Form No. 3352–150 DFS Vac Collection System 400 Series Z Master Model No. 78510—Serial No. 250000001 and Up Operator’s Manual Register your product at www.Toro.
Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety and Instruction Decals . . . . . . . . . . . . . . . . Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loose Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the Clutch and Drive Pulley Assembly . Removing the Drive Wheels . . . . . . . . . . . . . . . .
• Never operate with the discharge deflector raised or removed and never altered, unless using a grass catcher or mulching baffles. 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. • Keep hands and feet away from moving parts. Do not make adjustments with the engine running.
107-1613 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 1 Description Qty.
Step 8 9 10 11 12 13 14 15 Description Qty.
Step 1 1 2 5 Parts needed for this step: 3 • 1 Bolt, 7/16 x 4–1/2 inch—Kawasakir engines only 4 • 1 Bolt, 7/16 x 4 inch—Kohlerr engines only m–6024 Figure 2 • 1 Drive pulley assembly 1. Engine 2. Clutch 3. Curved washers • 1 Clutch spacer Installing the Clutch and Drive Pulley Assembly 4. Clutch bolt—discard 5. Drive spacer 1 Note: Apply anti–seize compound to crank shaft before installing the clutch and drive pulley assembly. 1.
Step 2 Step 3 No parts needed for this step. No parts needed for this step. Removing the Drive Wheels Removing the Rear Heat Shield on 44 and 48 inch Mowers Danger 1. Remove the 8 bolts and nuts securing the rear of the heat shield to the engine straps and the rear bumper (Fig. 4). Mechanical or hydraulic jacks may fail to support machine and cause a serious injury. 2.
Step 4 Step No parts needed for this step. 5 Parts needed for this step: • 1 Bagger mounting bracket Removing the Rear Weight and Heat Shields on 52 inch Mowers • 16 Bolts, 5/16 x 1 inch • 16 Flange nuts, 5/16 inch • 6 Flat washers, 5/16 inch 1. Remove the 8 bolts, washers, and nuts securing the rear weight to the engine straps and the rear bumper (Fig. 4). Installing the Bagger Mounting Bracket 2.
2. Loosely install the bagger mounting bracket to the side of the rear bumper and the engine guard straps, with 8 bolts (5/16 x 1 inch), 6 flat washers (5/16 inch), and 8 flange nuts (5/16 inch) (Fig. 7). Step Note: The bagger mounting bracket is to be installed to the inside of the engine guard straps.
2 5 Step 7 Parts needed for this step: • 1 Bagger • 2 Clevis pins • 2 Hairpin cotters Installing the Bagger 3 1. Install the bagger onto the bagger mounting bracket (Fig. 11). 1 4 2. Install clevis pins into the bagger and bagger mounting bracket. Secure them with hairpin cotter pins (Fig. 11). Figure 9 1. Skid plate 2. Idler pulley bracket 3. Rear bumper 4. Bolt, 5/16 x 7/8 inch 5. Flange nut, 5/16 inch 4.
Step 8 7 Parts needed for this step: 6 • 1 Bagger belt 4 Installing the Bagger Belt 1. Remove the 2 wing nuts (5/16 inch) securing the pulley guard to the bottom of the bagger (Fig. 12). 2 1 3 5 6 m–6832 Figure 13 1. 2. 3. 4. 2 2 1 5. Bagger belt 6. Clutch drive pulley 7. Clutch 7. Install the pulley guard to the bottom of the bagger with 2 wing nuts (5/16 inch) (Fig. 12). Figure 12 1. Pulley guard Tensioner spring Idler arm Bagger tensioner pulley Bagger pulley 2.
Step 9 Parts needed for this step: 1 • 3 Spacers–Pillow bearing Figure 15 Checking/Adjusting the Bagger Belt Tension 1. Pillow block 2. Fan shaft 1. With the bagger belt tensioned, measure the gap as shown in Figure 14 at the tensioner pulley (Fig. 14). The gap must be 1–3/4 to 2–1/8 inches. If the gap is not between 1–3/4 and 2–1/8 inches, proceed to the next step. 2 3 1 m–7649 Figure 14 1. Bagger belt 2. Tensioner pulley 3 2 3. 1–3/4 to 2–1/8 inch gap 2. To adjust the belt tension: A.
