Toro Z Master Commercial 2000 Series User manual

FormNo.3373-452RevC
48in,52in,and60inE-ZVac™
TwinSoftBagger
ZMaster®2000SeriesMower
ModelNo.78569—SerialNo.312000001andUp
G018353
Registeratwww.Toro.com.
OriginalInstructions(EN)*3373-452*C

Introduction
Readthisinformationcarefullytolearnhowtooperateand
maintainyourproductproperlyandtoavoidinjuryand
productdamage.Youareresponsibleforoperatingthe
productproperlyandsafely.
YoumaycontactTorodirectlyatwww.Toro.comforproduct
andaccessoryinformation,helpndingadealer,ortoregister
yourproduct.
Wheneveryouneedservice,genuineToroparts,oradditional
information,contactanAuthorizedServiceDealerorToro
CustomerServiceandhavethemodelandserialnumbers
ofyourproductready.Figure1,andFigure2identifythe
locationofthemodelnumbersandserialnumbersonthe
product.Writethemodelnumberandserialnumberinthe
spaceprovided.
G018356
1
Figure1
1.Blowermodelandserialnumberlocation
ModelNo.
SerialNo.
g018357
1
Figure2
1.Baggermodelandserialnumberlocation
ModelNo.
SerialNo.
Thismanualidentiespotentialhazardsandhassafety
messagesidentiedbythesafety-alertsymbol(Figure3),
whichsignalsahazardthatmaycauseseriousinjuryordeath
ifyoudonotfollowtherecommendedprecautions.
Figure3
1.Safety-alertsymbol
Thismanualuses2wordstohighlightinformation.
Importantcallsattentiontospecialmechanicalinformation
andNoteemphasizesgeneralinformationworthyofspecial
attention.
©2012—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN554202
Contactusatwww.Toro.com.
PrintedintheUSA
AllRightsReserved

Contents
Safety...........................................................................3
SafetyandInstructionalDecals.................................4
Setup............................................................................5
1PreparingtheMower.............................................6
2InstallingtheSideBumpersandSupport
Brackets.............................................................6
3InstallingtheTailpipeExtension.............................7
4DrillingtheExhaust-ShieldMounting
Holes.................................................................9
5InstallingtheExhaustShield..................................11
6InstallingtheHopperSupportFrameandHood
Rod...................................................................12
7InstallingtheHoodBafe.....................................13
8InstallingtheHoodAssemblyandBags...................14
9RoutingtheBlowerBeltintotheBlower
Assembly...........................................................16
10InstallingtheBlowerAssembly.............................17
11InstallingtheBeltCover......................................19
12InstallingtheDischargeTube...............................19
13InstallingtheWeights..........................................23
14CheckingtheTirePressure..................................25
Operation....................................................................25
EmptyingtheGrassBags.........................................26
ClearingObstructionsfromtheBagger
System..............................................................26
RemovingtheBagger..............................................26
UsingtheGrassDeector.......................................27
TransportingMachines............................................27
OperatingTips......................................................27
Maintenance.................................................................29
RecommendedMaintenanceSchedule(s)......................29
PreparingforMaintenance.......................................29
CleaningtheHoodScreen.......................................29
CleaningtheBaggerandBags...................................29
InspectingtheBlowerBelt.......................................29
ReplacingtheBlowerBelt........................................29
GreasingtheIdlerArm...........................................30
InspectingtheBagger.............................................30
InspectingtheMowerBlades...................................30
ChoosingtheMowerBlades.....................................30
ReplacingtheGrassDeector..................................30
Storage........................................................................31
Troubleshooting...........................................................32
Safety
ThefollowinglistcontainssafetyinformationspecictoToro
productsandothersafetyinformationyoumustknow.
•Becomefamiliarwiththesafeoperationoftheequipment,
withtheoperatorcontrols,andsafetysigns.
•Useextracarewithgrasscatchersorotherattachments.
Thesecanchangetheoperatingcharacteristicsandthe
stabilityofthemachine.
•Followthemanufacturer'srecommendationsforadding
orremovingwheelweightsorcounterweightstoimprove
stability.
•Donotuseagrasscatcheronsteepslopes.Aheavy
grasscatchercouldcauselossofcontroloroverturnthe
machine.
•Slowdownanduseextracareonhillsides.Besureto
travelintherecommendeddirectiononhillsides.Turf
conditionscanaffectthemachine'sstability.Useextreme
cautionwhileoperatingneardrop-offs.
•Keepallmovementonslopesslowandgradual.Donot
makesuddenchangesinspeed,directionsorturning.
•Thegrasscatchercanobstructtheviewtotherear.Use
extracarewhenoperatinginreverse.
•Usecarewhenloadingorunloadingthemachineintoa
trailerortruck.
•Neveroperatewiththedischargedeectorraised,
removedoraltered,unlessusingagrasscatcher.
•Keephandsandfeetawayfrommovingparts.Donot
makeadjustmentswiththeenginerunning.
•Stoponlevelground,disengagedrives,chockorblock
wheels,shutofftheenginebeforeleavingtheoperator's
positionforanyreasonincludingemptyingthegrass
catcheroruncloggingthechute.
•Ifyouremovethegrasscatcher,besuretoinstallany
dischargedeectororguardthatmighthavebeen
removedtoinstallthegrasscatcher.Donotoperatethe
mowerwithouteithertheentiregrasscatcherorthegrass
deectorinplace.
•Shutofftheenginebeforeremovingthegrasscatcheror
uncloggingthechute.
•Useastick,notyourhands,toremoveanobstruction
fromtheblowertube.
•Donotleavegrassingrasscatcherforextendedperiods
oftime.
•Grasscatchercomponentsaresubjecttowear,damage
anddeterioration,whichcouldexposemovingpartsor
allowobjectstobethrown.Frequentlycheckcomponents
andreplacewithmanufacturer'srecommendedparts,
whennecessary.
3

SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaofpotential
danger.Replaceanydecalthatisdamagedorlost.
1-653558
103–2076
106-0871
121–3212
1.Warning—readthe
Operator’sManual.
4.Cutting/dismemberment
hazard,
impeller—disengage
thePTO,removethekey
fromtheignition,waitfor
allmovingpartstostop.
2.Warning—wearhearing
protection.
5.Thrownobjecthazard—do
notruntheblowerwithout
thecollectionsystem
installedandlatched.
3.Cutting/dismemberment
hazard,impeller—keep
handsawayfrommoving
parts;keepallguardsin
place.
6.Warning;lossof
traction/control
hazard—ultravac
counterbalanceweight(s)
installedwithoutultravac
maycauselossoftraction
andsteeringcontrol;
ultravacinstalledwithout
ultravaccounterbalance
weight(s)willcause
reducedstability;install
theweight(s)onlywhen
ultravacisinstalled.
109–6809
1.Crushinghazardofhand—donotremovethewholebaggerfromthemachine:1.Openthebaggertop.2.Removethebag(s)
fromthebagger.3.Donotremovethebaggertopwhenitisclosed;openthebaggertopandthenremoveit.
4

Setup
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
1Nopartsrequired–Preparethemower.
Leftbumper1
Leftframe-supportbracket1
Rightbumper1
Rightframe-supportbracket1
Carriagebolt(3/8x1-1/4inches)6
2
Flangenut(3/8inch)6
Installthesidebumpersandsupport
brackets.
Tailpipeextension1
3Washer-headscrew(#8x1/2inch,
self-threading)1Installthemuferextension.
Exhaustshield1
Flange-hex-headbolt(3/8x1inch)2
4Nut(3/8inch)2
Drilltheexhaust-shieldmountingholes.
Exhaustshield1
Flange-hex-headbolt(3/8x1inch)3
5Nut(3/8inch)3
Installtheexhaustheatshield.
Hopper-supportframe1
Hairpin2
6Hoodhold-downrod1
Installthebaggermountingbrackets.
Baggerhood1
Bafe1
7Hairpin(small)2
Installthehoodbafe.
Hoodassembly1
8Bag2Installthehoodassemblyandbags.
Blower(fromthebloweranddrivekit)1
9Blowerbelt(fromthebloweranddrive
kit)1
Routetheblowerbeltintotheblower
assembly.
Blowerassembly(fromtheblowerand
drivekit)1
10Spring(fromthebloweranddrivekit)1
Installtheblowerassembly.
Beltcover(fromthebloweranddrivekit)1
11Coverknob1Installthebeltcover.
Upperdischargetube1
Screw(1/4x3/4inch)3
Locknut(1/4inch)3
12Lowerdischargetube1
Installthedischargetubes.
5

