Toro 100 Series Z Master Operator'S Manual Download Page 4

Page: 4 / 28

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

Description

Qty.

Use

Template

Bolt, #6 x1/2 inch

Drilling holes for the clutch

Bolt, 7/16 x 4–1/2 inch—Kawasaki



engines only

Bolt, 7/16 x 4 inch—Kohler



engines

only

Drive pulley assembly

Clutch spacer

Installing the clutch and drive pulley
assembly

No parts needed

Removing the drive wheels

No parts needed

Removing the heat shield

Template

Drilling the holes for the bagger

Bagger mounting bracket

Bolt, 5/16 x 1 inch

Flange nut, 5/16 inch

Flat washer, 5/16 inch

Installing the bagger mounting bracket

Idler pulley assembly with bracket

Bolt, 5/16 x 7/8 inch

Flange nut, 5/16 inch

Spring bracket

Shoulder bolt, 3/8 x 2–1/2 inch

Nut, 3/8 inch

Installing the bagger idler pulley and
skid plate

Summary of Contents for 100 Series Z Master

Page 1: ...Operator s Manual English CE Form No 3350 765 DFS Vac Collection System 100 Series Z Master Model No 78500 Serial No 230000001 and Up ...

Page 2: ...m 25 Greasing the Fan Shaft Bearings 26 Inspecting the Bagger 26 Inspecting the Mower Blades and Baffles 26 Storage 26 Troubleshooting 27 Introduction 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 ope...

Page 3: ... 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 D...

Page 4: ...ve pulley assembly Clutch spacer 1 1 1 1 Installing the clutch and drive pulley assembly 3 No parts needed Removing the drive wheels 4 No parts needed Removing the heat shield 5 Template 1 Drilling the holes for the bagger 6 Bagger mounting bracket Bolt 5 16 x 1 inch Flange nut 5 16 inch Flat washer 5 16 inch 1 16 16 6 Installing the bagger mounting bracket 7 Idler pulley assembly with bracket Bol...

Page 5: ...3 8 inch Bolt 3 8 x 4 1 2 inch Bolt 3 8 x 3 4 inch Self tapping bolt 3 8 x 5 8 inch 1 1 2 2 1 4 2 8 8 16 4 2 1 Installing the weights 12 Weight Weight bracket Large Washer Locknut 5 16 inch Bolt 5 16 x 1 1 4 inch Washer 11 32 inch 1 2 2 2 2 2 Installing the front weight 13 Bagger bracket Carriage bolt 5 16 x 1 inch Flange nut 5 16 inch 1 8 8 Installing the boot and discharge tubes 14 Bolt 1 2 x 1 ...

Page 6: ...tch and Drive Pulley Assembly on page 7 1 2 2 2 Figure 2 1 Clutch 2 Holes in clutch Drilling Holes in the Clutch Use the metal template included with the bagger to locate the clutch holes 1 Remove the clutch strap for the clutch Fig 3 2 Unplug the clutch connector Fig 3 1 2 3 4 m 4119 Figure 3 1 Clutch strap 2 Bolt 3 Clutch connector 4 Clutch 3 Remove the existing deck belt from the clutch 4 Remov...

Page 7: ... Assembly Note Apply anti seize compound to crank shaft before installing the clutch and drive pulley assembly 1 If not already removed remove the existing clutch bolt from the machine and discard Fig 4 and 6 2 If not already removed remove the existing drive spacer from the clutch Fig 4 and 6 3 Install the new pulley spacer into the clutch Fig 6 4 Install the drive pulley assembly into the three ...

Page 8: ... x 4 inch for Kohler engines 8 Drive spacer 3 Step No parts needed for this step Removing the Drive Wheels Danger Mechanical or hydraulic jacks may fail to support machine and cause a serious injury Use jack stands when supporting machine Do not use hydraulic jacks 1 Loosen the drive wheel lugs or nuts 2 Raise the rear of the machine and support with jack stands 3 Remove the drive wheels ...

