Toro 78463 User manual

FormNo.3443-711RevC
BaggerKit
ZMaster®4000SeriesRidingMower
ModelNo.78463—SerialNo.400000000andUp
Registeratwww.Toro.com.
OriginalInstructions(EN)*3443-711*

WARNING
CALIFORNIA
Proposition65Warning
UseofthisproductmaycauseexposuretochemicalsknowntotheStateofCalifornia
tocausecancer,birthdefects,orotherreproductiveharm.
Introduction
Readthisinformationcarefullytolearnhowtooperate
andmaintainyourproductproperlyandtoavoid
injuryandproductdamage.Youareresponsiblefor
operatingtheproductproperlyandsafely.
Visitwww.Toro.comforproductsafetyandoperation
trainingmaterials,accessoryinformation,helpnding
adealer,ortoregisteryourproduct.
Wheneveryouneedservice,genuineToroparts,or
additionalinformation,contactanAuthorizedService
DealerorToroCustomerServiceandhavethemodel
andserialnumbersofyourproductready.Figure1
andFigure2identifythelocationofthemodeland
serialnumbersontheproduct.Writethenumbersin
thespaceprovided.
g341471
Figure1
1.Baggermodelandserialnumberlocation
g341472
Figure2
1.Blowermodelandserialnumberlocation
ModelNo.
SerialNo.
©2021—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN554202
Contactusatwww.Toro.com.
PrintedintheUSA
AllRightsReserved

Thismanualuses2wordstohighlightinformation.
Importantcallsattentiontospecialmechanical
informationandNoteemphasizesgeneralinformation
worthyofspecialattention.
Thesafety-alertsymbol(Figure3)appearsbothin
thismanualandonthemachinetoidentifyimportant
safetymessagesthatyoumustfollowtoavoid
accidents.Thissymbolwillappearwiththeword
Danger,Warning,orCaution.
•Dangerindicatesanimminentlyhazardous
situationwhich,ifnotavoided,willresultindeath
orseriousinjury.
•Warningindicatesapotentiallyhazardous
situationwhich,ifnotavoided,couldresultin
deathorseriousinjury.
•Cautionindicatesapotentiallyhazardoussituation
which,ifnotavoided,mayresultinminoror
moderateinjury.
g000502
Figure3
Safety-alertsymbol
Contents
Safety.......................................................................4
SafetyandInstructionalDecals..........................5
Setup........................................................................7
1PreparingtheMachine.....................................9
2InstallingtheROPSPivotShoulder
Bolts................................................................9
3InstallingtheWeights.......................................9
4InstallingtheBaggerSupportsand
Brackets........................................................10
5InstallingtheBaggerFrame...........................12
6InstallingtheBags.........................................13
7InstallingtheHitchCover...............................13
8RemovingtheExistingBeltCover,Bracket,
andDischargeChute....................................14
9InstallingtheCEKit........................................14
10InstallingtheBlower-PulleyAssembly
andBelt-CoverBracket.................................15
11InstallingtheBafe.......................................18
12InstallingtheBlowerAssembly.....................19
13InstallingtheBlowerBelt,Spring,and
Blower-BeltCover.........................................20
14InstallingtheDischargeTubes.....................22
15AdjustingtheParkingBrake.........................24
16CheckingtheTirePressure..........................24
Operation................................................................25
EmptyingtheGrassBags.................................25
ClearingObstructionsfromtheBagger
System..........................................................26
RemovingtheBagger.......................................26
TransportingtheMachine.................................26
OperatingTips.................................................27
Maintenance...........................................................28
RecommendedMaintenanceSchedule(s)...........28
CleaningtheHoodScreen................................28
InspectingtheBaggerAttachment....................29
CleaningtheBaggerandBags.........................29
InspectingtheBlowerBelt................................29
ReplacingtheBlowerBelt.................................29
GreasingtheIdlerArm......................................30
InspectingtheBagger.......................................30
InspectingtheMowerBlades............................30
SelectingtheMowerBlades.............................30
ReplacingtheGrassDeector..........................31
Storage...................................................................31
Troubleshooting......................................................32
3