ProcedureDescriptionQty.Use
Weight-mountbracket1
Carriagebolt(5/16x3/4inch)2
Flangenut(5/16inch)2
Frontweight3
Bolt(3/8x1inch)6
Lockwasher6
Flatwasher6
13
Flangenut(3/8inch)3
Installtheweights.
14Nopartsrequired–Checkthetirepressure.
Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.
1
PreparingtheMower
NoPartsRequired
Procedure
Performthefollowingproceduretopreparethemowerfor
attachingtheblowerandbaggerkit.
1.DisengagethePTO,movethemotion-controllevers
totheNEUTRALlockedposition,andsettheparking
brake.
2.Shutofftheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.
3.Repairallbentordamagedareasofthemowerdeck
andreplaceanymissingparts.
4.Cleanthemowerofanydebrisonthedeckorrearpart
ofthemowertoeaseinstallation.
2
InstallingtheSideBumpers
andSupportBrackets
Partsneededforthisprocedure:
1Leftbumper
1Leftframe-supportbracket
1Rightbumper
1Rightframe-supportbracket
6Carriagebolt(3/8x1-1/4inches)
6Flangenut(3/8inch)
Procedure
1.Removetheleftandrightbumpersasfollows:
A.Removethenutsandboltssecuringtheleftside
bumperandmufershieldtothechassisand
centerengineguardasshowninFigure4.
6

G018358
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8
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8
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4
Figure4
SideBumperandBracketInstallation
1.Leftsidebumper5.Rightsidebumper
2.Centerengineguard6.Rightframe-support
bracket
3.Leftframe-supportbracket7.Carriagebolt(3/8x1-1/4
inches)
4.Mufershield8.Flangenut(3/8inch)
B.Removetheleftbumperandmufershieldfrom
themachine.
Note:Retainthemufershieldforinstallation
withthenewleftsidebumper.
C.Removethenutsandboltssecuringtherightside
bumpertothechassisandcenterengineguard.
Note:Discardthecarriageboltsandangenuts
thatsecuretheoriginalleftandrightsidebumpers
tothemachine.
2.Installthenewleftsidebumperasfollows:
A.Alignthenewleftsidebumperwiththe
forward-mountingpointonthechassisandthe
bumper-mountingpointsonthecenterengine
guard(Figure4).
B.Alignthemountingange(theangewith2
holes)oftheleftframe-supportbrackettotheleft
asshowninFigure4.
C.Aligntheholesoftheleftframe-supportbracket
andthebackholesoftheleftsidebumperwith
theholesinthecenterengineguard(Figure4).
D.Looselysecurethebracketandbumpertothe
centerengineguardatthelowerholewitha
carriagebolt(3/8x1-1/4inches)andaangenut
(3/8inch)(Figure4).
E.Positionthemuferheatshieldwiththemounting
angesinsidetheleftsidebumper(Figure4).
F.Aligntheholesfortheleftframe-supportbracket,
leftsidebumperandmuferguardtotheupper
holeinthecenterengineguard(Figure4).
G.Looselysecurethebracket,bumperandmufer
guardtothecenterengineguardattheupperhole
withacarriagebolts(3/8x1-1/4inches)anda
angenut(3/8inch)(Figure4).
H.Alignthefrontholesintheleftsidebumperand
themuferguardwiththeforward-mounting
pointonthechassis.(Figure4).
I.Securethebumperandguardtothemounting
pointwithacarriagebolt(3/8x1-1/4inches)and
aangenut(3/8inch)(Figure4).
J.Tightenthehardwarethatsecuresthebracket,
bumperandmuferguardtothecenterengine
guard.
3.Installthenewrightsidebumperasfollows:
A.Alignthenewrightsidebumperwiththe
forward-mountingpointonthechassisandthe
bumper-mountingpointsonthecenterengine
guard(Figure4).
B.Alignthemountingange(theangewith2
holes)oftherightframe-supportbrackettothe
leftasshowninFigure4.
C.Aligntheholesoftherightframe-supportbracket
andbackholesoftherightsidebumperwiththe
back,centerengineguard(Figure4).
D.Looselysecurethebracketandbumpertothe
centerengineguardwith2carriagebolts(3/8x
1-1/4inches)and2angenut(3/8inch)(Figure
4).
E.Alignthefrontholeinthenewrightsidebumper
withtheforwardmountingpointonthechassis
(Figure4).
F.Securethebumpertothemountingpointwith
acarriagebolt(3/8x1-1/4inches)andaange
nut(3/8inch)(Figure4).
G.Tightenthehardwarethatsecuresthebracketand
bumpertothecenterengineguard.
7

