Form No. 3359-401 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. You may contact Toro directly at www.Toro.com for product and accessory information, help finding a dealer, or to register your product. Figure 2 Bagger Serial Number 1.
Safety 9 Installing the Discharge Tubes.......................... 13 10 Installing the Belt Cover ................................. 15 11 Installing the Weights ..................................... 16 12 Adjusting the Parking Brake ........................... 16 13 Checking the Tire Pressure............................. 17 Operation................................................................... 18 Positioning the Adjustable Baffle ........................ 18 Emptying the Bagger........................
Frequently check components and replace 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.
Procedure 12 13 Description Use Qty. No parts required – Adjust the parking brake. No parts required – Check the tire pressure. 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 Perform the following procedure to prepare the mower for attaching the blower and finishing kit. 1.
2 bolts (3/8 x 1 inch) for Z593 mowers as shown in Figure 5), 2 curved washers (3/8 inch), and 2 flange nuts (3/8 inch) (Figure 4, Figure 5, and Figure 6). Figure 5 For Kubota Diesel Mowers 1. 2. 3. 4. Figure 4 For Z500 Gas Mowers 1. Bolt, (3/8 x 1-1/2 inches) 2. Curved washer, (3/8 inch) 3. Bagger mounting bracket 4. Spacer Bolt, (3/8 x 1 inch) Curved washer, (3/8 inch) Bagger mounting bracket Bolt, (3/8 x 1-1/2 inches) 5. Spacer 6. ROPS 7. Flange nut, (3/8 inch) 8. Side view of bagger side plate 9.
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 1. Position the handle assembly between the ROPS roll bar and the bagger mounting bracket (Figure 8). 2. Install the handle assembly to the bagger mounting bracket and the machine with 3 bolts (3/8 x 1-1/4 inches) and 3 locknuts (3/8 inch) (Figure 7 and Figure 8).
4 Tightening all Mounting Bolts No Parts Required Procedure 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 35 ft-lb (48 N⋅m). 1. Tighten the bagger mounting bracket to the rear frame first. 2. Tighten the ROPS and side brackets to the side of the mower. 3.
Figure 11 1. Idler pulley 2. Mower deck pulley 3. Spring Figure 10 1. Hood assembly 2. Clevis pin 3. Hairpin cotter 4. Bagger mounting bracket 7 6 Installing the Blower Assembly Routing the Blower Belt into the Blower Assembly Parts needed for this procedure: Parts needed for this procedure: 1 4. Peg 5. Belt 6. Blower pulley 1 Blower assembly (from Blower and Drive Kit) 1 Spring (from Blower and Drive Kit) Blower belt (from Blower and Drive Kit) Procedure Procedure 1.
Figure 12 1. Bolt 2. Spacer 3. Locknut 5. Spring installed 6. Grass Deflector 7. L end of spring, place behind deck edge before installing bolt 8. J hook end of spring 4. Spring 2. Slide the blower assembly peg into the pivot hole. For 60 inch mowers refer to Figure 13 and for 72 inch mowers refer toFigure 14. Figure 14 72 inch Mower Deck 1. Blower assembly 2. Mower deck, 72 inch (183 cm) shown 3. Pivot hole 4. Blower assembly peg 3.
8 Sizing the Upper Tube for 60 inch Mowers with Gas Engines Parts needed for this procedure: 1 Upper tube Procedure Note: This procedure is for 60 inch mowers with gas engines only. Figure 16 1. Spring loaded idler pulley 2. Short hook end 3. Long hook end 1. Measure up 3–1/2 inches (89 mm) 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). 5.
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 the rubber seal is protruding out (Figure 19). Figure 19 1. Upper tube 2. Bagger opening Figure 18 1. Indentations for drilling holes 2. Upper tube 3. Cut off 3–1/2 inches (89 mm) for 60 inch mowers with gas engines only 4.
6. Once the 3/4 inch (19 mm) measurement has been achieved, mark the upper tube on the out side where the rubber seal protrudes out. This is marked to ensure the correct position for the upper tube when drilling the holes and connecting the upper and lower tubes (Figure 21). Note: The rubber seal must protrude out from the bagger hood. Figure 22 1. Lower tube 2. Upper tube 8. Slide the lower tube onto the boot and latch them together (Figure 23).