Safety
•Becomefamiliarwiththesafeoperationofthe
equipment,withtheoperatorcontrols,andsafety
signs.
•Useextracarewithgrasscatchersorother
attachments.Thesecanchangetheoperating
characteristicsandthestabilityofthemachine.
•Followthemanufacturer'srecommendations
foraddingorremovingwheelweightsor
counterweightstoimprovestability.
•Donotuseagrasscatcheronsteepslopes.A
heavygrasscatchercouldcauselossofcontrol
oroverturnthemachine.
•Slowdownanduseextracareonhillsides.Be
suretotravelintherecommendeddirectionon
hillsides.Turfconditionscanaffectthestabilityof
themachine.Useextremecautionwhileoperating
neardrop-offs.
•Keepallmovementonslopesslowandgradual.
Donotmakesuddenchangesinspeed,direction,
orturning.
•Thegrasscatchercanobstructtheviewtothe
rear.Useextracarewhenoperatinginreverse.
•Usecarewhenloadingorunloadingthemachine
intoatrailerortruck.
•Neveroperatewiththedischargedeectorraised,
removedoraltered,unlessusingagrasscatcher.
•Keephandsandfeetawayfrommovingparts.Do
notmakeadjustmentswiththeenginerunning.
•Parkthemachineonalevelsurface,disengage
thedrives,shutofftheengine,leavetheoperator’s
position,andchockthewheelsbeforeperforming
anytasksuchasemptyingthegrasscatcheror
uncloggingthechute.
•Ifyouremovethegrasscatcher,besuretoinstall
anydischargedeectororguardthatmighthave
beenremovedtoinstallthegrasscatcher.Donot
operatethemowerwithouteithertheentiregrass
catcherorthegrassdeectorinplace.
•Shutofftheenginebeforeremovingthegrass
catcheroruncloggingthechute.
•Donotleavegrassinthegrasscatcherfor
extendedperiodsoftime.
•Grasscatchercomponentsaresubjecttowear,
damageanddeterioration,whichcouldexpose
youtomovingpartsorallowobjectstobethrown.
Frequentlycheckcomponentsandreplacewith
themanufacturer'srecommendedparts,when
necessary.
4

SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyarea
ofpotentialdanger.Replaceanydecalthatisdamagedormissing.
decal133-8061
133-8061
decal126-4662
126-4662
1.Warning—readtheOperator’sManualforthecorrect
quantityofcounterbalanceweight(s).
2.Lossoftractionandsteeringorreducedstabilityhazard—Ez
Vaccounterbalanceweight(s)installedwithouttheEzVac
maycauselossoftractionandsteeringcontrol.TheEzVac
installedwithouttheEzVaccounterbalanceweight(s)can
causereducedstability.Installweight(s)onlywhentheEz
Vacisinstalled.
decal126-9451
126-9451
1.Thrownobjectshazard—Donotruntheblowerwithoutthe
entirecollectionsysteminstalledandlatched.
2.Warning–ReadtheOperator’smanualaboutcounterbalance
weightinstallation.
3.Lossoftractionandsteeringorreducedstabilityhazard–Ez
Vaccounterbalanceweight(s)installedwithouttheEzVac
maycauselossoftractionandsteeringcontrol.TheEzVac
installedwithouttheEzVaccounterbalanceweight(s)can
causereducedstability.Installweight(s)onlywhentheEz
Vacisinstalled.
decal126-4659
126-4659
1.Warning—hotpulley;allowtocool.
decal126-4853
126-4853
1.Impeller/Rotatingbladeshazard—keephandsawayfrom
movingparts.Keepallsafetydevicesinplaceandworking.
Donotreachintotheblowerunlesstherotationindicator
hasstopped.
5

decal106-5517
106-5517
1.Warning—donottouchthehotsurface.
decal126-9595
126-9595
1.Rotationindicator
2.Impeller/RotatingBladeshazard-Keephandsawayfrom
movingparts.Keepallsafetydevicesinplaceandworking.
Donotreachintotheblowerunlesstherotationindicator
hasstopped.DisengagethePTO,shutofftheengine,
removethekey,andwaitforallmovingpartstostop.
6

Setup
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
1Nopartsrequired–Preparethemachine.
Shoulderbolt2
Wavewasher2
2Locknut(1/2inch)2
InstalltheROPSpivotshoulderbolt.
Weight2
Carriagebolt(3/8x1inch)4
3Flangenut(3/8inch)4
Installtheweights.
Lowersupport2
Uppersupport1
Left,upperbracket1
Right,upperbracket1
Backerplate2
Carriagebolt(5/16x2-1/4inches)4
Flangenut(5/16inch)8
Plainwasher4
Hex-headbolt(5/16x3-1/4inches)4
Flange-headbolt(3/8x1-1/4inches)2
Locknut(3/8inch)4
4
Flange-headbolt(5/16x1inch)2
Installthebaggersupportsandbrackets.
Bagsupport1
5Lock-pinassembly2Installthebaggerframe.
6Bags2Installthebags.
7Hitchcover1Installthehitchcover.
8Nopartsrequired–Removetheexistingbeltcover,bracket,
anddischargechute.
9CEKit1InstalltheCEKit(forCEmachines
only).
Blowerpulley1
Pulleymount1
Locknut(3/8inch)3
Belt-coverbracket1
Speednut1
Carriagebolt(1/4x3/4inch)2
10
Locknut(1/4inch)2
Installtheblower-pulleyassembly.
Bafe1
Carriagebolt(5/16x7/8inch)1
Flangenut(5/16inch)1
Carriagebolt(3/8x7/8inch)2
11
Flangenut(3/8inch)2
Installthebafe.
7

