730

Figure 44

4. Nut, 1/4 inch

5. Flat washer, 1/4 inch

6. Bolt, 1/4 x 1–1/2 inch

1. Hood assembly 2. Bagger mounting bracket

m–6740

Figure 45

2. Install the 2 clevis pins into the hood assembly and

bagger mounting bracket. Secure it with 2 hairpin cotter pins (Fig. 46).

4. Lower the bagger hood over the bags.

m–6741

Figure 46

1. Hood assembly

2. Bagger mounting bracket

3. Hairpin cotter pin

4. Clevis pin

3. Install the bag tab into the notch in the hood assembly

(Fig. 47). Do this for all the bags.

Note: The bag will rest on the bagger frame (Fig. 47).

m–6719

Figure 48

1. Hood

2. Bags

3. Bagger latch

4. Latch hook

5. Position the bagger latch under the latch hook

(Figures 48 and 49).

6. Push down on the bagger latch until it locks into place

(Fig. 49).

1. Hood assembly

2. Bag

3. Bag tab

m–6264

Figure 49

1. Bagger latch 2. Latch hook

m–6718

Figure 47

4. Notch

5. Bagger frame

Step

Parts needed for this step:

• 1 Bagger tube

• 1 Clamp

• 2 Knobs

• 1 Blower adapter

Installing the Bagger Tube

Note: To ease assembly of the bagger tube to the blower adapter, apply soapy water to both the bagger tube and the adapter.

1. Install one end of the tube, 4 to 4–1/2 inches (102 to

114 mm) onto the blower adapter and secure it with a clamp (Fig. 50).

m–6252

Figure 51

1. Tube

2. Blower assembly

3. Top blower stud

Note: There are nubs on the inside of the bagger elbow that hold the upper end of the bagger tube (Fig. 52).

4. Place the upper tube into the bagger elbow (Fig. 52).

5. Move the upper tube back and forth, until at least two

ribs engage into the nubs inside the bagger elbow.

6. Make sure the tube rests on the tube support (Fig. 52).

4. Knob

5. Side blower stud

Figure 50

1. Tube

2. Blower adapter

3. Clamp

4. 4 to 4–1/2 inches (102 to 114 mm)

2. Place the blower adapter over the top blower stud and slide it into the side stud (Fig. 51).

3. Install the knobs onto the top and side stud (Fig. 51). This will secure the lower tube end to the blower assembly.

5. Tube installed onto the adapter 4 to 4–1/2 inches (102 to 114 mm)

m–6815

m–6728

1. Tube

2. Bagger hood

3. Nubs

Figure 52

4. Ribs

5. Elbow

6. Tube support

Step

3 6

Parts needed for this step:

• 2 Caster weights

• 2 Top weights

• 2 U–bolts

• 4 Nuts, 1/2 inch

• 2 Plates

• 4 Lock washers, 1/2 inch

• 2 Bolts, 1/2 x 3 inch

Installing the Weights

To comply with ANSI/OPEI B71.4–1999 Standard, weights must be added to the machine.

Installing the Caster Weights

Caution

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.

m–5882

Figure 53

1. Front caster weight

2. U–bolt

3. Plate

4. Nut

5. Front caster

6. Lock washer

Installing the Extra Top Weight

1. Install the top weight on top of the caster weight with a

bolt (1/2 x 3 inch) (Fig. 54).

• Install the front caster weights and top weights.

1. Place a caster weight on the front caster and install the

U–bolt through the caster weight (Fig. 53).

2. Install the plate, the nuts (1/2 inch) and the lock washer

(1/2 inch) under the frame and caster weight (Fig. 53).

3. Repeat for the opposite side.

1. Top weight

2. Bolt

m–6756

Figure 54

3. Front caster weight

4. Front caster wheel

Checking the Tire Pressure

Check and adjust the air pressure in the front and rear tires. Front tire pressure: 25 psi (172 kPa) (Fig. 54).

Rear tire pressure: 20 psi (140 kPa) (Fig. 55).

Figure 55

1. Valve stem

Check the Level of the Mower

Refer to the mower Operator’s Manual for the correct procedure.

m–1872

Figure 56

1. Brake lever

2. Spring 2–5/8 inch (67 mm)

3. Adjusting nut and jam nut below the spring

3. If adjustment is necessary, loosen the jam nut below the spring and adjust the nut directly below the spring (Fig. 56).

4. Turn the nut until the correct measurement is obtained. Turn the nut clockwise to shorten the spring length and turn them counterclockwise to lengthen the spring.

