Form No. 3371-273 Rev B 48in, 52in, 60in or 72in E-Z Vac™ DFS Collection System Gen II Z Master® Mower Model No. 78566—Serial No. 290000001 and Up Model No. 78567—Serial No. 290000001 and Up Model No. 78568—Serial No. 290000001 and Up Register at www.Toro.com.
WARNING CALIFORNIA Proposition 65 Warning This product contains a chemical or chemicals known to the State of California to cause cancer, birth defects, or reproductive harm. Figure 2 48- and 52-inch bagger serial number Introduction 1. Bagger model and serial number location 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.
Contents Installing the Mower Blades .....................................34 Installing the Grass Deflector...................................34 Storage ........................................................................35 Troubleshooting ...........................................................36 Safety ........................................................................... 4 Safety and Instructional Decals ................................. 4 Setup .............................................
Safety • Use care when loading or unloading the machine into a trailer or truck. If the machine is to be driven on to a truck or trailer with the hopper full, always back up the ramp. The following list contains safety information specific to Toro products and other safety information you must know. • Never operate with the discharge deflector raised, • Become familiar with the safe operation of the equipment, removed or altered, unless using a grass catcher.
106-0871 106-3339 103-3508 48-inch and 52-inch decks only 109-5890 60-inch and 72-inch decks only 5
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 1 2 3 4 5 6 7 8 9 10 11 Description Qty.
Procedure 12 13 14 15 Description Use Qty. Caster weight (if needed) Clevis pin Hairpin cotter Lock washer (3/8 inch) Weight-mount bracket Bolt (3/8 x 1 inch) Flat washer (3/8 inch) Flange nut (small flange–3/8 inch) Carriage bolt (5/16 x 3/4 inch) Flange nut (5/16 inch) Front weight (48-inch, 52-inch, and 60-inch decks) Front weight (72-inch decks) Tap bolt (3/8 x 1-3/4 inches) Nut (3/8 inch) Bumper Spacer Locknut (5/16 inch) 2 2 2 6 1 6 6 3 2 2 No parts required – Adjust the parking brake.
1 2 Preparing the Mower Installing the Side Bumpers 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. Disengage the PTO, move the motion-control levers to the NEUTRAL-LOCKED position and set the parking brake. 1 Left bumper 1 Right bumper 2 Carriage bolt (3/8 x 1-1/4 inches) 6 Flange nut (large flange–3/8 inch) Procedure 1.
2. Install the upper mounting bracket to the left and right bumpers with 2 carriage bolts (1/2 x 2-1/2 inches) and 2 flange nuts (1/2 inch) as shown in Figure 6.
3. Install the handle and bracket assembly to the side of the machine with 3 carriage bolts (3/8 x 1-1/4 inches) and 3 flange nuts (large flange–3/8 inch) as shown in Figure 8. 5 Installing the Handle Assembly and Bracket for 48- and 52-inch Mowers Note: Ensure that the bolts go through the left bumper and the lower bagger bracket and connect them to the side of the machine.
6 Installing the Bagger Assembly Parts needed for this procedure: 1 Bagger assembly 2 Pin and hairpin cotter assembly Procedure 1. Position the bagger on its back (Figure 10). 2. Slide the hooks onto the lower mounting bracket (Figure 10). 3. Rotate the bagger up on the lower bagger mounting bracket. 4. Align the hole in the bagger with the upper mounting bracket (Figure 10). 5. Install the pin and secure it with the hairpin cotter on both sides (Figure 10). Figure 10 1. Lower mounting bracket 4.
7 Installing the Muffler Deflector Parts needed for this procedure: 3. Clevis-pin spring 2. Bagger-handle linkage 4. Yoke Muffler deflector 2 Flange nut (small flange–3/8 inch) 2 Carriage bolt (3/8 x 1-1/4 inches) Procedure Figure 11 1. Bagger-arm assembly 1 Install the muffler deflector to the side of the bagger frame (Figure 12). Note: Ensure that the muffler deflector is positioned over the tail pipe on the muffler. Figure 12 60- and 72-inch bagger shown 1. Muffler deflector 2.
8 Routing the Blower Belt into the Blower Assembly Parts needed for this procedure: 1 Blower belt (from the Blower and Drive Kit) Procedure 1. For 60- and 72-inch mowers, install the belt around the blower pulley (Figure 13). Figure 14 Blower for 48- and 52-inch mowers Figure 13 Blower for 60- and 72-inch Mowers 1. Idler pulley 4. Peg 2. Mower-deck pulley 5. Belt 3. Spring 6. Blower pulley 2. For 48- and 52-inch mowers, loosen the belt guide (Figure 14). 3.
2. Slide the blower-assembly peg into the pivot hole (Figure 16 or Figure 17). 9 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 Figure 16 48- and 52-inch mower deck shown 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. 1. Blower assembly 3. Pivot hole 2.
3. Close the blower assembly to see if the latches are adjusted correctly (Figure 18). 5. Pull the spring-loaded idler pulley back and route the belt around the mower-deck pulley (Figure 20). Note: Loosen or tighten the bolt so the latches firmly hold the blower assembly against the mower deck but can be released by hand Note: Ensure that the belt is routed around the blower pulleys correctly Figure 18 1. Latch Figure 20 3. Blower assembly 1. Mower-deck pulley 2. Bolt 2.
10 Installing the Discharge Tubes Parts needed for this procedure: 1 Upper tube 1 Lower tube 3 Bolt (#10 x 3/4 inches) 3 Locknut (#10) 3 Washer (7/32 inch) Procedure Important: Make sure that the mower deck is in the lowest height-of-cut position while installing the discharge tubes. Figure 22 Note: Remember to replace the grass deflector when the bagger is removed from the mower. Refer to Installing the Grass Deflector (page 34). 1. Hood plate 4. 3/4 inch (19 mm) 2. Upper tube 5.
7. Install the lower tube into the upper tube (Figure 24). Figure 24 1. Lower tube 2. Upper tube 8. Slide the lower tube onto the boot and latch them together (Figure 25 or Figure 26). Figure 25 Note: There is a latch on the top and bottom of the blower housing. 1. Blower assembly 2. Lower tube Note: 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.
9. 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 27). Figure 26 60- and 72-inch bagger shown 1. Blower assembly Figure 27 3. Latch 2. Lower tube 1. Bagger hood 4. Lower tube 2. Upper tube 5. Blower assembly 3. Drill 7/32 inch diameter holes here (use the upper tube as a template) 10. Remove the lower tube from the blower.
11. 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 28. 1 2 G009305 Figure 29 48- and 52-inch bagger shown 1. Belt cover 2. Belt-cover support 3. Notch 1 Figure 28 1. Lower tube 4. Locknut (#10) 2. Upper tube 5. Bolt, (#10 x 3/4 inches) 2 3. Flat washer (7/32 inch) 12. Install the lower tube onto the blower housing and secure it with the latches.
3. Tighten the tap bolt so that it touches the frame and then tighten the jam nut against the weight.
6. Secure the front weights on top of the foot rest and to the weight-mount bracket with 6 bolts (3/8 x 1 inch), 6 lock washers (3/8 inch), 3 flange nuts (small flange) (3/8 inch) and 6 flat washers (3/8 inch) (Figure 33). 13 Installing the Bumpers Machines with MyRide™ Suspension System Parts needed for this procedure: 2 Bumper 2 Spacer 2 Locknut (5/16 inch) Procedure For 48-inch, 52-inch, and 60-inch decks, install the bumpers to the 2 outside holes of the toeboard (Figure 35). Figure 33 1.
