Toro 78502 Operator's Manual

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Page 1

Form No. 3350–164

60in TURBO FORCE Mower Finishing Kit

Z500 Triple Soft Bagger

Model No. 78502—Serial No. 230000001 and Up

Operator ’s Manual

Original Instructions (EN)

Page 2

Contents

Introduction

Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety and Instruction Decals 4. . . . . . . . . . . . . . .

Setup 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loose Parts 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Before Installation 7. . . . . . . . . . . . . . . . . . . . . . . . . . .

Prepare the Mower 7. . . . . . . . . . . . . . . . . . . . . . . .

Positioning the Flow Baffle 7. . . . . . . . . . . . . . . . .

Installation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing the Existing Belt Cover 8. . . . . . . . . . .

Removing the Existing Anti-Scalp

Roller and Bracket 8. . . . . . . . . . . . . . . . . . . . . .

Installing the New Bracket and Anti-Scalp Roller 9

Installing the Mounting Plate 9. . . . . . . . . . . . . . . .

Installing the Pulley Assembly 10. . . . . . . . . . . . . .

Removing the Drive Wheels and Bumper Guard 10

Installing the Bagger Brackets 11. . . . . . . . . . . . . . .

Installing the Bagger Tube Support and Elbow 12. .

Installing the Hood Assembly and Bags 12. . . . . . .

Installing the Blower Assembly 14. . . . . . . . . . . . . .

Installing the Bagger Belt and Idler Spring 14. . . . .

Installing the Belt Cover 16. . . . . . . . . . . . . . . . . . .

Installing the Bagger Tube 17. . . . . . . . . . . . . . . . . .

Installing the Weights 18. . . . . . . . . . . . . . . . . . . . .

Adjusting the Parking Brake 19. . . . . . . . . . . . . . . .

Operation 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emptying the Grass Bags 20. . . . . . . . . . . . . . . . . . .

Clearing Obstructions From the Bagger System 21.

Operating and Bagging Tips 21. . . . . . . . . . . . . . . .

Maintenance 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Maintenance Schedule 23. . . . . . . .

Cleaning the Hood Screen 23. . . . . . . . . . . . . . . . . .

Cleaning the Bagger 23. . . . . . . . . . . . . . . . . . . . . . .

Checking and Adjusting the Bagger Belt Tension 23

Checking and Adjusting the Blower Latch 24. . . . .

Replacing the Blower Belt 25. . . . . . . . . . . . . . . . . .

Checking the Blower Liner 26. . . . . . . . . . . . . . . . .

Replacing the Blower Liner 26. . . . . . . . . . . . . . . . .

Inspecting the Bagger 27. . . . . . . . . . . . . . . . . . . . .

Greasing the Blower 27. . . . . . . . . . . . . . . . . . . . . .

Inspecting the Mower Blades and Baffles 27. . . . . .

Installing Mower Blades 27. . . . . . . . . . . . . . . . . . .

Storage 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

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 o f 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.

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

Printed in the USA

Page 3

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.

• Do not use a grass catcher on steep slopes. A heavy

grass catcher could cause loss of control or overturn the machine.

• 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.

• 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.

• 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.

• Turn off the engine and wait for all moving parts to

stop before removing the grass catcher or unclogging the chute.

Page 4

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.

68-3650

93-1122

Page 5

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 2 3

4 5

6 7

No parts needed Removing the existing mower cover

No parts needed

Anti-scalp roller bracket Tapping screw, 3/8 x 1 inch

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

Pulley assembly 1 Installing the pulley assembly

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

1 1

1 2 2

1 1

1 10 10

Removing the anti-scalp roller and bracket

Installing the anti-scalp roller and bracket

Installing the mounting plate

Removing the drive wheels and bumper guard

Installing the bagger brackets

8 9

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

Hood assembly Bag Clevis pin Hairpin cotter

Blower assembly 1 Installing the blower assembly

Installing the bagger tube support and elbow

Installing the hood assembly and bags

Page 6

Step UseQty.Description

11 12 13

Blower belt cover Bagger Belt Idler spring Pulley cover

Belt cover 1 Installing the belt cover

Bagger tube Clamp Knob Blower adapter

Caster weight U–bolt Nut, 1/2 inch Lock washer, 1/2 inch Plate Top weight Bolt, 1/2 x 3 inch Plate

1 1 1 1

1 1 2 1

2 2 4 4 2 2 2 2

Installing the bagger belt and idler spring

Installing the bagger tube

Installing the weights

No parts needed Adjusting the parking brake

Page 7

Before Installation

Prepare the Mower

Perform the following procedure to prepare the mower for attaching the blower and finishing kit.