3
InstallingtheTailpipe
Extension
Partsneededforthisprocedure:
1Tailpipeextension
1Washer-headscrew(#8x1/2inch,self-threading)
Procedure
Installthetailpipeextensionasfollows:
1.Locatethemufertailpipeatthelowerleftcornerof
theengine.
Note:Ifyouneedadditionalroomtoinstallthe
tailpipeextension,dothefollowingsteps:
A.Removethe3angenutsthatsecurelower-left
engineguardtothemachine(Figure5).
Note:Retaintheseparts.
4
3
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4
3
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61
G018372
Figure5
Lower-LeftEngineGuard
1.Lower-leftengineguard
(USdomesticmowers)
4.Flangenut
2.Lower-leftengineguard
(Internationalmowers)
5.Carriagebolt(center
engineguard)
3.Carriagebolt(frontmount
point)
6.Mufertailpipe
B.Removethe2carriageboltsatthefront-mount
pointandthelower-leftengineguard.(Figure5).
Note:Retaintheseparts.Donotremovethe
carriageboltatthecenterengineguard.
2.Measure19mm(3/4inch)alongtheoutsideofthe
mufertailpipe,fromtheoutletendmovingtowardthe
muferasillustratedinFigure6,andmarkthesurface
ofthetailpipeatthismeasurement.
8

G018366
1
2
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1
Figure6
TailpipeExtensionInstallation
1.Mufertailpipe3.Tailpipeextension
2.3/4inch(19mm)4.Washerheadscrew(#8x
1/2inch,self-threading)
3.Slipthepre-drilledendofthetailpipeextensionover
themufertailpipe,andaligntheendoftheextension
withthemarkcreatedinstep2.Rotatethetailpipe
extensionuntilthepre-drilledholeintheextensionis
alignedoutwardandhorizontal(Figure6).
4.Marktheoutlineoftheholeinthetailpipeextension
ontothemufertailpipe,andremovethetailpipe
extension.
5.Locatethecenterofthemarkonthemufertailpipe
surface,andcenter-punchthelocation.
6.Drilla1.5mm(1/16inch)holeinthemufertailpipe
atthecenter-punchmark.
7.Slipthetailpipeextensiononthemufertailpipeand
aligntheholes.
8.Securethetailpipeextensionwiththeself-threading
screw(#8x1/2inch)(Figure6).
Note:Dothefollowingstepstoinstalltheengine
guardifremovedinstep1:
A.Aligntheholesintheguardwithbacksideofthe
front-mountingpointandthecenterengineguard
(Figure5).
B.Looselysecurethelowerengineguardtothe
carriageboltatthecenterengineguardwithone
ofthepreviouslyretainedangenuts(Figure5).
C.Securethelowerengineguardtothefront
mountingpointwiththepreviouslyretained
carriageboltsandangenuts(Figure5).
D.Tightenallthemountinghardwaretosecurethe
lower-leftengineguard.
4
DrillingtheExhaust-Shield
MountingHoles
Partsneededforthisprocedure:
1Exhaustshield
2Flange-hex-headbolt(3/8x1inch)
2Nut(3/8inch)
Procedure
Note:Iftheexhaust-shieldmountingholesarepresentin
thelower-leftengineguard,skiptotheinstructionsinsection
5InstallingtheExhaustShield(page11).
Note:Installthetailpipeextensionandthelower-leftengine
guardbeforeinstallingtheexhaust-heatshield.
Drilltheholesinthelower-leftbumperholesfortheexhaust
shieldasfollows:
1.Locatethemufertailpipeandtailpipeextensionatthe
left-rearcorneroftheengine,andlocatethelower-left
engineguard.
2.Aligntheexhaustshieldtothelower-leftengineguard
asfollows:
A.Centerthearchedpartoftheshieldtothetailpipe
extension.
B.Locateandmarktheheat-shieldmountingholes
asfollows:
•ForDomestic(US)Mowers
9