5. Tighten the two nuts, below the spring, together and repeat on the opposite side of the machine.

4. Collar on brake rod

5. 5/16 inch (8 mm)

6. Yoke and jam nut

7. Trunnion roller

m–3788

Step

No parts needed for this step.

Adjusting the Parking Brake

Check the parking brake for proper adjustment.

1. Disengage the brake lever (lever down).

2. Measure the length of the spring. The measurement

should be 2–5/8 inch (67 mm) between the washers (Fig. 56).

6. Engage the parking brake (lever up).

7. Measure the distance between the trunnion roller and

the collar on brake rod. The measurement needs be 5/16 inch (8 mm) (Fig. 56).

8. If adjustment is necessary, loosen the jam nut directly next to the yoke. Turn the nuts below the spring until the correct measurement is obtained (Fig. 56).

9. Tighten the jam nut next to the yoke and repeat on the opposite side of the machine.

Using the Grass Deflector

Installing the Grass Deflector

Note: Make sure the grass deflector is installed when the bagger and tubes are removed.

Warning

Without the grass deflector, bagger tubes or complete bagger assembly mounted in place, you and others are exposed to blade contact and thrown debris. Contact with the rotating mower blade(s) and thrown debris will cause injury or death.

• Always install the grass deflector when

removing the bagger and changing to side discharge mode.

• If the grass deflector is ever damaged, replace it

immediately. The grass deflector routes material down toward the turf.

• Never put your hands or feet under the mower.

• Never try to clear the discharge area or mower

blades unless you move the power take off (PTO) to off and rotate the ignition key to off. Also remove the key and pull the wire off of the spark plug(s).

1. 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.

2. 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.

Note: Make sure the grass deflector is installed when the bagger and tubes are removed.

The grass deflector spring will have either an L end or a straight end (Fig. 57).

Warning

An uncovered discharge opening could allow the lawn mower to throw objects in the operator’s or bystander’s direction and result in serious injury. Also, contact with the blade could occur.

Never operate the lawn mower unless you install a cover plate, a mulch plate, grass deflector or a grass chute and catcher.

1. Place spacer and spring onto grass deflector. Place the L

or the straight end of spring behind deck edge.

Note: Make sure the L or the straight end of spring is installed behind deck edge before installing the bolt as shown in figure 57.

2. Install bolt and nut. Place J hook end of spring around

grass deflector (Fig. 57).

Important The grass deflector must be lowered down

into position. Lift the deflector up to test that it lowers into the full down position.

1. Bolt

2. Spacer

3. Locknut

4. Spring

5. Spring installed

6. Grass Deflector

m–6085

Figure 57

7. L end of spring, place behind mounting bracket before installing bolt

8. J hook end of spring

9. Mounting bracket

10. Straight end—possible style of spring

Operation

Caution

Note: Determine the left and right sides of the machine from the normal operating position.

Important Set the parking brake when leaving the

machine unattended, even for just a few minutes.

Warning

To avoid personal injury, follow these procedures:

• Become familiar with all operating and safety

instructions in the operator’s manual for your mower before using this attachment.

• Never remove the bagger or bagger tubes while

the engine is running.

• Always turn the engine off and wait for all

moving parts to stop before clearing an obstruction from the bagging system.

• Never do maintenance or repairs while the

engine is running.

• Set the parking brake before clearing an

obstruction from the bagging system and before any maintenance.

Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended.

Always remove the ignition key and set the parking brake when leaving the machine unattended, even for just a few minutes.

Emptying the Grass Bags

Grass bags are heavy when full. Be careful when lifting or handling a grass bag that is full.

1. Disengage the PTO and set the parking brake.

2. Unlatch the bagger latches (Fig. 49).

3. Open the bagger hood.

4. Compress the debris into the bags. With both hands, lift

up on the bag and unhook it from the bagger bracket.

5. Grab the handle on the bottom of the bag and tip it over

to empty the bag (Fig. 58).

Warning

• Always install the grass deflector when

removing the bagger and changing to side discharge mode.

• If the grass deflector is ever damaged, replace it

immediately. The grass deflector routes material down toward the turf.

• Never put your hands or feet under the mower.

• Never try to clear the discharge area or mower

blades unless you move the power take off (PTO) to off and rotate the ignition key to off. Also remove the key and pull the wire off of the spark plug(s).

• Turn off the engine before unclogging the

discharge chute.

m–6242

Figure 58

1. Bag 2. Bottom handle

6. Repeat for the other bags.

7. Install the bag tab into the notch in the bagger support

frame (Fig. 47). Do this for all bags.