9. Make sure 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. Check to make sure the mark fromFigure 21 is still in place. 10. Using the three holes or indentations in the upper tube as a template, drill three holes (7/32 inch diameter) where the upper and lower tubes join together (Figure 24). Figure 25 1. Lower tube 2. Upper tube 3. Flat washer, (7/32 inch) 4. Locknut, (#10) 5. Bolt, (#10 x 3/4 inches) 13.
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. Figure 26 1. 2. 3. 4. Belt cover Blower assembly Pulley assembly Belt cover bracket 5. Latch 6. Belt cover notch 7. Belt cover support Figure 27 1. Front caster weight 2. U-bolt 3. Plate 11 Note: Only Z Master mowers with 60 inch mower decks receive the top weights. 4.
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. Note: Increase the tire pressure due to the additional weight. 1. Disengage brake lever (lever down). Check and increase the air pressure in the front caster wheels and rear tires (Figure 30). 2. Measure the length of the spring. The measurement should be 2-3/4 inch (70 mm) between washers (Figure 29).
Operation 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 leaving the machine unattended, even if just for a few minutes. Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes.
Emptying the Bagger Note: In most cases, the debris can be shaken out of the tubes. 1. Disengage the PTO and set the parking brake. 2. Lift up on the handle to open the door and empty the hopper. 3. Push the handle down to close the door (Figure 32). 7. If the blower assembly is plugged, unlatch the blower assembly, remove the belt, and swing it open. 8. Using a stick or similar object, not your hands, to remove and clear the obstruction from the blower assembly.
Cutting Height Using the Grass Deflector For optimum bagging performance, set the deck height-of-cut to remove no more that 2 to 3 inches (51 to 76 mm) or 1/3 of the grass height, which ever is less. Cutting off more than this will reduce the capacity of the vacuum system. 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.
then lower the mower to your normal cutting height and repeat the bagging process. 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 system, reduce 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 are bagging, a small amount of grass clippings normally blow out the front of the mower.
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.
Figure 35 1. Latch 2. Bolt Figure 33 1. Idler pulley 2. Mower deck pulley 3. Spring 4. Peg 5. Belt 6. Blower pulley 3. Blower assembly Greasing the Idler Arm and Handle Pivot 6. 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). Figure 34 1. Spring loaded idler pulley 2. Short hook end 3. Long hook end 7.
Grease the handle pivot (Figure 37). 5. After the stop bolts have been adjusted, the length of the hinge links can be adjusted to provide complete closing of the door and reasonable force on the handle. Lengthen the links to reduce the force. Shorten the links to increase the force (Figure 38 and Figure 39). 6. Make sure both the left and right sides are adjusted the same distance. With the door closed, the links should be slightly tight to minimize rattling. 7. Tighten the nuts.
Adjusting the Door Opening Perform this after adjusting the door closing. Adjust the handle link to obtain the maximum door opening. Lengthen the handle link to open the door farther. Shorten the handle link to open the door less (Figure 40). Note: The maximum door opening is controlled by the contact arm hitting the stop. The stop is not adjustable and prevents the door from being opened too far. Figure 41 1. Latch link 2. Latch rod Inspecting the Mower Blades 1.
Installing the Grass Deflector Storage 1. Clean the bagger. Refer to Cleaning the Bagger. 2. Inspect the bagger for damage. Refer to Inspecting the Collection System. An uncovered discharge opening could allow the lawn mower to throw objects in the operator’s or bystander’s direction and result in serious injury. Also, contact with the blade could occur. 3. Make sure the bagger is empty and thoroughly dry. 4. Check the belt for wear or cracks. 5.
Troubleshooting Problem Abnormal vibration. Reduced bagging performance. Blower and tubes plug too frequently. Possible Cause 1. Cutting blade(s) is/are bent or unbalanced. 1. Install new cutting blade(s). 2. 3. 4. 5. 2. 3. 4. 5. Blade mounting bolt is loose. Loose blower pulley or pulley assembly. Worn blower belt. Blower fan blade(s) is/are bent or unbalanced. 1. Always operate the collection system at full throttle. 2. Plugged screen in bagger hood. 3. Loose blower belt. 4.
The Toro Total Coverage Guarantee Landscape Contractor Equipment (LCE) A Limited Warranty Conditions and Products Covered Owner Responsibilities The Toro® Company and its afliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair the listed Toro Products if defective in materials or workmanship.