i.Aligntherightangeoftheexhaust
shield(theangewith2holes)tothe
rearsurfaceofthelower-leftengine
guard(Figure7).
G018637
Figure7
HeatShieldInstallationonUSDomesticMower
ii.Alignthebottomedgeofthe
exhaust-shieldrightangetothe
bottomedgeoftheengineguard
(Figure7).
iii.Aligntheleftangeoftheexhaust
shield(theangewith1hole)tothe
surfaceofthesmall,angularareaof
thelower-leftengineguard.(Figure7).
Note:Ensuretheleftange(the
angewith1hole)oftheexhaust
shieldisushwiththeengine-guard
surface.
iv .Alignthetopedgeofthe
exhaust-shieldleftangeand
thetopedgeofthelower-leftengine
guardsothattheangeedgeandthe
guardedgeareparallel(Figure7).
v.Marktheoutlineofallholesinthe
exhaust-shieldangesontothe
lower-leftengineguard,andremove
theexhaustshieldfromtheengine
guard.
•ForInternational(TE)Mowers
i.Aligntheholesoftheexhaust-shield
rightange(theangewith2holes)
tothetwoleft-most-verticalslotsin
thelower-leftengineguard(Figure8).
G018638
1
Figure8
HeatShieldInstallationonInternational(TE)Mower
1.Flange-hex-headbolt(3/8x1inch)andNut(3/8inch)
ii.Alignthebottomedgeoftheright
angeoftheoftheexhaustshieldto
thebottomedgeoftheengineguard
(Figure8).
iii.Looselysecuretherightangeofthe
exhaustshieldtotheengineguard
with2ange-hex-headbolts(3/8x1
inch)and2angenuts(3/8inch).
iv .Aligntheleftangeoftheexhaust
shield(theangewith1hole)to
angularareaofthelower-leftengine
guard(Figure8).
Note:Ensurethattheleftange
(theangewith1hole)oftheexhaust
shieldisushwiththeengine-guard
surface.
v.Marktheoutlineoftheholeintheleft
angeoftheexhaustshieldontothe
lower-leftengineguard.
vi.Removethefastenersandexhaust
shieldfromtheengineguard.
3.Locatethecenterofthemarksonthelower-left
engine-guardsurface,andcenter-punchthelocations.
4.Drilla10mm(3/8inch)holeintheengineguardat
thecenter-punchmarkcreatedinstep3.
10

Important:Ensurethatthedrillbitdoes
notcontactthemuferwhendrillingthe
heat-shield-mountingholeinthelower-leftengine
guard.
5
InstallingtheExhaustShield
Partsneededforthisprocedure:
1Exhaustshield
3Flange-hex-headbolt(3/8x1inch)
3Nut(3/8inch)
Procedure
Installtheexhaustguardonthelower-leftbumperasfollows:
1.Aligntheholeoftheexhaust-guardleftangetothe
holeinthesmall,angularareaoftheengineguardas
illustratedinFigure9forDomestic(US)mowersor
inFigure10forInternational(TE)mowers.
G018364
621
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5
Figure9
Heat-ShieldInstallationonUSDomesticMower
1.Lower-leftengineguard4.Nut(3/8inch)
2.Exhaustshield5.Flangenut(lower-left
engineguard,
back-mountingpoint)
3.Flange-hex-headbolt(3/8
x1inch)
6.Tailpipeextension
11

G018365
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Figure10
Heat-ShieldInstallationonInternational(TE)Mower
1.Lower-leftengineguard4.Nut(3/8inch)
2.Exhaustshield5.Flangenut(lower-left
engineguard,
back-mountingpoint)
3.Flange-hex-headbolt(3/8
x1inch)
6.Tailpipeextension
2.ForDomestic(US)Mowers,aligntheholesinthe
rightangeoftheexhaustguardwiththeholesinthe
backofthelower-leftbumper(Figure9).
ForInternational(TE)Mowers,aligntheholes
intherightangeoftheexhaustguardwiththe2
left-most-verticalslotsinthebackofthelower-left
engineguard(Figure10).
3.Securetheheatshieldtotheengineguardwiththe3
ange-hex-headbolts(3/8x1inch)and3angenuts
(3/8inch)(Figure9forUSDomestic(US)mowers
orFigure10forInternational(TE)mowers.)
6
InstallingtheHopperSupport
FrameandHoodRod
Partsneededforthisprocedure:
1Hopper-supportframe
2Hairpin
1Hoodhold-downrod
Procedure
Installthehopper-supportframeasfollows:
1.Alignthehopper-supportframesothatthe2
keyed-hoodpinsonthetopoftheframearepointing
totheright,andthemountingpinonthebottomof
theframeispointingtotheleftasshowninFigure11.
g018359
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Figure11
Hopper-SupportFrameInstallation
1.Hopper-supportframe4.Leftframe-supportbracket
2.Keyed-hoodpins5.Rightframe-support
bracket
3.Mountingpin6.Hairpin
2.Insertthehopper-supportframeintothesquare-shaped
openingoftheleftframe-supportbracket(Figure11).
3.Alignthemountingpintotherightoftheright
frame-supportbracket(Figure11).
4.LowertheframebetweentheU-shapetabsoftheof
therightbracket(Figure11).
12