8. Lower the bagger hood over the bags (Fig. 48).

9. Latch the bagger hood (Fig. 49).

Clearing Obstructions From the Bagger System

Danger

When the bagger is in operation, the blower can be rotating and cut off or injure hands.

• Before adjusting, cleaning, repairing and

inspecting the blower, and before unclogging the chute, turn off the engine and wait for all moving parts to stop. Remove the key.

• Use a stick, not your hands, to remove an

obstruction from the blower and tube.

• Keep face, hands, feet, and any other part of

your body or clothing away from concealed, moving, or rotating parts.

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. Empty the bags.

4. Remove the knobs and then the tube from the blower

assembly (Fig. 51).

5. Remove the tube from the bagger hood (Fig. 52).

6. Using a stick or similar object, not your hands, to

remove and clear the obstruction from the tube assembly.

Note: In most cases, the debris can be shaken out of the tube.

7. If the blower assembly is plugged, unlatch the bagger

blower assembly and swing it open (Fig. 41).

8. Using a stick or similar object, not your hands, to

remove and clear the obstruction from the blower assembly.

9. After you remove the obstruction, install the complete

bagger system and resume operation.

Operating and Bagging Tips

Machine Size

Remember that the machine is longer and wider with this attachment installed. By turning too sharply in confined places you may damage the attachment or other property.

Trimming

Bagging Long Grass

Excessively long grass is heavy and may not be propelled completely into the bagger. If this happens, the tube and blower assembly may plug.

Bagging Wet Grass

If possible, always try to cut grass when it is dry. Wet grass can cause plugging.

Always trim with the left side of the mower. Do not trim with the right side of the mower because you could damage the blower assembly and bagging tube.

Cutting Height

For optimum bagging performance, set the deck height–of–cut to remove no more that 2 to 3 inches (51 to 76 mm) or 1/3 of the grass height, whichever is less. Cutting off more than this will reduce the capacity of the vacuum system.

Cutting Frequency

Cut the grass often, especially when it grows rapidly. You will have to cut your grass twice if it gets excessively long Refer to Bagging Long Grass on page 33.

Cutting Technique

For best lawn appearance, be sure to slightly overlap the mower into the previously cut area. This helps reduce the load on the engine and reduces the chance of plugging the blower assembly and tube.

Bagging Speed

The bagging system may plug if you drive too fast and the engine speed gets too slow. On hills it may be necessary to slow the machines ground speed. Mow down hill whenever possible.

Reducing Plugging

To avoid plugging the bagging system, reduce ground speed and mow the grass at a high height-of-cut, then lower the mower to your normal cutting height and repeat the bagging process.

Signs of Plugging

As you are bagging, a small amount of grass clippings normally blow out the front of the mower. An excessive amount of clipping blow-out indicates that the bagger is full or the tube is plugged.

Bagging Blades

In most mowing conditions, improved bagging performance can be achieved by using bagging blades (high lift). Contact an Authorized Service Dealer for the proper blades for different mowing conditions.

Curb Climbing and Loading

Always lift the deck to the highest position when loading the machine on trailers or ascending/descending a curb. Leaving the mower in a lower position can cause damage to mower baffles while loading and going over a curb. If a curb is higher than 6 inches (152 mm), cross it at a sharp angle with the deck fully raised. Use extreme caution

when loading onto a trailer.

Caution

As the bagger fills, extra weight is added to the back of the machine. If you stop and start suddenly on hills, you may lose steering control or the machine may tip.

• Do not start or stop suddenly when going uphill

or downhill. Avoid uphill starts.

• If you do stop the machine when going uphill,

disengage the PTO. Then back down the hill using a slow speed.

• Do not change speeds or stop on slopes.

Maintenance

Important If the machine is on a slope and set the parking brake to prevent the machine from slowly rolling.

Recommended Maintenance Schedule

Maintenance Service

Interval

Each Use • Hood screen—clean

First 8 Hours

25 Hours

40 Hours • Blower liner—inspect

100 Hours • Bagger—inspect

Storage Service

Note: Determine the left and right side of the machine from the normal operating position.

Cleaning the Hood Screen

The screen needs to be cleaned before each use. In wet grass it will need to be cleaned more often.

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.

Maintenance Procedure

• Bagger—inspect

• Bagger belt—check and adjust

• Bagger idler arm—grease

• Belt—check for wear/cracks

• Bagger—inspect

• Bagger—clean

Cleaning the Bagger

The bagger needs to be cleaned as needed when debris is observed and at storage.

