Form No. 3440-329 Rev A 60in and 72in DFS E-Z Vac™ Collection System Z500 Series Z Master® Mowers Model No. 78544—Serial No. 280000001 and Up Model No. 78545—Serial No. 280000001 and Up Register at www.Toro.com.
Introduction Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage. You are responsible for operating the product properly and safely. g007732 Figure 2 Bagger Serial Number You may contact Toro directly at www.Toro.com for product safety and operation training materials, accessory information, help finding a dealer, or to register your product. 1.
Safety 11 Installing the Weights ................................... 17 12 Adjusting the Parking Brake ......................... 17 13 Checking the Tire Pressure .......................... 18 Operation ................................................................ 19 Positioning the Adjustable Baffle....................... 19 Emptying the Bagger ........................................ 20 Clearing Obstructions from the Collection System..........................................................
with manufacturer's recommended parts, when necessary. Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 1 Description Qty. Use No parts required – Bagger mounting bracket Bagger side plate Spacer Bolt (3/8 x 1-1/2 inches) Bolt (3/8 x 1 inch) (for Z593 mowers only) Flange nut (3/8 inch) Curved washer Handle assembly Washer Bolt (3/8 x 1-1/4 inches) Clevis-pin spring Locknut (3/8 inch) 1 2 2 14 14 14 1 2 3 1 3 4 No parts required – Tighten all mounting bolts.
Note: Determine the left and right sides of the machine from the normal operating position. 1 2 Preparing the Mower Installing the Bagger Mounting Bracket No Parts Required Parts needed for this procedure: Procedure 1 Bagger mounting bracket 2 Bagger side plate 2 Spacer 14 Bolt (3/8 x 1-1/2 inches) 2 Bolt (3/8 x 1 inch) (for Z593 mowers only) 14 Flange nut (3/8 inch) 14 Curved washer Perform the following procedure to prepare the mower for attaching the blower and finishing kit. 1. 2.
g003379 Figure 5 For Kubota Diesel Mowers g003380 Figure 4 For Z500 Gas Mowers 1. Bolt (3/8 x 1 inch) 6. Bagger side plate 6. ROPS 2. Curved washer (3/8 inch) 7. ROPS 2. Curved washer (3/8 inch) 7. Flange nut (3/8 inch) 3. Bagger mounting bracket 8. Flange nut (3/8 inch) 3. Bagger mounting bracket 8. Side view of bagger side plate 4. Bolt (3/8 x 1-1/2 inches) 9. Side view of bagger side plate 4. Spacer 9. Holes to use when installing the side bracket 5. Spacer 1.
3 Installing the Handle Assembly Parts needed for this procedure: 1 Handle assembly 2 Washer 3 Bolt (3/8 x 1-1/4 inches) 1 Clevis-pin spring 3 Locknut (3/8 inch) Procedure g003378 Figure 6 For Daihatsu Diesel Mowers 1. Bolt (3/8 x 1-1/2 inches) 6. ROPS 2. Curved washer, (3/8 inch) 7. Flange nut (3/8 inch) 3. Bagger mounting bracket 8. Side view of bagger side plate 4. Spacer 9. Holes to use when installing the side bracket 1.
g007701 Figure 9 1. Bagger arm link 3. Clevis pin spring 2. Bagger assembly 4 Tightening all Mounting Bolts g007703 Figure 8 1. Handle assembly 4. Nut (3/8 inch) 2. Bolt (3/8 x 1-1/4 inches) 5. This bolt is not used on Kubota powered machines No Parts Required Procedure 3. Washer 3. The following steps are the correct sequence to tighten the side brackets and the bagger mounting bracket. All mounting bolts need to be torqued to 48 N⋅m (35 ft-lb).
5 6 Installing the Bagger Assembly Routing the Blower Belt into the Blower Assembly Parts needed for this procedure: Parts needed for this procedure: 1 Bagger assembly 2 Clevis pin 2 Hairpin cotter 1 Blower belt (from the Blower and Drive Kit) Procedure 1. Install the belt around the blower pulley (Figure 11). 2. Install the spring to the idler arm and the peg on the blower assembly (Figure 11). Procedure 1. Install the bagger assembly onto the bagger mounting bracket (Figure 10). 2.