ProcedureDescriptionQty.Use
Blowerassembly1
Pivotpin1
12Rollpin1
Installtheblowerassembly.
Blower-beltcover1
13Coverknob1
Installthebaggerbelt,spring,and
blower-beltcover.
Uppertube1
Lowertube1
Bolt(#10x3/4inch)3
Locknut(#10)3
14
Washer(7/32inch)3
Installthedischargetubes.
15Nopartsrequired–Adjusttheparkingbrake.
16Nopartsrequired–Checkthetirepressure(formachine
withpneumatictiresonly).
Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.
8

1
PreparingtheMachine
NoPartsRequired
Procedure
1.Parkthemachineonalevelsurface.
2.Movethemotion-controlleverstotheNEUTRAL-LOCKposition.
3.Engagetheparkingbrake.
4.Shutofftheengineandremovethekey.
g037289
Figure4
2
InstallingtheROPSPivot
ShoulderBolts
Partsneededforthisprocedure:
2Shoulderbolt
2Wavewasher
2Locknut(1/2inch)
Procedure
1.Securetheshoulderbolttotherollbarusinga
wavewasherandlocknut(1/2inch)asshown
inFigure5.
2.Repeatthisprocedureontheotherside.
g341473
Figure5
1.Locknut(1/2inch)3.Shoulderbolt
2.Wavewasher
9

3
InstallingtheWeights
Partsneededforthisprocedure:
2Weight
4Carriagebolt(3/8x1inch)
4Flangenut(3/8inch)
Procedure
1.Securetheweighttothecasterarmusing2
carriagebolts(3/8x1inch)and2angenuts
(3/8inch)asshowninFigure6.
2.Repeatthisprocedureontheotherside.
g341474
Figure6
1.Carriagebolt(3/8x1inch)3.Flangenut(3/8inch)
2.Weight
4
InstallingtheBagger
SupportsandBrackets
Partsneededforthisprocedure:
2Lowersupport
1Uppersupport
1Left,upperbracket
1Right,upperbracket
2Backerplate
4Carriagebolt(5/16x2-1/4inches)
8Flangenut(5/16inch)
4Plainwasher
4Hex-headbolt(5/16x3-1/4inches)
2Flange-headbolt(3/8x1-1/4inches)
4Locknut(3/8inch)
2Flange-headbolt(5/16x1inch)
Procedure
1.Looselysecuretheuppersupporttotherear
engineguardusing2ange-headbolts(5/16x
1inch)and2angenuts(5/16inch)asshown
inFigure7.
g341518
Figure7
1.Flangenut(5/16inch)3.Flange-headbolt(5/16x
1inch)
2.Uppersupport
10

2.Removethe2torx-headboltsand2nutsfrom
theleft,rearguard(Figure8).
Note:Performthestepaboveon1sideofthe
machine,thentheother.
g341515
Figure8
1.Left,rearguard3.Torx-headbolt
2.Nut
3.Looselysecuretheleft,upperbrackettotheleft,
rearguardanduppersupportusing2hex-head
bolts(5/16x3-1/4inches),2plainwashers,2
angenuts(5/16inch),1ange-headbolt(3/8x
1-1/4inches),and1locknut(3/8inch)asshown
inFigure9.
Note:Performthestepaboveon1sideofthe
machine,thentheother.
g341516
Figure9
1.Left,rearguard5.Flange-headbolt(3/8x
1-1/4inches)
2.Flangenut(5/16inch)6.Left,upperbracket
3.Locknut(3/8inch)7.Plainwasher
4.Uppersupport8.Hex-headbolt(5/16x
3-1/4inches)
4.Looselysecurethelowersupporttotheengine
plateusing2carriagebolts(5/16x2-1/4inches),
1backerplate,and2angenuts(5/16inch)as
showninFigure10.
Note:Performthestepaboveon1sideofthe
machine,thentheother.
g341517
Figure10
1.Backerplate3.Lowersupport
2.Carriagebolt(5/16x2-1/4
inches)
4.Flangenut(5/16inch)
5.Tightallthefasteners.
11

5
InstallingtheBaggerFrame
Partsneededforthisprocedure:
1Bagsupport
2Lock-pinassembly
Procedure
1.Arrangethebaggerframearoundthepivotpins
onthesupportbracketandrotateitforward
(Figure11).
g341549
Figure11
1.Pivotpin2.Baggerframe
2.Insertthelockpinthroughthebaggerframeand
crossbrace(Figure12).
Note:Youmayneedtoloosenthehardwareto
alignthelockpintothehole.
g038187
Figure12
1.Hairpincotter2.Lockpin
3.Usethehairpincottertosecurethelockpin
(Figure12).
4.Tightenallloosehardware.
12

6
InstallingtheBags
Partsneededforthisprocedure:
2Bags
Procedure
1.Hookthebagtothebaggerframe(Figure13).
g341571
Figure13
1.Baggerframe2.Bag
2.Closeandlatchthehoodassembly.
7
InstallingtheHitchCover
Partsneededforthisprocedure:
1Hitchcover
Procedure
1.Applyalubricanttothenippleonthehitchcover.
2.Alignthehitchcoveroverthehitchandpressit
intoplace(Figure14).
g341572
Figure14
1.Hitchcover3.Hitch
2.Nipple
13

8
RemovingtheExisting
BeltCover,Bracket,and
DischargeChute
NoPartsRequired
Procedure
Note:Cleantheareaaroundthebeltcoverbefore
removingit.
1.Lowerthemowerdecktothelowestheight-of-cut
position.
2.Removetherightbeltcover(Figure15).
g038092
Figure15
3.Removetherightbelt-coverbracket,2washers
(60-inchmowerdeckonly),and2angenuts
fromthemowerdeck(Figure16).
Note:Retainthehardwarethatyouremoved
duringthisproceduresothatitisavailablefor
changeover.
g038093
Figure16
1.Rightbelt-coverbracket3.Flangenuts
2.Washers-onlyon152cm
(60inch)mowerdeck
4.Removethelocknut,bolt,spring,andspacer
holdingthedeectortothepivotbrackets
(Figure17).
g015594
Figure17
1.Bolt5.Springinstalled
2.Spacer6.Grassdeector
3.Locknut7.J-hookendofspring
4.Spring
5.Removethegrassdeector(Figure17).
Note:Retainthehardwarethatyouremoved
duringthisproceduresothatitisavailablefor
changeover.
9
InstallingtheCEKit
ForCEMachinesOnly
Partsneededforthisprocedure:
1CEKit
Procedure
ForCEmachines,youneedtoinstalltheCEKit;refer
totheDeclarationofConformityfortheCEKitmodel
number.
14

10
InstallingtheBlower-Pulley
AssemblyandBelt-Cover
Bracket
Partsneededforthisprocedure:
1Blowerpulley
1Pulleymount
3Locknut(3/8inch)
1Belt-coverbracket
1Speednut
2Carriagebolt(1/4x3/4inch)
2Locknut(1/4inch)
Procedure
1.Usea3/8-inchratchetinthesquareholeinthe
idlerarmtoremovetensionontheidlerspring
(Figure18).
g334846
Figure18
1.Spring4.Spring-loadedidler
assembly
2.Clutchpulley5.Ratchet
3.Mowerbelt6.Squareholeintheidler
armfortheratchet
2.Removethebeltfromtherightmower-deck
pulley.
15

3.Useawrench(1-1/2inches)toholdthespindle
shaft,asyouremovethehexnut(3/4inch)and
washerfromthespindleshaft(Figure19).
Note:Retainthehexnut(3/4inch)andwasher.
g341576
Figure19
1.Hexnut(3/4inch)3.Rightspindleshaft
2.Washer
4.Insertthethreadedstudsonpulleymount
throughtheholesinthedeckpulley(Figure20).
5.Securethedeckpulleytothespindleshaftusing
thepreviouslyremovedhexnut(3/4inch)and
washer(Figure20).
6.Torquethehexnut(3/4inch)to176to217N∙m
(130to160ft-lb).
7.Arrangetheblowerpulleyontothethreaded
studsandlooselyinstallthe3locknuts(3/8inch)
asshowninFigure20.
8.Rotatetheblowerpulleyuntilthenarrowslots
stoponthestuds.
9.Torquethe3locknuts(3/8inch)to18N∙m(13
ft-lb).
Ensurethatthepulleydoesnotrotatewhile
torquingthelocknuts.
Note:Iftheblowerpulleyisnotcenteredon
thestuds,itcouldcauseprematuredamageto
theblowerbelt.
g341574
Figure20
1.Locknut(3/8inch)5.Existingdeckpulley
2.Blowerpulley6.Pulleymount
3.Hexnut(3/4inch)7.Rightspindleshaft
4.Washer
16