Page 9: ...If there is no large opening proceed to next step 2 Using the two large holes in the template temporarily install the template to the rear bumper of the mower with 2 bolts 5 16 x 7 8 inch and 2 nuts 5 16 inch supplied with kit Fig 8 1 2 4 4 4 3 Figure 8 1 Template 2 Rear bumper 3 Large opening in bumper 4 Holes to drill 3 Mark and center punch the 3 holes to be drilled Fig 8 4 Mark the outline of ...

Page 10: ...gger mounting bracket 2 Bolt 5 16 x 1 inch 3 Flange nut 5 16 inch 4 Back of rear bumper 5 Engine guard strap 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 10 Note The bagger mounting bracket is to be installed to the inside of the engine guard straps 1 5 6 ...

Page 11: ...umper 3 Bolt 5 16 x 7 8 inch 4 Flange nut 5 16 inch 2 Install the skid plate and idler pulley bracket to the rear bumper with 3 bolts 5 16 x 7 8 inch and 3 flange nuts 5 16 inch Fig 12 3 Install the skid plate to the bottom of the rear bumper with 2 bolts 5 16 x 7 8 inch and 2 flange nuts 5 16 inch Fig 12 2 1 4 5 3 Figure 12 1 Skid plate 2 Idler pulley bracket 3 Rear bumper 4 Bolt 5 16 x 7 8 inch ...

Page 12: ...otter pin 4 Clevis pin 9 Step Parts needed for this step 1 Bagger belt Installing the Bagger Belt 1 Remove the 2 wing nuts 5 16 inch securing the pulley guard to the bottom of the bagger Fig 15 1 2 2 Figure 15 1 Pulley guard 2 Wing nut 5 16 inch 2 Install the bagger belt onto the clutch drive pulley Fig 16 3 Route the bagger belt onto the idler pulley Fig 16 4 Route the bagger belt through the hol...

Page 13: ...the bagger belt tensioned measure the gap as shown in Figure 17 at the tensioner pulley Fig 17 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 1 3 2 m 7649 Figure 17 1 Bagger belt 2 Tensioner pulley 3 1 3 4 to 2 1 8 inch gap 2 To adjust the belt tension A Loosen the 2 nuts on the lower fan shaft pillow block Fig 18 B Insert a spacer b...

Page 14: ...he two outside bolts that connect the front floor pan to the carrier frame Fig 19 Save this hardware 2 Remove the 4 bolts and washers that hold the front floor pan to the front frame Fig 19 Save this hardware m 6047 4 6 4 5 5 5 2 1 3 7 8 Figure 19 1 Front floor pan 2 Footrest 3 Front frame 4 Bolt 5 Nut 6 Washer 7 Front caster wheel 8 Carrier frame 3 With the two holes towards the front place the l...

Page 15: ...isting flange nuts 5 16 inch Fig 22 Note If the right hand flange nut can not be reached drill an 11 32 inch diameter hole through the front floor pan using the support plate as a template Fig 21 m 6111 2 2 3 1 6 5 4 Figure 21 1 Flange nut 5 16 inch 2 Bolt 5 16 x 1 inch 3 Existing flat washer 5 16 inch 4 Front floor pan 5 Support plate 6 Hole to drill if needed 9 Using the support plate as a templ...

Page 16: ...weight brackets to the front of the footpan with 2 bolts 5 16 x 1 1 4 inch and 2 large washers and 2 washers previously removed Fig 23 1 5 m 7168 2 3 4 Figure 23 1 Front of footpan 2 Weight bracket 3 Previously removed washer 4 Bolt 5 16 x 1 1 4 inch 5 Large washer 3 Install the weight onto the weight brackets with 2 washers 5 16 inch and 2 locknuts 5 16 inch Fig 24 4 3 m 7169 3 5 2 1 Figure 24 1 ...

Page 17: ...front slot on the mounting bracket Fig 25 5 Place the rear hook over the rear of the mounting bracket Fig 25 6 Install the upper tube into the bagger Fig 25 7 Slide the clamp onto the middle tube Fig 25 8 Align the knob on the middle tube with the notch in the upper tube Slide the middle tube into the upper tube and twist the middle tube 60 degrees Fig 25 9 Tighten the clamp around the upper and m...

Page 18: ...tom of the lever away from the stop bracket Fig 26 5 Insert the bolt into the stop bracket hole and thread another jam nut 1 2 inch onto the bolt Do not tighten 6 Secure the bagger cable clevis to the bagger dump handle with the clevis pin and cotter pin previously removed Fig 26 7 Adjust the handle stop refer to Adjusting the Bagger Dump Lever page 18 15 Step No parts needed for this step Adjusti...

Page 19: ...Tire Pressure Check the air pressure in the front caster wheel Fig 22 and rear tires Fig 28 Use the following tire pressures when the bagger is installed Pressure Rear tires 20 psi 138 kPa Front caster wheels 25 psi 241 kPa 1 m 1872 Figure 28 1 Valve stem ...

Page 20: ...ely The grass deflector routes material down toward the turf Never put your hands or feet under the mower Never try to clear the discharge area or mower blades unless you move the power take off PTO to off and rotate the ignition key to off Also remove the key and pull the wire off of the spark plug s Turn off the engine before unclogging the discharge chute Warning Children or bystanders may be i...

Page 21: ...e a stick not your hands to remove an obstruction from the blower and tube Keep face hands feet and any other part of your body or clothing away from concealed moving or rotating parts 1 Empty the bagger 2 Disengage the PTO set the parking brake and chock or block the drive wheels 3 Turn off the engine remove the key and wait for all moving parts to stop before leaving the operating position 4 Rem...

Page 22: ...Grass Deflector on page 22 9 Remove all front weights Figures 20 and 22 Installing the Grass Deflector The grass deflector spring will have either an L end or a straight end Fig 31 Note Make sure the grass deflector is installed when the bagger and tubes are removed An uncovered discharge opening could allow the lawn mower to throw objects in the operator s or bystander s direction and result in s...

Page 23: ...gage the PTO Then back down the hill using a slow speed Do not change speeds or stop on slopes Caution Bagging Long Grass Excessively long grass is heavy and may not be propelled completely into the bagger If this happens the tube and boot may plug Bagging Wet Grass If possible always try to cut grass when it is dry Wet grass can cause plugging Reducing Plugging To avoid plugging the bagging syste...

Page 24: ...causes of reduced performance Curb Climbing and Loading Always lift the deck to the highest position when loading the machine on trailers or ascending descending a curb Leaving the mower in a lower position can cause damage to mower baffles while loading and going over a curb If a curb is higher than 6 inches 152 mm cross it at a sharp angle with the deck fully raised Use extreme caution when load...

Page 25: ...arking brake and chock or block the drive wheels 2 Turn off the engine remove the key and wait for all moving parts to stop before leaving the operating position 3 Open the bagger and hold the bagger door open Refer to Holding the Bagger Door Open on page 21 4 Clean the debris from the screens 5 Close the bagger door Cleaning the Bagger The bagger needs to be cleaned as needed when debris is obser...

Page 26: ...n Replace any parts that are cracked or broken 5 Tighten all nuts bolts and screws Inspecting the Mower Blades and Baffles 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 attachm...

Page 27: ...d rear door 4 Ensure the rear door is latched 5 A plugged boot 5 Locate and remove plugged debris 6 Improper seal around the upper tube going into the hopper 6 Ensure that there is a good seal at hopper 7 Full hopper 7 Empty hopper Boot and tubes plug too frequently 1 Hopper is too full 1 Dump more frequently g q y 2 Low engine speed 2 Always operate the bagger at full throttle 3 Grass is too wet ...

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