5.Slidethehopper-supportframetotheleftuntilthe
mountingpinpassesthroughtheholeintheright
frame-supportbracket(Figure11).
Note:Thehopper-supportframeandthe
frame-supportbracketsareacloset.Ifnecessary,
useasoft-facedmallettopositionthehopper-frame
supportintheframebrackets.
6.Installthehairpinthroughtheholeofthemounting
pintosecuretheframetothebracket(Figure11).
Installthehoodrodasfollows:
1.Alignthehoodrodsothatthestopangeistowardthe
hopper-supportframe(Figure12).
g018360
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Figure12
HoodRodInstallation
1.Hoodrod3.Hopper-supportframe
2.Stopange4.Hairpin
2.Inserttherodthroughtheholeinthehopper-support
frameuntilthestopangeisagainstthebacksideof
theframe(Figure12).
Note:Ensurethattheholeinthehoodrodis
extendingbeyondtheforwardsideofthehopper-frame
hole.
3.Securethehoodrodtothesupportframebyinserting
thehairpinthroughtheholeinthehoodrod(Figure
12).
7
InstallingtheHoodBafe
Partsneededforthisprocedure:
1Baggerhood
1Bafe
2Hairpin(small)
InstalltheBafeintheBaggerHood
1.Removeandretainthehairpinsfromthebafe.
2.Locatethebafeslotsinthefrontandbacksidewalls
ofthebaggerhood,andthemountingtabsonthe
hoodbafe(Figure13).
G018355
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Figure13
Hood,Bafe,andHairpin
1.Hairpin4.Bafeslot
2.BaggerHood5.Bafe
3.Bafe-mountingtab6.Ductseal
3.Positionthehoodsothattheductsealisonyourleft,
asillustratedinFigure13.
4.Alignthebafesothatthescreenedareaisupand
angledleft(Figure13).
5.Insertthebafeupintothehoodfromthebottom
(Figure13).
13

6.Alignthebafe-mountingtabswiththebafeslotsin
thehood,andpushthemountingtabsupandthrough
theslots(Figure13).
7.Securethebafetothehoodbyinsertingthehairpins
intotheholesinthebafe-mountingtabsasshown
inFigure14.
g018354
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5
Figure14
BaggerHoodAssembly
1.Hairpin4.Bafeslot
2.Baggerhood5.Bafe
3.Bafe-mountingtab6.Ductseal
8
InstallingtheHoodAssembly
andBags
Partsneededforthisprocedure:
1Hoodassembly
2Bag
Procedure
Removetheair-cleanercoverasfollows:
1.Openthe2latchesthatsecuretheair-ltercovertothe
air-lterhousing(Figure15).
123
G018608
Figure15
Air-CleanerCoverRemoval
1.Air-cleanercover3.Air-cleanerlatch
2.Breathervalve
2.Pulltheair-lter-coverbackandremovetheair-lter
cover.
Installthehoodassemblyasfollows:
1.Onthehood,locatethekeyholeslotintheleftand
right-hoodbrackets(Figure16).
2.Onthehopper-supportframe,locatethe2keyedpins
atthepivotbracketsonthetopofthehopper-support
frame(Figure16).
14

5
2
4
G018361
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Figure16
HoodInstallation
1.Hood4.Pivotbracketwith
keyed-pivotpin
2.Hoodbracketwithkeyhole
slot
5.Hoodinstalled
3.Hopper-supportframe
3.Rotatethehoodsothatthekeyholeslotisup,andalign
thehoodtotherightofthekeyed-pivotpins(Figure
16).
4.Assemblethehoodtothehopperframebyslidingthe
keyholebracketsoverthekeyedpins(Figure16).
5.Rotatethehooddowntosecurethehoodtothe
hopper-supportframeasshowninFigure16.
Installtheair-cleanercoverasfollows:
Note:Ensurethattheprimaryairlterisfullyseatedby
pushingonitsouterrim.
Important:Donotpressonthesoftinsideareaofthe
lter
1.Positiontheair-cleanercoversothatthebreathervalve
islocatedatapproximately5o’clock(Figure17).
1
3
2
3
G018610
Figure17
Air-CleanerCover
1.Air-cleanercover3.Air-cleanerlatch
2.Breathervalve
2.Securethelatches(Figure15).
Installthebagassembliesontothehopper-supportframe
asfollows:
1.Raisethehoodtoexposethenotched-bagbracketson
thehopper-supportframeasshowninFigure18.
15

G018362
1
2
3
5
4
Figure18
BagInstallation
1.Hood4.Mounttab
2.Notched-bagbracket5.Bag
3.Hopper-supportframe
2.Alignthemounttabofthebagassemblywiththe
notched-bagbracket(Figure18).
3.Lowerthebagassemblyuntilthebagtabisfullyseated
intothenotchedbracket(Figure18).
4.Repeatsteps1and2fortheotherbag(Figure18).
5.Lowerthebaggerhoodoverthebags(Figure18).
6.Aligntheholeinthehoodlatchwiththehood
hold-downrod.(Figure19).
7.Pushthehoodlatchforwarduntiltheendofthehood
rodhaspassedthroughlatchasshowninFigure19.
g018363
1
2
3
Figure19
9
RoutingtheBlowerBeltinto
theBlowerAssembly
Partsneededforthisprocedure:
1Blower(fromthebloweranddrivekit)
1Blowerbelt(fromthebloweranddrivekit)
Procedure
1.Installthebeltaroundtheblowerpulley(Figure20and
Figure21).
G018368 1
2
3
4
Figure20
BlowerBeltRouting
1.Drivepulley3.Blowerpulley
2.Blowerbelt4.Idler/tensionpulley
16

G018367
1
2
3
2
4
6
5
7
7
Figure21
BlowerBeltRouting
1.Drivepulley5.Blower(housing
repositionedforillustrative
purposes)
2.Blowerbelt6.Blowerinposition(housing
portionremovedfor
illustrativepurposes)
3.Blowerpulley7.Mowerdeck
4.Idler/tensionpulley
2.Ensurethatthebeltremainsalignedtotheblower
pulleywhileyouareinstallingtheblowerassembly.
10
InstallingtheBlowerAssembly
Partsneededforthisprocedure:
1Blowerassembly(fromthebloweranddrivekit)
1Spring(fromthebloweranddrivekit)
Procedure
WARNING
Anuncovereddischargeopeningcouldallow
thelawnmowertothrowobjectstowardyouor
bystanders,resultinginseriousinjury.Also,contact
withthebladecouldoccur.
•Neveroperatethelawnmowerunlessyouinstall
acoverplate,amulchplate,oragrasschuteand
catcher.
•Ensurethatthegrassdeectorisinstalledwhen
youremovethegrasschuteandcatcher.
Removetheside-dischargechuteasfollows:
Important:Installtheside-dischargechutewhenyou
removethebaggerandblower.
Important:Saveallthehardwareandtheside-discharge
chute.
1.Removethelocknut,bolt,spacer,andspringthatsecure
theside-dischargechutetothemowerdeck(Figure22).
Note:Retaintheremovedhardware.
2.Removethesidedischargechutefromthemowerdeck.
Note:Retainthechute.
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g015594
1
6 2 4
7
3
5
Figure22
1.Bolt5.Springinstalled
2.Spacer6.Grassdeector
3.Locknut7.Jhookendofspring
4.Spring
Installtheblowerassemblyasfollows:
1.Removetheoriginalright-handbeltcoverfromthe
mowerdeck.
Note:Retaintheoriginalbeltcoverforinstallation
whenyouoperatethemowerwiththebagging-kit
blowerremoved.
2.Alignthepivotpinontheblowerwiththepivot-pin
holeinthedeck(Figure23).
3.Lowertheblowerandslidethepivotpinintothepivot
hole(Figure23).
Note:Ensurethatthebeltremainspositionedinthe
blowerpulley.
43
2
1
G018369
Figure23
InstallingBlowertoDeckPivotHole
1.Blowerassembly3.Pivothole
2.Deck4.Blower-pivotpin
4.Movethelatchpinfromthelockingpositiontothe
openposition(Figure24).
G018370
1
2
3
3
4
5
7
6
4
Figure24
SecuringtheBlowertotheChuteBracket
1.Blowerassembly5.Idlerpivotbracket
2.Latchpin(lockingposition)6.Idlerpulley
3.Latchpin(openposition)7.Belt(beneaththeidler
pulley)
4.Chutebracket
5.Closetheblowerassemblyandalignthelatchpinwith
theholeinthechutebracket.
6.Movethelatchpintothelockingposition(Figure25).
Note:Ensurethatthelatchpinextendsthroughthe
holeinchutebracket.
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g018371
1
2
3
9
6
8
4
7
5
Figure25
InstallingtheT ensionSpringandAligningtheBelt
1.Blowerassembly6.Spring
2.Latchpin(lockingposition)7.Idlerspringpost
3.Chutebracket8.Springhookend
4.Idlerpivotbracket9.Belt(alignedtotheidler
pulley)
5.Fixedspringpost
Note:Ensurethatthelatchrmlyholdstheblower
assemblyagainstthemowerdeck,butcanbereleased
byhand.
7.Routethebeltaroundthedrivepulleyasillustratedin
Figure20andFigure21.
8.Temporarilyroutethebeltbeneaththeidlerpulley
(Figure25).
9.Movetheidlerpivotbrackettowardthexedspring
post.Installthespringbyaligningthespringhookon
totheidlerspringpost(Figure25).
Note:Ensurethatthespringhooksarecorrectly
positionedonthespringposts.
10.Pullthespringloadedidlerpulleyawayfromthexed
springpost,androutethebeltaroundthemowerdeck
pulley(Figure25).
Note:Ensurethebeltisroutedaroundtheblower
pulleycorrectly.
11
InstallingtheBeltCover
Partsneededforthisprocedure:
1Beltcover(fromthebloweranddrivekit)
1Coverknob
Procedure
1.Lowerthemowerdecktothelowestheight-of-cut
position.
2.Alignthenewright-handbeltcoverwiththebelt-cover
bracketandthenotchesinthedeckbracket.
3.Installthenewbeltcoversothatthenotchesonboth
sidesofthecovergooverthebelt-coversupportsand
securethelatch(Figure26).
G018445
3
2
1
4
Figure26
InstallingtheBeltCover
1.Beltcover3.Coverknob
2.Belt-coversupport4.Notch
4.Securethenewbeltcovertothedeckbyinstallingthe
coverknobfromthebloweranddrivekitthroughthe
coverandthreadedintothebeltcoversupport(Figure
26).
19