2. 7 Slide the blower-assembly peg into the pivot hole. For 152 cm (60 inch) mowers refer to Figure 13 and for 183 cm (72 inch) mowers refer to Figure 14. Installing the Blower Assembly Parts needed for this procedure: 1 Blower assembly (from the Blower and Drive Kit) 1 Spring (from the Blower and Drive Kit) Procedure WARNING An uncovered discharge opening could allow the lawn mower to throw objects at you or bystanders, resulting in serious injury. Also, contact with the blade could occur.
Note: Make sure that the hooks are in the correct position. g003638 Figure 16 1. Spring-loaded idler pulley 3. Long-hook end 2. Short-hook end 5. g003377 Figure 14 183 cm (72 inch) Mower Deck 1. Blower assembly 3. Pivot hole 2. Mower deck, 183 cm (72 inch) shown 4. Blower-assembly peg 3. Pull the spring-loaded idler pulley back and route the belt around the mower-deck pulley (Figure 17). Note: Ensure that the belt is routed around the blower pulleys correctly (Figure 17).
8 Sizing the Upper Tube for 152 cm (60 inch) Mowers with Gas Engines Parts needed for this procedure: 1 Upper tube Procedure Note: This procedure is for 152 cm (60 inch) mowers with gas engines only. 1. 2. Measure up 89 mm (3-1/2 inches) from the bottom of the upper tube. Use the existing 3 holes as marks and then mark it in several places to create a line around the tube (Figure 18). g003391 Figure 18 Cut the 89 mm (3-1/2 inches) off the upper tube (Figure 18). 1. Indentations for drilling holes 2.
Note: Remember to replace the grass deflector when the bagger is removed from the mower. Refer to Installing the Grass Deflector (page 27). 1. Disengage the PTO and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Lower the mower deck to the lowest height-of-cut position. 4. Install the upper tube into the bagger opening and pull it back out so that the rubber seal is protruding out (Figure 19).
7. Install the lower tube into the upper tube (Figure 22). g003424 Figure 22 1. Lower tube 2. Upper tube g003423 8. Figure 23 Slide the lower tube onto the boot and latch them together (Figure 23). 1. Blower assembly Note: There is a latch on the top and bottom 2. Lower tube 3. Latch of the blower housing. 9. Make sure that the mower deck is in the lowest height-of-cut position and the mark on the upper tube is still positioned against the protruding rubber seal.
10. 12. Using the 3 holes or indentations in the upper tube as a template, drill 3 holes (7/32 inch diameter) where the upper and lower tubes join together (Figure 24). Join the upper and lower tubes with 3 bolts (#10 x 3/4 inches), 3 flat washers (7/32 inch), and 3 locknuts (#10) as shown in Figure 25. g003392 Figure 25 g003390 Figure 24 1. Lower tube 4. Locknut (#10) 5. Bolt, (#10 x 3/4 inches) 1. Bagger hood 4. Lower tube 2. Upper tube 2. Upper tube 5. Blower assembly 3.
2. Install plate, nuts (1/2 inch) and lock washer (1/2 inch) under the frame and weight (Figure 27). 3. Repeat for opposite side. Note: All Z Master mowers receive the caster weights. g003370 Figure 26 1. Belt cover 2. Blower assembly 5. Latch 6. Belt cover notch 3. Pulley assembly 7. Belt cover support g001366 Figure 27 4. Belt cover bracket 11 1. Front caster weight 4. Nut 2. U-bolt 3. Plate 5. Front caster 6.
the correct measurement is obtained (Figure 29). Tighten jam nut at the yoke. 12 13 Adjusting the Parking Brake Checking the Tire Pressure No Parts Required No Parts Required Procedure Procedure Check the parking brake for proper adjustment. 1. Disengage brake lever (lever down). 2. Measure the length of the spring. Note: Increase the tire pressure due to the additional weight. Check and increase the air pressure in the front caster wheels and the rear tires (Figure 30).
Operation CAUTION Children or bystanders may be injured if they move or attempt to operate the tractor while it is unattended. Note: Determine the left and right sides of the machine from the normal operating position. Important: Set the parking brake when you leave Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes. the machine, even if just for a few minutes.