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.

Position B

Use this position when bagging.

Middle Position

3. Clean the mower of any debris on the deck or rear of

mower to ease installation.

Positioning the Flow Baffle

The following figures are only recommendations for use. Adjustments will vary by grass type, moisture content, and height of grass. The middle position or Position B is recommended for bagging.

Note: If the engine power draws down and the mower ground speed is the same, open up the baffle.

Position A

This is the full rear position. The suggested use for this position is a follows.

• Use for short, light grass mowing conditions.

• Use in dry conditions.

• For smaller grass clippings.

• Propels grass clippings farther away from the mower.

Full Rearward Position

m–6880

Figure 3

Position C

This is the full open position. The suggested use for this position is as follows.

• Use in tall, dense grass mowing conditions.

• Use in wet conditions.

• Lowers the engine power consumption.

• Allows increased ground speed in heavy conditions.

• This position is similar to the benefits of the Toro SFS

mower.

Full Forward Position

Figure 2

m–6879

Figure 4

m–6881

Page 8

Installation

Step

No Parts needed for this step.

Removing the Existing Belt Cover

Note: Clean the area around the belt cover before removing.

1. Unlatch and remove the right belt cover (Fig. 5).

2. Store the right belt cover for later use. If the bagger

blower and pulley is removed it can be reused.

Step

No Parts needed for this step.

Removing the Existing Anti-Scalp Roller and Bracket

Note: Clean the area around the right, rear anti-scalp wheel

1. Remove the anti-scalp roller from the bracket by

loosening and removing the flange nut (3/8 inch) and axle bolt (3/8 x 4-1/2 inch) as shown in figure 6.

2. Remove the three carriage bolts (3/8 x 3/4 inch) and

flange nuts (3/8 inch) securing the bracket to the mower (Fig. 6). Save the fasteners for later use.

3. Remove the bracket and discard.

Figure 5

1. Belt cover 2. Latch

m–6824

1. Anti-scalp roller

2. Anti-scalp bracket

3. Bolt, 3/8 x 4-1/2 inch

m–6981

Figure 6

4. Carriage bolt, 3/8 x 3/4 inch

5. Flange nut, 3/8 inch

6. Mower deck

Page 9

Step

Parts needed for this step:

• 1 Anti-scalp roller bracket

• 1 Tapping screw

Installing the New Bracket and Anti-Scalp Roller

1. Install the new anti–scalp roller bracket using the three

carriage bolts (3/8 x 3/4 inch) and flange nuts (3/8 inch) removed previously (Fig. 7).

2. Install a tapping screw (3/8 x 1 inch) into the deck and

roller bracket (Fig. 7).

Note: The screw requires effort to turn. By installing the screw, threads will be cut into the new bracket.

3. Install the anti-scalp roller with the axle bolt

(3/8 x 4-1/2 inches), flange nut (3/8 inch) (Fig. 7).

Parts needed for this step:

• 1 Mounting plate

• 2 Bolts, 3/8 x 1-1/4 inch

• 2 Flange nuts, 3/8 inch

Installing the Mounting Plate

1. Move the grass deflector into the upright position. Note: When the mower is switched to bagging leave the

grass deflector on the machine. The grass deflector will rest against the blower belt cover.

2. Install the mounting plate to the inside of the deck

mounting bracket with 2 bolts (3/8 x 1-1/4 inch) and 2 flange nuts (3/8 inch) as shown in figure 8.

1. Anti-scalp bracket, new

2. Carriage bolt, 3/8 x 3/4 inch

3. Flange nut, 3/8 inch

Figure 7

m–6980

4. Screw, tapping, 3/8 x 1inch

5. Bolt, 3/8 x 4-1/2 inch

6. Anti-scalp roller

m–7005

1. Mounting plate

2. Bolt, 3/8 x 1–1/4 inch

Figure 8

3. Flange nut, 3/8 inch

Page 10

Step

Note: If the pulley does not turn, loosen the bolts to raise the bolt heads and allow the pulley to lock into position.

4. After the new pulley assembly is in position, tighten

the existing bolts to secure new pulley.

Parts needed for this step:

• 1 Pulley assembly

Installing the Pulley Assembly

1. Loosen, but do not remove, the tapping bolts on the

existing pulley (Fig. 9). There should be a 1/4 inch (0.64 cm) clearance between the bolt head and pulley.

1/4 inch

(0.64 cm)

Important Torque the nuts to 23 ft-lb ± 2 ft-lb

(31 N⋅m ± 3 N⋅m).

Step

No parts needed for this step.

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.

m–7004

Figure 9

1. Pulley assembly, bagger belt

2. Pulley assembly, drive belt

2. Align the new pulley assembly so that the openings fit over the pulley bolt heads loosened in step 1 and install (Fig. 9).

3. Turn the pulley to lock it into position (Fig. 9).

3. Locking slots

4. Bolts heads

m–6794

Figure 10

1. Rear bumper guard

2. Bolt

1. Remove the existing rear bumper guard (Fig. 10).

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

Page 11

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 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 12.

1. Remove the existing two bolts in the bottom of the

rear frame (Fig. 12).

Installing the Bagger Brackets

Installing the 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 11.

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 inch) (Fig. 11).

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 11

4. Machine side frame

5. Existing hole

6. Belleville washer, 3/8 inch

m–6742

1. Bagger mounting bracket

2. Bolt, 3/8 x 1 inch

3. Flange nut, 3/8 inch

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 inch) (Fig. 12).

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. 12).

Figure 12

4. Belleville washer, 3/8 inch

5. Rear frame

6. Existing bolts located here

m–6743

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. 12).

2. Tighten the bagger mounting bracket to the side

brackets (Fig. 12).

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

(Fig. 11).

Page 12

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

(128 N⋅M).

5. Lower the machine onto the drive wheels.

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. 13).

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

with 4 bolts (1/4 x 1-1/2 inch), 4 washers (1/4 inch), and 4 nuts (1/4 inch) (Fig. 13).

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

Figure 13

4. Nut, 1/4 inch

5. Flat washer, 1/4 inch

6. Bolt, 1/4 x 1-1/2 inch

m–6730

1. Install the hood assembly onto the bagger mounting

bracket (Fig. 14).

m–6740

Figure 14

1. Hood assembly 2. Bagger mounting bracket

Page 13

2. Install the 2 clevis pins into the hood assembly and bagger mounting bracket. Secure it with 2 hairpin cotter pins (Fig. 15).

5. Position the bagger latch under the latch hook

(Figures 17 and 18).

m–6741

Figure 15

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. 16). Do this for all the bags.

Note: The bag will rest on the bagger frame (Fig. 16).

m–6719

Figure 17

1. Hood

2. Bags

3. Bagger latch

4. Latch hook

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

(Fig. 18).

Figure 16

1. Hood assembly

2. Bag

3. Bag tab

4. Notch

5. Bagger frame

4. Lower the bagger hood over the bags.

m–6264

Figure 18

1. Bagger latch 2. Latch hook

m–6718

Page 14

Step

Parts needed for this step:

• 1 Blower assembly

Installing the Blower Assembly

Important Make sure the mounting plate is installed

to the mower.

1. Move the grass deflector into the upright position.

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

bracket (Fig. 19).

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. Check that the blower assembly is closed and ensure

the blower front latch is engaged on the front peg.

2. Slide the spring into the blower eyebolt (Fig. 20).

Figure 19

1. Mower deck

2. Blower assembly

3. Blower assembly peg

3. Close the blower assembly. (Fig. 22).

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

Refer to Checking and Adjusting the Blower Latch on page 24.

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

4. Mounting plate hole

5. Mounting plate

m–7006

3. Install the spring into the idler arm eyebolt (Fig. 20).

3 1

m–6276

Figure 20

1. Idler spring

2. Blower assembly

3. Idler arm eyebolt

4. Blower eyebolt

5. Idler arm

Page 15

m–7007

Figure 21

1. Blower pulley

2. Mower

3. Blower assembly

4. Top pulley of mower pulley assembly

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

the blower assembly (Fig. 21).

5. Install the bagger belt on the top mower pulley

(Fig. 21).

6. Route the bagger belt around the top pulley of the mower pulley assembly (Fig. 21).

7. Feed the belt between the idler pulleys (Fig. 21).

8. Route the bagger belt around the spring–loaded idler pulley (Fig. 21). The backside of belt will be touching

the pulley.

9. Route the bagger belt around the fixed idler pulley (Fig. 21).

10.Route the bagger belt around the blower pulley (Fig. 21).

11. Close the blower assembly and ensure the blower front latch engages onto the front peg (Fig. 22).

5. Spring loaded idler pulley (belt back side touching pulley)

6. Fixed idler pulley

7. Front latch (red)

Figure 22

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

Important Make sure to check the belt tension and

spring length after the initial 8 hours of use.

m–7008

Page 16

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

Adjusting the Bagger Belt Tension on page 23.

13.Install the belt cover over the pulley assembly and

secure the 3 cover latches into the blower (Fig. 23).

3 2

Step

Parts needed for this step:

• 1 Belt cover

1. Blower assembly

2. Blower belt cover

Figure 23

3. Latch

m–6236

Installing the Belt Cover

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

secure the latches (Fig. 24).

m–7020

Figure 24

1. Pulley assembly

2. Belt cover

3. Latch

Page 17

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. 25).

m–6252

Figure 26

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. 27).

4. Place the upper tube into the bagger elbow (Fig. 27).

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. 27).

4. Knob

5. Side blower stud

Figure 25

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. 26).

3. Install the knobs onto the top and side stud (Fig. 26). 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 27

4. Ribs

5. Elbow

6. Tube support

Page 18

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 28

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. 29).

• 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. 28).

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

washer (1/2 inch) under the frame and caster weight (Fig. 28).

3. Repeat for the opposite side.

1. Top weight

2. Bolt

m–6756

Figure 29

3. Front caster weight

4. Front caster wheel

Page 19

Checking the Tire Pressure

Check and adjust the air pressure in the front and rear tires.

Pressure: 13 psi (90 kPa) drive wheels and caster wheels (Fig. 29).

5. Tighten the two nuts, below the spring, together and

repeat on the opposite side of the machine.

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. 31).

m–1872

Figure 30

1. Valve stem

Check the Level of the Mower

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

Step

Figure 31

1. Brake lever

2. Spring 2–5/8 inch (67 mm)

3. Adjusting nut and jam nut below the spring

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. 31).

9. Tighten the jam nut next to the yoke 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

No parts needed for this step.

Adjusting the Parking Brake

Check the parking brake for proper adjustment.

Important It is necessary to adjust and check the

proper function of the brake due to the added weight of the bagger to the unit.

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. 31).

3. If adjustment is necessary, loosen the jam nut below

the spring and adjust the nut directly below the spring (Fig. 31).

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.

Page 20

Operation

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

Caution

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.

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.

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. 18).

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. 32).

• Always move the grass deflector into position

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.

• Turn off the engine before unclogging the

discharge chute.

m–6242

Figure 32

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. 16). Do this for all bags.

Page 21

8. Lower the bagger hood over the bags (Fig. 17).

9. Latch the bagger hood (Fig. 18).

Clearing Obstructions From

Trimming

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.

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. 26).

5. Remove the tube from the bagger hood (Fig. 27).

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 21.

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.

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. 21).

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.

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.

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.

Page 22

Bagging Wet Grass

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

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.

Page 23

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

Maintenance Procedure

• Bagger—inspect

• Bagger belt—check and adjust

• Bagger idler arm—grease

• Belt—check for wear/cracks

• Bagger—inspect

• Bagger—clean

Checking and Adjusting the

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.

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

4. Clean the debris from the screen.

5. Close the bagger hood.

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. 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.

Bagger Belt Tension

Check the bagger belt tension after the first 8 hours of use. 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. 33).

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.

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3. Close the blower assembly and measure between the

spring coil ends. See Figure 33 for measuring the spring length and eye hook orientation.

m–6275

Figure 33

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

6. Adjust the fixed idler towards the rear to lengthen the spring and increase belt tension (Fig. 34).

7. Adjust the fixed idler towards the front to shorten the spring and decrease belt tension (Fig. 34).

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

blower assembly (Fig. 34).

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

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. 35). If there is a gap, proceed to step 3 and shorten the latch.

Top view

Note: When adjustment is needed, set the spring length between 4 inches and 4–3/4 inches (102 and 121 mm)

(Fig. 33).

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

remove tension from the bagger belt (Fig. 39).

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

blower assembly (Fig. 34).

m–6213

Figure 34

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

1. Blower assembly

2. Blower front latch (Red)

m–626

Figure 35

3. Gap shown

4. Front peg

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2. The blower latch must engage over the front peg

(Fig. 36). If it does not, proceed to step 3 and lengthen the latch.

4. To lengthen the latch turn the hex nut

counterclockwise to loosen the nut. (Fig. 37).

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

tighten the nut. (Fig. 37).

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

nuts. (Fig. 37).

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.

m–6721

Figure 36

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

3. To adjust the blower latch, loosen the jam nut.

(Fig. 37).

3. Push down on the front latch and open the blower

assembly (Fig. 39). This will automatically remove the tension from the blower belt.

4. Remove the blower belt cover (Fig. 38).

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

the mower pulley assembly (Fig. 39).

3 2

1. Blower front latch (red)

2. Blower

Figure 37

3. Hex nut

4. Jam nut

m–6720

Figure 38

1. Blower assembly

2. Blower belt cover

3. Latch

6. Remove the bagger belt from the spring–loaded idler

pulley and the fixed idler pulley (Fig. 39).

m–6236

Page 26

7. Remove the bagger belt from the blower assembly

pulley (Fig. 39).

m–7007

Figure 39

1. Blower pulley

2. Mower

3. Blower assembly

4. Top mower pulley

5. Spring loaded idler pulley

6. Fixed idler pulley

7. Front latch

8. Install the new bagger belt. Refer to Installing the

Bagger Belt and Idler Spring on page 14.

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. 26).

m–6244

Figure 40

1. Blower

2. Liner

3. Bolt

4. Washer

5. Nut

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. 40).

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

(Fig. 41).

2. Inspect 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.

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. 26).

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

blower (Figures 40 and 41).

5. Pull the liner out of the blower (Fig. 40).

m–6243

1. Blower

2. Bolt

Figure 41

3. Nut

4. Impeller

Page 27

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

until the blower liner conforms to the inside of the blower (Fig. 42). 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. 42). Adjust the liner if necessary.

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

(Fig. 42).

Greasing the Blower

Grease the bagger belt idler arm every 25 hours (Fig. 43). Grease the blower pivot after installing the blower into the

mounting hole (Fig. 43).

Figure 42

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.

m–6220

m–6982

Figure 43

1. Bagger idler arm 2. Grease fitting

Inspecting the Mower Blades and Baffles

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.

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

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.

1. Refer to the Operator’s Manual for more information.

Page 28

Storage

1. Clean the bagger attachment. Refer to Cleaning the

Bagger on page 23.

2. Inspect the bagger attachment for damage. Refer to

Inspecting the Bagger on page 27.

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.

Page 29

Troubleshooting

Problem Possible Causes Corrective Action

Abnormal vibration.

Reduced bagging performance.

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

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. 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.

grass clippings from the screen.

debris.

Blower and tube plug too frequently.

Debris blowout.

Blower impeller does not spin freely.

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

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

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.

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