10.Ensurethatthebladeboltistorquedto75to81
N∙m(55to60ft-lb).
11.Installthemowerbeltaroundthelowerpulleyof
thedoublepulley(Figure21).
g341575
Figure21
1.Lowerpulley2.Mowerbelt
12.Installthebelt-coverbrackettothemowerdeck
using2carriagebolts(1/4x3/4inch)and2
locknuts(1/4inch)asshowninFigure22.
13.Installthespeednutontothebelt-coverbracket
(Figure22).
g038112
Figure22
1.Carriagebolt(1/4x3/4
inch)
3.Speednut
2.Belt-coverbracket4.Locknut(1/4inch)
14.Installthemowerdeckbeltaroundthe
spring-loadedidlerpulley(Figure18).
17

11
InstallingtheBafe
Partsneededforthisprocedure:
1Bafe
1Carriagebolt(5/16x7/8inch)
1Flangenut(5/16inch)
2Carriagebolt(3/8x7/8inch)
2Flangenut(3/8inch)
Procedure
1.Removethe2existingangenuts(3/8inch)and
2carriagebolts(3/8x7/8inch)fromthemower
deck(Figure23).
Note:Retainthehardwarethatyouremoved
duringthisproceduresothatitisavailablefor
changeover.
g038113
Figure23
1.Flangenut(3/8inch)2.Carriagebolt(3/8x7/8
inch)
2.Installthebafeusingthecarriagebolt(5/16x
7/8inch),angenut(5/16inch),2carriagebolts
(3/8x7/8inch),and2angenuts(3/8inch)as
showninFigure24.
g341587
Figure24
1.Flangenut(3/8inch)4.Flangenut(5/16inch)
2.Carriagebolt(3/8x7/8
inch)
5.Carriagebolt(5/16x7/8
inch)
3.Bafe
18

12
InstallingtheBlower
Assembly
Partsneededforthisprocedure:
1Blowerassembly
1Pivotpin
1Rollpin
Procedure
Verifythatthepivotpinissecuredontheblower
assemblyinthecorrectlocation(Figure25orFigure
26).
•Ifyouhavea48-inchor52-inchmowerdeck,
thereisonlyasingleholetoinstallthepivotpin
(Figure25).
g341588
Figure25
1.Blowerassembly3.Pivotpin
2.Rollpin
•Ifyouhavea60-inchmowerdeck,installthepivot
pinintherearhole(Figure26).
g341589
Figure26
1.Blowerassembly3.Rollpin
2.Rearhole4.Pivotpin
1.Alignthepivotpinontheblowerwiththe
pivot-pinholeinthemowerdeck(Figure27).
g038256
Figure27
1.Blowerassembly3.Pivothole
2.Deck4.Blower-pivotpin
2.Lowertheblowerandslidethepivotpinintothe
pivothole(Figure27).
Note:Ensurethatthebeltremainspositioned
intheblowerpulley.
19

3.Movethelatchpinfromthelockingpositionto
theopenposition(Figure28).
g018370
Figure28
1.Blowerassembly5.Idler-pivotbracket
2.Latchpin(lockingposition)6.Idlerpulley
3.Latchpin(openposition)7.Belt(beneaththeidler
pulley)
4.Chutebracket
4.Closetheblowerassemblyandalignthelatch
pinwiththeholeinthechutebracket(Figure28).
5.Movethelatchpintothelockingposition.
Note:Ensurethatthelatchpinextendsthrough
theholeinthechutebracket.
Note:Ensurethatthelatchrmlyholdsthe
blowerassemblyagainstthemowerdeck,but
youcanreleaseitbyhand.
13
InstallingtheBlowerBelt,
Spring,andBlower-Belt
Cover
Partsneededforthisprocedure:
1Blower-beltcover
1Coverknob
Procedure
1.Arrangetheblowerbeltaroundthedrivepulley
asshowninFigure29.
g341600
Figure29
1.Blowerpulley4.Drivepulley
2.Idler/pulley5.Idler/tensionpulley
3.Blowerbelt
2.Temporarilyroutethebeltbeneaththeidler
pulley(Figure30).
20