Emptying the Bagger Note: In most cases, the debris can be shaken 1. Disengage the PTO and set the parking brake. 2. Lift the handle to open the door and empty the hopper. 3. Push the handle down to close the door (Figure 32). out of the tubes. 7. If the blower assembly is plugged, unlatch the blower assembly, remove the belt, and swing it open. 8. Use a stick or similar object, not your hands, to remove and clear the obstruction from the blower assembly. 9.
Using the Grass Deflector (2 to 3 inches) or 1/3 of the grass height, whichever is less. Cutting off more than this will reduce the capacity of the vacuum system. DANGER Without the grass deflector, discharge cover, or complete grass catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris. Contact with rotating mower blade(s) and thrown debris will cause injury or death.
Reducing Plugging To avoid plugging the bagging system, reduce the ground speed and mow the grass at a high height-of-cut, then lower the mower to your normal cutting height and repeat the bagging process. Signs of Plugging As you use the bagger, a small amount of grass clippings normally blow out the front of the mower. An excessive amount of clipping blow-out indicates that the bagger is full or the tube is plugged.
Maintenance Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 8 hours • Inspect the blower belt. • Inspect the collection system. Before each use or daily • Clean the hood screen. • Clean the collection system. Every 25 hours • Inspect the blower belt. Every 50 hours • Grease the idler arm. Every 100 hours • Grease the handle pivot. • Inspect the collection system.
6. Greasing the Idler Arm and Handle Pivot Install the spring as shown in Figure 34. Service Interval: Every 50 hours—Grease the idler arm. Every 100 hours—Grease the handle pivot. Grease the blower belt idler arm (Figure 36). g003638 Figure 34 1. Spring-loaded idler pulley 3. Long-hook end 2. Short-hook end 7. Pull back on the spring-loaded idler pulley and install the belt onto the spring-loaded idler pulley (Figure 33).
Inspecting the Collection System Service Interval: After the first 8 hours Every 100 hours 1. Disengage the PTO, move the motion-control levers to the NEUTRAL-LOCKED position, and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Check the upper tube, lower tube, bagger, and the blower assembly. g008022 Figure 38 Note: Replace these parts if they are cracked 1. Contact arm—straight up and down 2.
Inspecting the Mower Blades Figure 40 2. If blades are badly worn or damaged, install new blades. Refer to your mower Operator's Manual for complete blade maintenance. In most mowing conditions, the standard high-lift blades will provide the best bagging performance. 3. Stop 2. Handle link The Toro Atomic blade is recommended for bagging leaves in dry conditions. In dry dusty conditions, the medium-lift or low-lift blades reduces dust and dirt blowout while providing effective bagging air flow.
Installing the Grass Deflector WARNING An uncovered discharge opening could allow the lawn mower to throw objects at you or others and result in serious injury. Also, contact with the blade could occur. • Never operate the lawn mower unless you install a cover plate, a mulch plate, or a grass chute and catcher. • Make sure that the grass deflector is in the down position. 1. g002519 Figure 42 Remove the locknut, bolt, spring and spacer holding the deflector to the pivot brackets (Figure 42). 2.
Storage 1. Clean the bagger. Refer to Cleaning the Bagger Screen (page 23) and Cleaning the Collection System (page 23). 2. Inspect the bagger for damage. Refer to Inspecting the Collection System (page 25). 3. Make sure that the bagger is empty and thoroughly dry. 4. Check the belt for wear or cracks. 5. Store the machine in a clean, dry place, out of direct sunlight. If you must store the machine outside, cover it with a weatherproof cover.
Troubleshooting Problem There is abnormal vibration. Bagging performance is reduced. Blower and tubes plug too frequently. Possible Cause 1. Cutting blade(s) is/are bent or unbalanced. 1. Install new cutting blade(s). 2. A blade-mounting bolt is loose. 3. A blower pulley or pulley assembly is loose. 4. A blower belt is worn. 5. Blower fan blade(s) is/are bent or unbalanced. 2. Tighten the blade-mounting bolt. 3. Tighten the appropriate pulley. 1. The engine speed is low. 1.
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The Toro Total Coverage Warranty Landscape Contractor Equipment (LCE) A Limited Warranty (see warranty periods below) Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to the original purchaser to repair the Toro Products listed below if defective in materials or workmanship.
