Toro 78479 User manual

FormNo.3450-633RevA
BaggerKit
ZMaster®4000SeriesRidingMower
ModelNo.78479—SerialNo.400000000andUp
ModelNo.78489—SerialNo.400000000andUp
Registeratwww.Toro.com.
OriginalInstructions(EN)*3450-633*

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
DealerorT oroCustomerServiceandhavethemodel
andserialnumbersofyourproductready.Figure1
andFigure2identifythelocationofthemodeland
serialnumbersontheproduct.Writethenumbersin
thespaceprovided.
g375725
Figure1
1.Baggermodelandserialnumberlocation
g375726
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........................................................14
5InstallingtheBaggerFrame...........................16
6InstallingtheBags.........................................17
7InstallingtheHitchCover...............................17
8RemovingtheExistingBeltCover,Bracket,
andDischargeChute....................................18
9InstallingtheBlower-PulleyAssemblyand
Belt-CoverBracket........................................19
10InstallingtheBafe.......................................22
11InstallingtheBlowerAssembly.....................24
12InstallingtheBlowerBelt,Spring,and
Blower-BeltCover.........................................28
13InstallingtheDischargeTubes.....................29
14CheckingtheTirePressure..........................31
Operation................................................................32
EmptyingtheGrassBags.................................32
ClearingObstructionsfromtheBagger
System..........................................................33
RemovingtheBagger.......................................33
TransportingtheMachine.................................34
OperatingTips.................................................34
Maintenance...........................................................35
RecommendedMaintenanceSchedule(s)...........35
CleaningtheHoodScreen................................35
InspectingtheBaggerAttachment....................36
CleaningtheBaggerandBags.........................36
InspectingtheBlowerBelt................................36
ReplacingtheBlowerBelt.................................36
GreasingtheIdlerArm......................................37
InspectingtheBagger.......................................37
InspectingtheMowerBlades............................37
SelectingtheMowerBlades.............................37
ReplacingtheGrassDeector..........................38
Storage...................................................................39
Troubleshooting......................................................40
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
decal126-4659
126-4659
1.Warning—hotpulley;allowtocool.
decal127-2857
127–2857
1.Warning—keepawayfrommovingparts;keepallguards
andsafetiesinplace.
decal126-9595
126-9595
1.Rotationindicator
2.Impeller/RotatingBladeshazard-Keephandsawayfrom
movingparts.Keepallsafetydevicesinplaceandworking.
Donotreachintotheblowerunlesstherotationindicator
hasstopped.DisengagethePTO,shutofftheengine,
removethekey,andwaitforallmovingpartstostop.
5

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.
6

Setup
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
1Nopartsrequired–Preparethemachine.
Shoulderbolt2
Wavewasher2
2Locknut(1/2inch)2
InstalltheROPSpivotshoulderbolt.
12.5lbweightplate(60-inchmachines
only)2
Carriagebolt(3/8x2-1/2
inches)—60-inchmachinesonly4
Hex-socketangenut(3/8
inch)—60-inchmachinesonly4
Casterweight2
Carriagebolt(3/8x1inch)8
Flangenut(3/8inch)8
Weightbracketassembly1
Suitcaseweight2
Locknut(3/8inch)2
3
Carriagebolt(3/8x5inches)2
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.
6Bag3Installthebags.
7Hitchcover1Installthehitchcover.
8Nopartsrequired–Removetheexistingbeltcover,bracket,
anddischargechute.
Blowerpulley1
Pulleymount1
Locknut(3/8inch)3
Belt-coverbracket1
Speednut1
Carriagebolt(1/4x3/4inch)2
9
Locknut(1/4inch)2
Installtheblower-pulleyassembly.
7

ProcedureDescriptionQty.Use
Bafe1
Carriagebolt(5/16x7/8inch)1
Flangenut(5/16inch)1
Carriagebolt(3/8x7/8inch)2
10
Flangenut(3/8inch)2
Installthebafe.
Blowerassembly1
Pivotpin1
Latch1
Hex-headbolt(3/8x1-1/2inches)1
Spacer1
11
Locknut(3/8inch)1
Installtheblowerassembly.
Blower-beltcover1
12Coverknob1
Installthebaggerbelt,spring,and
blower-beltcover.
Uppertube1
Lowertube1
Bolt(#10x3/4inch)3
Locknut(#10)3
13
Washer(7/32inch)3
Installthedischargetubes.
14Nopartsrequired–Checkthetirepressure.
Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.
Important:Ifthereinforcementplates(Figure4)arenotinstalledonthemachine,youcannotinstall
theBaggerKitontothemachine.
g376188
Figure4
Leftsideshown
1.Reinforcementplate
8

1
PreparingtheMachine
NoPartsRequired
Procedure
1.Parkthemachineonalevelsurface.
2.Movethemotion-controlleverstotheNEUTRAL-LOCKposition.
3.Engagetheparkingbrake.
4.Shutofftheengineandremovethekey.
g037289
Figure5
2
InstallingtheROPSPivot
ShoulderBolts
Partsneededforthisprocedure:
2Shoulderbolt
2Wavewasher
2Locknut(1/2inch)
Procedure
1.Securetheshoulderbolttotherollbarusinga
wavewasherandlocknut(1/2inch)asshown
inFigure6.
2.Repeatthisprocedureontheotherside.
g341473
Figure6
1.Locknut(1/2inch)3.Shoulderbolt
2.Wavewasher
9

3
InstallingtheWeights
Partsneededforthisprocedure:
212.5lbweightplate(60-inchmachinesonly)
4Carriagebolt(3/8x2-1/2inches)—60-inchmachines
only
4Hex-socketangenut(3/8inch)—60-inchmachines
only
2Casterweight
8Carriagebolt(3/8x1inch)
8Flangenut(3/8inch)
1Weightbracketassembly
2Suitcaseweight
2Locknut(3/8inch)
2Carriagebolt(3/8x5inches)
10

60-inchMachines
1.Removetheexisting2carriageboltsand2nutsfromthetopofthecasterweight(Figure7).
Discardthe2carriageboltsand2nuts.
2.Securethe12.5lbweightplatetothecasterweightandbracketusingthe2carriagebolts(3/8x2-1/2
inches)and2hex-socketangenuts(3/8inch)asshowninFigure7.
g375819
Figure7
11

3.Securetheassembledcasterweighttothecasterarmusing2carriagebolts(3/8x1inch)and2ange
nuts(3/8inch)asshowninFigure8.
g375807
Figure8
1.Carriagebolt(3/8x1inch)3.Flangenut(3/8inch)
2.Weight
4.Repeatsteps1through3ontheotherside.
5.Securetheweightbracketassemblytotheframeusing4carriagebolts(3/8x1inch)and4ange
nuts(3/8inch)asshowninFigure9.
6.Insertthe2suitcaseweightsintotheweightbracketassemblyandsecurethemusing2carriagebolts(3/8
x5inches)and2locknuts(3/8inch)asshowninFigure9.
12

g375806
Figure9
13

72-inchMachines
1.Securetheweighttothecasterarmusing2
carriagebolts(3/8x1inch)and2angenuts
(3/8inch)asshowninFigure10.
2.Repeatthisprocedureontheotherside.
g341474
Figure10
1.Carriagebolt(3/8x1inch)3.Flangenut(3/8inch)
2.Weight
3.Securetheweightbracketassemblytothe
frameusing4carriagebolts(3/8x1inch)and4
angenuts(3/8inch)asshowninFigure9.
4.Insertthe2suitcaseweightsintotheweight
bracketassemblyandsecurethemusing2
carriagebolts(3/8x5inches)and2locknuts
(3/8inch)asshowninFigure9.
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
inFigure11.
g341518
Figure11
1.Flangenut(5/16inch)3.Flange-headbolt(5/16x
1inch)
2.Uppersupport
14

2.Removethe2torx-headboltsand2nutsfrom
theleft,rearguard(Figure12).
Note:Performthestepaboveon1sideofthe
machine,thentheother.
g341515
Figure12
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
inFigure13.
Note:Performthestepaboveon1sideofthe
machine,thentheother.
g341516
Figure13
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
showninFigure14.
Note:Performthestepaboveon1sideofthe
machine,thentheother.
g341517
Figure14
1.Backerplate3.Lowersupport
2.Carriagebolt(5/16x2-1/4
inches)
4.Flangenut(5/16inch)
5.Tightallthefasteners.
15

5
InstallingtheBaggerFrame
Partsneededforthisprocedure:
1Bagsupport
2Lock-pinassembly
Procedure
1.Arrangethebaggerframearoundthepivotpins
onthesupportbracketandrotateitforward
(Figure15).
g341549
Figure15
1.Pivotpin2.Baggerframe
2.Insertthelockpinthroughthebaggerframeand
crossbrace(Figure16).
Note:Youmayneedtoloosenthehardwareto
alignthelockpintothehole.
g038187
Figure16
1.Hairpincotter2.Lockpin
3.Usethehairpincottertosecurethelockpin
(Figure16).
4.Tightenallloosehardware.
16

6
InstallingtheBags
Partsneededforthisprocedure:
3Bag
Procedure
1.Hookthebagstothebaggerframe(Figure17).
2.Closeandlatchthehoodassembly.
g375808
Figure17
1.Baggerframe2.Bag
7
InstallingtheHitchCover
Partsneededforthisprocedure:
1Hitchcover
Procedure
Note:72-inchmachinesdonotcomewithahitch
installed.IfyouhavetheHitchKitinstalled,installthe
hitchcovertoprotectthebags.
1.Applyalubricanttothenippleonthehitchcover.
2.Alignthehitchcoveroverthehitchandpressit
intoplace(Figure18).
g341572
Figure18
1.Hitchcover3.Hitch
2.Nipple
17

8
RemovingtheExisting
BeltCover,Bracket,and
DischargeChute
NoPartsRequired
Procedure
Note:Cleantheareaaroundthebeltcoverbefore
removingit.
1.Lowerthemowerdecktothelowestheight-of-cut
position.
2.Removetherightbeltcover(Figure19).
g038092
Figure19
3.Removetherightbelt-coverbracket,2washers,
and2angenutsfromthemowerdeck(Figure
20).
Note:Retainthehardwarethatyouremoved
duringthisproceduresothatitisavailablefor
changeover.
g038093
Figure20
1.Rightbelt-coverbracket3.Flangenuts
2.Washers
4.Removethelocknut,bolt,spring,andspacer
holdingthedeectortothepivotbrackets
(Figure21).
g015594
Figure21
1.Bolt5.Springinstalled
2.Spacer6.Grassdeector
3.Locknut7.J-hookendofspring
4.Spring
5.Removethegrassdeector(Figure21).
Note:Retainthehardwarethatyouremoved
duringthisproceduresothatitisavailablefor
changeover.
18

9
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
(Figure22).
g334846
Figure22
1.Spring4.Spring-loadedidler
assembly
2.Clutchpulley5.Ratchet
3.Mowerbelt6.Squareholeintheidler
armfortheratchet
2.Removethebeltfromtherightmower-deck
pulley.
19

3.Useawrench(1-1/2inches)toholdthespindle
shaft,asyouremovethehexnut(3/4inch)and
washerfromthespindleshaft(Figure23).
Note:Retainthehexnut(3/4inch)andwasher.
g341576
Figure23
1.Hexnut(3/4inch)3.Rightspindleshaft
2.Washer
4.Insertthethreadedstudsonpulleymount
throughtheholesinthedeckpulley(Figure24).
5.Securethedeckpulleytothespindleshaftusing
thepreviouslyremovedhexnut(3/4inch)and
washer(Figure24).
6.Torquethehexnut(3/4inch)to176to217N∙m
(130to160ft-lb).
7.Arrangetheblowerpulleyontothethreaded
studsandlooselyinstallthe3locknuts(3/8inch)
asshowninFigure24.
8.Rotatetheblowerpulleyuntilthenarrowslots
stoponthestuds.
9.Torquethe3locknuts(3/8inch)to18N∙m(13
ft-lb).
Ensurethatthepulleydoesnotrotatewhile
torquingthelocknuts.
Note:Iftheblowerpulleyisnotcenteredon
thestuds,itcouldcauseprematuredamageto
theblowerbelt.
g341574
Figure24
1.Locknut(3/8inch)5.Existingdeckpulley
2.Blowerpulley6.Pulleymount
3.Hexnut(3/4inch)7.Rightspindleshaft
4.Washer
20