For 72-inch decks, install the bumpers to the 2 inside holes of the toeboard (Figure 36). 15 Checking the Tire Pressure No Parts Required Procedure Note: Increase the tire pressure due to the additional weight. Check and increase the air pressure in the front caster wheels and therear tires (Figure 37). Pressure: Rear tires: 138 kPa (20 psi) Front caster wheels: 172 kPa (25 psi) Figure 36 1. Locknut (5/16 inch) 3. Bumper 2.
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 the machine, 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 7. If the blower assembly is plugged, unlatch the blower assembly, remove the belt, and swing it open. 1. Disengage the PTO and set the parking brake. Important: Use a stick or similar object, not your hands, to remove and clear the obstruction from the blower assembly. 2. Lift the handle to open the door and empty the hopper. 3. Push the handle down to close the door (Figure 39). 8. After you remove the obstruction, install the complete collection system and resume operation.
Cutting Frequency Using the Grass Deflector Cut the grass often, especially when it grows rapidly. You need to cut your grass twice if it gets excessively long (refer to Bagging Long Grass Bagging Long Grass (page 25)). 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. After the first 100 hours • Adjust the parking brake (also when replacing or removing a brake component). 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.
Inspecting the Blower Belt 6. Install the spring as shown in Figure 41. Service Interval: After the first 8 hours Every 25 hours Check the belts for cracks, frayed edges, burn marks, or any other damage. Replace damaged belts. Replacing the Blower Belt for 60- and 72-inch Mowers 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.
Checking and Adjusting the Blower Latch Close the blower assembly to see if the latches are adjusted correctly. Loosen or tighten the bolts so the latches firmly hold the blower assembly against the mower deck but can be released by hand. Figure 42 1. Idler pulley 5. Belt 2. Mower-deck pulley 6. Belt-guide bolt 3. Spring 7. Fixed-idler pulley 4. Spring peg 8. Blower pulley Figure 44 1. Latch 3. Blower assembly 2. Bolt 8. Install the spring as shown in Figure 43.
Adjusting the Closed Door for 60- and 72-inch Mowers For 60-and 72-inch mowers only, grease the handle pivot (Figure 46). 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. With the door closed, loosen the nuts and adjust the stop bolts so that the contact arm is straight up and down (Figure 47). 4.
Adjusting the Open Door for 60- and 72-inch Mowers Adjusting the Latches for 60and 72-inch Mowers Note: Perform this procedure after adjusting the door to completely close. Note: Adjust the open door and closed door positions before adjusting the latches. 1. Disengage the PTO, move the motion-control levers to the NEUTRAL-LOCKED position, and set the parking brake. Adjust the handle link to so that the door opens as much as possible(Figure 48 and Figure 49).
Adjusting the Closed Door for 48- and 52-inch Mowers 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. With the door closed, check and ensure that it is slightly tight against the frame when closed. 4. If adjustment is needed, adjust the nuts. Note: Lengthen the links to reduce the force. Shorten the links to increase the force.
Adjusting the Open Door for 48- and 52-inch Mowers Perform this after adjusting the closed door. 1. Remove the side plate from both sides of the bagger (Figure 54). Figure 55 1. Lower lip of the molded hood 2. The measurement is between an 3.2 mm (1/8 inch) and 9.6 mm (3/8 inch). 4. If adjustment is needed, adjust the hinge stops on both sides so that the distance between the upper tube of the door frame and the lower lip of the molded hood is between an 3.2 mm (1/8 inch) and 9.6 mm (3/8 inch).
Adjusting the Parking Brake Installing the Grass Deflector Service Interval: After the first 100 hours WARNING Refer to the Operator’s Manual for the machine to adjust the parking brake. 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. Inspecting the Mower Blades • Never operate the lawn mower unless you install a cover plate, a mulch plate, or a grass chute and catcher. 1.
Storage 1. Clean the bagger. Refer to Cleaning the Bagger Screen (page 27) and Cleaning the Collection System (page 27). 2. Inspect the bagger for damage. Refer to Inspecting the Collection System (page 30). 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.