1. Wash the inside and outside of the bagger hood, tube,

and the underside of the mower. Use a mild automotive detergent to remove dirt.

2. Make sure you remove matted grass from all parts.

3. Open the bagger and hold the bagger hood open.

4. Clean the debris from the screen.

5. Close the bagger hood.

3. After washing all parts, let them dry thoroughly. Note: With all parts installed, start and run the machine for

a minute to assist in drying.

Checking and Adjusting the Bagger Belt Tension

Check the bagger belt tension after the first 8 hours of use.

7. Adjust the fixed idler towards the front to shorten the spring and decrease belt tension (Fig. 60).

8. Tighten the two bolts that hold the fixed idler to the

blower assembly (Fig. 60).

Check the bagger belt tension every 25 hours.

Important Make sure to inspect the belt and check the

spring length after the first 8 hours of use. Note: When checking the belt tension, the spring length

needs to be between 4 inches and 4–3/4 inches (102 and 121 mm) (Fig. 59).

Important Adjust the bagger belt if the spring length is

4 inches (102 mm) or less.

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. Close the blower assembly and measure between the

spring coil ends. See Figure 59 for measuring the spring length and eye hook orientation.

9. Close the blower assembly and measure the spring length again. Adjust the fixed idler until the correct spring length is achieved.

Figure 60

1. Fixed idler

2. Blower assembly

3. Adjust idler to the front to shorten the spring

4. Bolts

5. Adjust idler to the rear to lengthen the spring

m–6213

m–6275

Figure 59

1. Spring

2. End of spring coils

3. Blower assembly peg

4. Distance between spring coil ends, 4 to 4–3/4 inches (102 mm to 121 mm)

5. Eyebolt

Note: When adjustment is needed, set the spring length to 4–3/4 inches (121 mm) +/– 1/4 inch (6 mm) (Fig. 59).

4. If adjustment is needed, open the blower assembly to

remove tension from the bagger belt (Fig. 65).

5. Loosen the two bolts that hold the fixed idler to the

blower assembly (Fig. 60).

6. Adjust the fixed idler towards the rear to lengthen the spring and increase belt tension (Fig. 60).

Checking and Adjusting the

Blower Latch

Adjust the blower latch when it is does not engage the front peg correctly.

1. There must not be a gap between the mounting plate the

the blower assembly (Fig. 61). If there is a gap, proceed to step 3 and shorten the latch.

Topview

1. Blower assembly

2. Blower front latch (Red)

Figure 61

3. Gap shown

4. Front peg

m–626

m–6721

Figure 62

1. Blower front latch (Red) 2. Front peg

3. To adjust the blower latch, loosen the jam nut. (Fig. 63).

4. To lengthen the latch turn the hex nut counterclockwise

to loosen the nut. (Fig. 63).

5. To shorten the latch turn the hex nut clockwise to

tighten the nut. (Fig. 63).

6. When the desired latch length is correct, tighten both

nuts. (Fig. 63).

2. The blower latch must engage over the front peg

(Fig. 62). If it does not, proceed to step 3 and lengthen the latch.

1. Blower front latch (red)

2. Blower

m–6720

Figure 63

3. Hex nut

4. Jam nut

Replacing the Blower Belt

Check the bagger belt for wear and cracks after the first 8 hours and then every 25 hours.

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. Push down on the front latch and open the blower assembly (Fig. 65). This will automatically remove the tension from the blower belt.

4. Remove the blower belt cover (Fig. 64).

5. Remove the bagger belt from the top mower pulley of

the mower pulley assembly (Fig. 65).

3 2

m–6236

Figure 64

1. Blower assembly

2. Blower belt cover

3. Latch

m–6732

Figure 65

1. Blower pulley

2. Mower

3. Blower assembly

4. Top mower pulley

5. Spring loaded idler pulley

6. Fixed idler pulley

7. Front latch

Greasing the Blower

Grease the bagger belt idler arm every 25 hours (Fig. 66). Grease the blower pivot after installing the blower into the

mounting hole (Fig. 66).

6. Remove the bagger belt from the spring–loaded idler pulley and the fixed idler pulley (Fig. 65).

7. Remove the bagger belt from the blower assembly pulley (Fig. 65).

8. Install the new bagger belt. Refer to Installing the Bagger Belt and Idler Spring on page 23.

Figure 66

1. Bagger idler arm 2. Grease zerk

m–6727

Checking the Blower Liner

Check the blower liner inside the blower every 40 hours and more often in extreme mowing and bagging conditions.

