Toro 110-0891 Installation Instructions

FormNo.3355-269RevA

MountingKit

forDFSVacCollectionSystemonaZ593
andZ595SeriesZMasters

ModelNo.110–0891

Registeratwww.T oro.com.OriginalInstructions(EN)

Introduction

Readthisinformationcarefullytolearnhowtooperate
andmaintainyourproductproperlyandtoavoidinjury
andproductdamage.Youareresponsibleforoperating
theproductproperlyandsafely.

YoumaycontactTorodirectlyatwww.Toro.comfor
productandaccessoryinformation,helpndinga
dealer,ortoregisteryourproduct.

Wheneveryouneedservice,genuineToroparts,
oradditionalinformation,contactanAuthorized
ServiceDealerorToroCustomerServiceandhave
themodelandserialnumbersofyourproductready.
Figure1identiesthelocationofthemodelandserial
numbersontheproduct.Writethenumbersinthe
spaceprovided.

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Thismanualidentiespotentialhazardsandhas
safetymessagesidentiedbythesafetyalertsymbol
(Figure2),whichsignalsahazardthatmaycauseserious
injuryordeathifyoudonotfollowtherecommended
precautions.

Figure2

1.Safetyalertsymbol

Thismanualuses2otherwordstohighlightinformation.
Importantcallsattentiontospecialmechanical
informationandNoteemphasizesgeneralinformation
worthyofspecialattention.

Contents

Introduction.................................................................2

Safety...........................................................................3

SafetyandInstructionalDecals.............................3

Setup............................................................................4

1RemovingtheExistingBagger,Mounting

Bracket,andW eights........................................5

2InstallingtheBaggerMountingBracket..............7

3TighteningallMountingBolts............................8

4InstallingtheBaggerDrivePulley.......................9

5InstallingtheSpringLoadedIdlerPulleyand

SpringAnchor..................................................9

6InstallingtheFixedIdlerPulley.........................10

7InstallingtheIdlerArmBracket........................11

8InstallingtheBagger........................................11

9InstallingtheBaggerBelt.................................12

10CheckingandAdjustingtheBaggerBelt

Tension..........................................................13

11InstallingtheW eights.....................................13

12InstallingtheBootandDischarge

Tubes.............................................................14

13AdjustingtheBaggerDumpLever..................15

14CheckingtheTirePressure.............................16

Operation...................................................................16

PositioningtheAdjustableBafe........................17

OpeningtheBagger...........................................17

HoldingtheBaggerDoorOpen..........................17

AdjustingtheBaggerDoorOpeningand

Cable..............................................................17

ClearingObstructionsFromtheBagger

System............................................................18

RemovingtheDischargeTubes...........................18

RemovingtheBagger.........................................19

SecuringtheBaggerIdlerPulley..........................19

ReplacingtheGrassDeector.............................20

OperatingTips...................................................20

Maintenance...............................................................22

RecommendedMaintenanceSchedule(s)................22

CleaningtheScreens...........................................22

CleaningtheBagger............................................22

CheckingtheBaggerBelt....................................22

GreasingtheIdlerArm.......................................22

GreasingtheFanShaftBearings..........................22

InspectingtheBagger.........................................23

InspectingtheMowerBlades..............................23

Troubleshooting.........................................................24

©2007—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

Contactusatwww.Toro.com.

2

PrintedintheUSA.

AllRightsReserved

Safety

•Usecarewhenloadingorunloadingthemachine
intoatrailerortruck

Thefollowinglistcontainssafetyinformationspecic
toToroproductsandothersafetyinformationyoumust
know .

•Becomefamiliarwiththesafeoperationofthe
equipment,withtheoperatorcontrols,andsafety
signs.

•Useextracarewithgrasscatchersorother
attachments.Thesecanchangetheoperating
characteristicsandthestabilityofthemachine.

•Followthemanufacturer’srecommendationsfor
addingorremovingwheelweightsorcounterweights
toimprovestability.

•Donotuseagrasscatcheronsteepslopes.Aheavy
grasscatchercouldcauselossofcontroloroverturn
themachine.

•Slowdownanduseextracareonhillsides.Besure
totravelintherecommendeddirectiononhillsides.
Turfconditionscanaffectthemachine’sstability.
Useextremecautionwhileoperatingneardrop-offs.