10 Step 1 6 Parts needed for this step: • 4 Weight plates • 8 Nuts, 3/8 inch 4 • 2 U–bolts, 3/8 x 3 inch 2 • 4 Locknuts, 3/8 inch • 4 Bolts, 3/8 x 2 inch • 4 Belleville washers 3 5 3 5 4 Figure 16 Installing the Weight Plates 1. U–bolt 2. Weight plate 3. Bolt, 3/8 x 2 inch 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. • Install the front weights. 1.
11 12 Step Step Parts needed for this step: Installing the Weight Bars • 1 Bagger bracket Parts needed for this step: • 8 Carriage bolts, 5/16 x 1 inch • 4 Weight bars • 8 Flange nuts, 5/16 inch • 2 Locknuts, 3/8 inch • 2 Belleville washers Installing the Boot and Discharge Tubes Procedure 1. Disengage the PTO, set the parking brake, and chock or block the drive wheels. • 2 Bolts, 3/8 x 5–3/4 inch 2.
13 Step 11 3 4 6 2 5 Parts needed for this step: 9 1 • 1 Bolt, 1/2 x 1–3/4 inch 10 • 2 Jam nuts, 1/2 inch Installing the Bagger Dump Lever Stop Bolt 1. Move the bagger dump lever rearward to increase the slack in the bagger cable (Fig. 19). 8 2. Remove the cotter pin and clevis pin securing the bagger cable clevis to the bagger dump handle (Fig. 19). 7 m–5889 Figure 18 1. 2. 3. 4. 5. 6. Boot Middle tube Knob Upper tube Latch Notch in upper tube 7. 8. 9. 10. 11.
14 15 Step Step No parts needed for this step. No parts needed for this step. Adjusting the Bagger Dump Lever Checking the Tire Pressure Check the air pressure in the front caster wheel and rear tires (Fig. 21). Use the following tire pressures when the bagger is installed. The bagger lever needs to be adjusted to remove slack in the bagger cable. Pressure: Rear tires—20 psi (138 kPa) Front caster wheels—25 psi (241 kPa) 1. Loosen the nuts on both sides of the stop bracket (Fig. 20). 2.
Operation Caution Note: Determine the left and right sides of the machine from the normal operating position. Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. Important Set the parking brake, and chock or block the tires when leaving the machine unattended, even if just for a few minutes. Always remove the ignition key, set the parking brake and chock or block tires when leaving the machine unattended, even if just for a few minutes.
Holding the Bagger Door Open Clearing Obstructions From the Bagger System Warning Danger Hands, fingers and arms can get pinched between the back and front sections of the collector. When the bagger is in operation, the blower can be rotating and cut off or injure hands. • Keep people away from collector while emptying it. • If working on the inside, use the holding pin to hold the collector door open.
Installing the Grass Deflector 4. Remove the tube assembly from the bagger (Fig. 18). 5. Remove the boot from the mounting bracket (Fig. 18). The grass deflector spring will have either an L end or a straight end (Fig. 24). 6. If you are changing to side discharge mode, install the grass deflector. Refer to Installing the Grass Deflector on page 19. Note: Make sure the grass deflector is installed when the bagger and tubes are removed.
Transporting Machines Bagging Speed Do not leave grass or debris in the bagger while transporting the machine. 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. Warning Caution Transporting the machine with grass or debris in the bagger can damage the machine. As the bagger fills, extra weight is added to the back of the machine.
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.
Maintenance Important If the machine is on a slope, set the parking brake and chock or block the wheels to prevent the machine from slowly rolling.
Greasing the Fan Shaft Bearings Inspecting the Mower Blades and Baffles Grease the upper and lower bagger fan shaft bearings (Fig. 26 & 27) every 100 hours. 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. Storage 1. Clean the bagger attachment. Refer to Cleaning the Bagger Attachment on page 22. 2.
Troubleshooting Problem Abnormal vibration. Reduced bagging performance. Boot and tubes plug p g too frequently. q y Debris blowout. Possible Causes Corrective Action 1. Cutting blade(s) is/are bent or unbalanced. 1. Install new cutting blade(s). 2. Blade mounting bolt is loose. 2. Tighten blade mounting bolt. 3. Loose bagger pulley or pulley assembly. 3. Tighten the appropriate pulley. 4. Bagger belt is worn or damaged. 4. Replace the bagger belt. 5. Bagger impeller is out of balance.