1. Remove the blower adapter and tube from the blower

(Fig. 51).

2. Check the liner for any excessive wear. Do not use your

hands to check the liner or remove debris.

3. Replace the liner if any excessive wear is noticed.

9. Loosely install 2 bolts into the liner and the blower

(Fig. 68).

Replacing the Blower Liner

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. Remove the blower adapter and tube from the blower

(Fig. 51).

4. Remove the five bolts that hold the blower liner to the

blower (Figures 67 and 68).

5. Pull the liner out of the blower (Fig. 67).

6. Remove any debris from the blower. Do not use your

hands to remove the debris.

7. Slide the new liner around the blower impeller.

8. Install 3 bolts into the rear of the blower and the liner

(Fig. 67).

m–6243

Figure 68

1. Blower

2. Bolt

3. Nut

4. Impeller

10.Push the top 2 bolts down, toward the front of blower,

until the blower liner conforms to the inside of the blower (Fig. 69). This will provide clearance between the impeller and the liner.

11. Rotate the blower pulley to verify that the blower fan

does not hit the liner (Fig. 69). Adjust the liner if necessary.

12.Tighten the 2 top bolts in the liner and the blower

(Fig. 69).

m–6244

1. Blower

2. Liner

3. Bolt

Figure 67

4. Washer

5. Nut

m–6220

Figure 69

1. Blower 2. Top bolt and nut

Inspecting the Bagger

Inspect the bagger attachment after the first 8 hours of operation and 100 hours thereafter.

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. Check the tube, blower assembly, and the bagger hood. Replace these parts if they are cracked or broken.

4. Check the bags, bagger frame, and screen. Replace any parts that are cracked, worn or broken.

5. Tighten all nuts, bolts and screws.

Inspecting the Mower Blades and Baffles

1. Inspect the mower blades and baffles regularly and whenever a blade strikes a foreign object.

2. If blades or baffles are badly worn or damaged, install new blades or baffles. Refer to your mower operator’s manual for complete blade maintenance.

Installing Mower Blades

1. Refer to Installing the Blade Stiffener on page 16.

Storage

1. Clean the bagger attachment. Refer to Cleaning the Bagger on page 34.

2. Inspect the bagger attachment for damage. Refer to Inspecting the Bagger on page 34.

3. Make sure the bags are empty and thoroughly dry.

4. Check the belt for wear or cracks.

5. Store the machine in a clean, dry place, out of direct

sunlight. If you must store the machine outside, cover it with a weatherproof cover. This protects the plastic parts and extends the life of the machine.

Troubleshooting

Problem Possible Causes Corrective Action

Abnormal vibration.

Reduced bagging performance.

Blower and tube plug too frequently.

1. Cutting blade(s) bent or unbalanced.

2. Blade mounting bolt is loose. 2. Tighten blade mounting bolt.

3. Loose blower pulley or pulley assembly.

4. Blower belt is worn or damaged.

5. Blower impeller is out of balance.

6. Blade interferes with mower baffles.

1. Low engine speed. 1. Always operate the bagger at

2. Plugged screen. 2. Remove debris, leaves or grass

3. Loose blower belt. 3. Adjust the blower belt tension.

4. A plugged tube. 4. Locate and remove plugged

5. Full bags. 5. Empty bags.

1. Bags are too full. 1. Dump more frequently.

2. Low engine speed. 2. Always operate the bagger at

1. Install new cutting blade(s).

3. Tighten the appropriate pulley.

4. Replace the blower belt.

5. Contact Authorized Service Dealer.

6. Do not use machine. Replace bent blades and/or baffles.

full throttle.

clippings from the screen.

debris.

full throttle.

Debris blowout.

Blower impeller does not spin freely.

3. Grass is too wet. 3. Cut grass when dry.

4. Grass is too long. 4. Cut no more that 2 to 3 inches (51 to 76 mm) or 1/3 of the grass height, which ever is less.

5. Plugged screen. 5. Remove debris, leaves or grass clippings from the screen.

6. Ground speed is too fast. 6. Drive slower at full throttle.

7. Worn blower belt. 7. Replace belt.

1. Bags are too full. 1. Dump more frequently.

2. Ground speed is too fast. 2. Drive slower at full throttle.

3. Mower is not leveled. 3. See the mower operator’s manual for leveling the mower.

1. Plugged blower. 1. Remove debris, leaves or grass clippings from the blower impeller.

2. Impeller not aligned. 2. Contact Authorized Service Dealer.

Toro 78499 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual