Toro 78507 Operator's Manual

Form No. 3353–631 Rev A

44I, 48Iand 52I Twin Soft Bagger

Z100 and Z400 Series Z Master

Model No. 78507—Serial No. 250000351 and Up

Operator’s Manual

Original Instructions (EN)

Contents

Introduction

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

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

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

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

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

Before Installation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Prepare the Mower 6. . . . . . . . . . . . . . . . . . . . . . . . .

Positioning the Flow Baffle (Z400 Mowers only) 6. Installing the Bagger Bracket (All Z100 Mowers and

Z400 Mowers with 44in and 48in Mower Decks) 6 Installing the Bagger Bracket

(Z400 Mowers with 52in Mower Decks) 9. . . . . . . .

Installing the Blower Assembly 10. . . . . . . . . . . . . . .

Installing the Bagger Belt and Idler Spring 11. . . . . .

Installing the Hood Assembly and Bags 13. . . . . . . .

Installing the Bagger Tube 15. . . . . . . . . . . . . . . . . . .

Checking the Tire Pressure 16. . . . . . . . . . . . . . . . . .

Operation 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Positioning the Flow Baffle (Z400 Mowers only) 17.

Emptying the Grass Bags 17. . . . . . . . . . . . . . . . . . . .

Clearing Obstructions From the Bagger System 18. .

Removing the Bagger 18. . . . . . . . . . . . . . . . . . . . . . .

Using the Grass Deflector 19. . . . . . . . . . . . . . . . . . .

Transporting Machines 19. . . . . . . . . . . . . . . . . . . . . .

Operating and Bagging Tips 19. . . . . . . . . . . . . . . . .

Maintenance 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Maintenance Schedule 21. . . . . . . . .

Cleaning the Hood Screen 21. . . . . . . . . . . . . . . . . . .

Cleaning the Bagger 21. . . . . . . . . . . . . . . . . . . . . . . .

Checking and Adjusting the Bagger Belt Tension 22.

Checking and Adjusting the Blower Latch 22. . . . . .

Replacing the Blower Belt 23. . . . . . . . . . . . . . . . . . .

Greasing the Idler Arm 24. . . . . . . . . . . . . . . . . . . . .

Checking the Blower Liner 24. . . . . . . . . . . . . . . . . .

Replacing the Blower Liner 24. . . . . . . . . . . . . . . . . .

Inspecting the Bagger 24. . . . . . . . . . . . . . . . . . . . . . .

Inspecting the Mower Blades and Baffles 25. . . . . . .

Installing Mower Blades 25. . . . . . . . . . . . . . . . . . . .

Installing the Grass Deflector 25. . . . . . . . . . . . . . . . .

Storage 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The Toro Total Coverage Guarantee 28. . . . . . . . . . . . . .

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.

You may contact Toro directly at www.Toro.com for product and accessory information, help finding a dealer, or to register your product.

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.

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.

W 2005 by The Toro Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196

Danger signals an extreme hazard that will cause serious injury or death if you do not follow the recommended precautions.

Printed in the USA

Warning signals a hazard that may cause serious injury or death if you do not follow the recommended precautions.

Safety

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.

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.

• 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.

• 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 leave grass or debris in grass catcher while transporting the machine.

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.

Step Description Qty. Use

1 2

3 4

Bagger bracket

Bolt, 5/16 x 1 inch

Flange nut, 5/16 inch

Bagger bracket 1

Blower assembly 1 Installing the blower assembly

Blower belt cover

Idler spring

Bagger belt

Hood assembly

Bag

Clevis pin

Hairpin cotter

Bagger tube

Clamp

Knob

Blower adapter

Installing bagger bracket (All Z100 Mowers and Z400 Mowers with 44in and 48in Mower Decks)

Installing bagger bracket (Z400 Mowers with 52in Mower Decks)

Installing the bagger belt and idler spring

Installing the hood assembly and bags

Installing the bagger tube

Important Bagger model 78507 MUST be paired with either model 78508, 78509, 78511, or 78512 finishing kit. Failure

to match the appropriate finishing kit with the appropriate bagger will result in misalignment of the blower assembly relative to the deck, as well as misalignment of the latch components, and potential interference between the blower inlet shelf and the deck baffles.

No parts needed – Checking the tire pressure

Before Installation

Prepare the Mower

Step

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.

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

Positioning the Flow Baffle (Z400 Mowers only)

The middle position or Position B is recommended for bagging.

Move the adjustable flow baffle to the middle position. To adjust the baffle refer to your mower Operator’s Manual.

Position B

Middle Position

Parts needed for this step:

• 1 Bagger bracket

• 8 Bolts, 5/16 x 1 inch

• 8 Flange nuts, 5/16 inch

Installing the Bagger Bracket (All Z100 Mowers and Z400 Mowers with 44in and 48in Mower Decks)

Note: Determine if machine is equipped with a back mount or back and side mount heat shield. If machine is equipped with a back mount heat shield (Fig. 4), use steps 1 thru 3. If machine has a back and side mount heat shield (Fig. 5), proceed to step 4.

1. Remove the rear heat shield (Fig. 3). Discard the bolts and nuts.

Figure 2

m–6880

m–5836

Figure 3

1. Rear heat shield

2. Bolts—remove and discard

2. Position the bagger bracket behind the engine guard straps and rear bumper (Fig. 4).

3. Install the bagger bracket and rear heat shield to the engine guard straps and rear bumper with 8 bolts (5/16 x 1 inch) and 8 flange nuts (5/16 inch) (Fig. 4).

3. Rear bumper

m–6221

Figure 4

1. Bagger bracket

2. Bolt, 5/16 x 1 inch

3. Flange nut, 5/16 inch

4. Rear bumper

5. Engine guard strap

6. Rear heat shield

4. Remove the 8 bolts and nuts securing the rear of the heat shield to the engine straps and rear bumper (Fig. 5). Discard the bolts and nuts.

5. Remove the 4 bolts, washers and nuts securing the sides of the heat shield to the engine straps, tailpipe guard and bumper. Retain the heat shield and these bolts, washers and nuts (Fig. 5).

m–6812

Figure 6

1. Heat shield

2. Bagger bracket

3. Bar

4. Heat shield notch

5. Front of bagger bracket

7. With the bagger bar in the heat shield notches, push the bottom of the heat shield towards the rear and past the back of the bagger bracket (Fig. 7).

m–6809

Figure 5

1. Heat shield

2. Engine straps

3. Tailpipe guard

4. Rear bumper

Note: Install the heat shield into the bagger bracket from the front of the bracket.

6. At an angle, insert the top of the heat shield under the bar of the bagger bracket. Position the bagger bar as far as possible into the heat shield notches (Fig. 6).

1. Heat shield notch

2. Back of bagger

Figure 7

m–6811

3. Bottom of heat shield

8. Slide the heat shield down until the holes align with the bagger bracket holes (Fig. 8).

m–6809

m–6810

Figure 8

Note: Make sure to install the bagger bracket correctly, as shown in figure 9.

m–6805

Figure 9

1. Correct position 2. Incorrect position

1. Bagger bracket

2. Engine straps

3. Rear bumper

Figure 10

4. Tailpipe guard

5. Heat shield

9. Install the bagger bracket and heat shield to the engine straps and rear bumper with 8 new bolts (5/16 x 1 inch) and 8 new flange nuts (5/16 inch) (Fig. 10).

10. Install the bagger bracket and heat shield to the engine straps, tailpipe guard and rear bumper with 4 bolts, 4 washers and 4 flange nuts, previously removed (Fig. 10).

Step

Note: Make sure to install the bagger bracket correctly, as shown in Figure 12.

Parts needed for this step:

• 1 Bagger bracket

Installing the Bagger Bracket (Z400 Mowers with 52in Mower Decks)

Note: Use these instructions if machine is equipped with a rear weight.

1. Remove the rear weight from the back of the machine (Fig. 11). Save the bolts and flange nuts.

Figure 12

1. Correct position 2. Incorrect position

2. Install the bagger bracket and weight to the engine straps, tailpipe guard, and rear bumper with the 8 existing bolts and nuts previously removed (Fig. 13).

m–7782

m–7783

1. Bolt

2. Flange nut

3. Rear bumper

Figure 11

4. Engine guard strap

5. Rear weight

m–7780

1. Bagger bracket

2. Bolt

3. Flange nut

Figure 13

4. Rear bumper

5. Engine guard strap

6. Rear weight

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