12
InstallingtheDischargeTube
Partsneededforthisprocedure:
1Upperdischargetube
3Screw(1/4x3/4inch)
3Locknut(1/4inch)
1Lowerdischargetube
Procedure
Important:Ensurethatthemowerdeckisinthelowest
height-of-cutpositionbeforeinstallingthedischarge
tubes.
Note:Remembertoinstallthegrassdeectorwhenyou
removethebaggerfromthemower;refertoReplacingthe
GrassDeector(page30).
1.DisengagethePTOandsettheparkingbrake.
2.Shutofftheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.
3.Lowerthemowerdecktothelowestheight-of-cut
position.
4.Removethebagsforviewingthetubeunderthehood.
5.Lowerandlatchthehoodforthehopper.
6.Forabaggerkitinstalledona52-inchmowerora
60-inchmower,skiptotheinstructionsforstep8.
7.Forabaggerkitinstalledona48-inchmower,cut
theupperdischargetubeasfollows:
A.Locatetheupperendoftheupperdischargetube
(Figure27).
Note:Thelowerendoftheupperdischargetube
haspre-drilledholes.
G018640
2
1
Figure27
UpperDischargeTube
1.Pre-drilledholes2.17.8cm(7inches)
B.Measure17.8cm(7inches)fromtheendofthe
tube,andmarkthetubeatthislocation(Figure
27).
C.Applymaskingtapearoundthecircumferenceof
theupperdischargetubealignedwiththemarkon
thetubecreatedinstepB(Figure27).
D.Usingtapeasaguide,carefullycutoffanddiscard
theexcesslengthoftube(Figure27).
8.Drilltheholesforthelowerdischargetubeasfollows:
A.Locatethewhitedotattheupperendofthelower
dischargetube.
B.Drillthelowerdischargetubewitha1/4inch(6.5
mm)drillbitatthecenter-punchmark(Figure28).
20