•Keepallmovementonslopesslowandgradual.Do
notmakesuddenchangesinspeed,directionsor
turning.

•Neveroperatewiththedischargedeectorraised,
removedoraltered,unlessusingagrasscatcher.

•Keephandsandfeetawayfrommovingparts.Do
notmakeadjustmentswiththeenginerunning.

•Stoponlevelground,disengagedrives,chockor
blockwheels,shutoffenginebeforeleavingthe
operator’spositionforanyreasonincludingemptying
thegrasscatcheroruncloggingthechute.

•Ifyouremovethegrasscatcher,besuretoinstallany
dischargedeectororguardthatmighthavebeen
removedtoinstallthegrasscatcher.Donotoperate
themowerwithouteithertheentiregrasscatcheror
thegrassdeectorinplace.

•Stoptheenginebeforeremovingthegrasscatcher
oruncloggingthechute.

•Donotleavegrassingrasscatcherforextended
periodsoftime.

•Grasscatchercomponentsaresubjecttowear,
damageanddeterioration,whichcouldexpose
movingpartsorallowobjectstobethrown.
Frequentlycheckcomponentsandreplacewith
manufacturer’srecommendedparts,whennecessary.

•Thegrasscatchercanobstructtheviewtotherear.
Useextracarewhenoperatinginreverse.

SafetyandInstructionalDecals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof
potentialdanger.Replaceanydecalthatisdamagedorlost.

107-1613

104-8569

106-3339

3

Setup

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

ProcedureDescription

1

2

3

4

5

6

7

8

9

Nopartsrequired

Sidebracket—right
Sidebracket—left
Bolt,(3/8x2–1/2)
Bolt,(3/8x3/4inch)
FlangeLocknut,(3/8inch)
Spacers

Nopartsrequired

Baggerdrivepulley1
Pulleyspacer3
Bolt,(3/8x1-3/4inches)
Flangenut,(3/8inch)
Springloadedidlerpulley
Idlerarm1
Carriagebolt,(3/8x2inches)
Bolt,(3/8x4–1/2inches)
Locknut,(3/8inch)
Washer,7/16inch
Washer,13/32inch
Longroundspacer1
Flangenut,(3/8inch)
Springanchor,(3/8inch)
Fixedidlerpulley1
Fixedidlerbracket1
Bolt,(3/8x1-1/2inches)
Bolt,(3/8x3/4inch)
Locknut,(3/8inch)
Flangenut,(3/8inch)
Washer,13/32inch
Idlerarmbracket1
Bolt,(3/8x3/4inch)
Flangenut,(3/8inch)
Bagger(frompreviousbagger)
Clevispin(frompreviousbagger)
Hairpincotter(frompreviousbagger)
Baggerbelt1
Spring

Qty.

Use

–

1
1
2
2
4
2

–

4
4
1

1
1
2
1
1

1
1

1
2
1
2
1

2
2
1
2
2

1

Removetheexistingbagger,mounting
bracket,andweights.

Installthebaggermountingbracket.

Tightenallmountingbolts.

Installthebaggerdrivepulley

Installthespringloadedidlerpulley

Installthexedidlerpulley

Installtheidlerarmbracket.

Installthebagger

Installthebaggerbelt.

10
11

Nopartsrequired

Largetopweight1
Bolt,(1/2x5inches)(fortopweights)

4

–

2

Checkandadjustthebaggerbelt.

Installtheweights

ProcedureDescription

12

Boot(frompreviousbagger)
Middletube(frompreviousbagger)
Uppertube(frompreviousbagger)
Clamp(frompreviousbagger)

Qty.

Use

1
1
1
1

Installthebootanddischargetubes

13
14

Note:UsethismanualwhentheDFSbaggerisinstalledandusedonaZ593–DZMaster.SavethepreviousDFS

baggermanualandpartsnotusedforwhenthebaggerisinstalledagainonagasengineZMaster.

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

Nopartsrequired

Nopartsrequired

–

–

Adjustthebaggerdumplever.

Checkthetirepressure.

1

RemovingtheExisting
Bagger,MountingBracket,
andWeights

NoPartsRequired

Procedure

Thisprocedureisforaircooledmachinesandliquid
cooledmachines.

1.Idlerarmandpulley3.Nuts

2.Bolts

Figure4

1.Removethespringfromtheeyebolt(Figure36).

Figure3

1.Idlerspring3.Belt

2.Eyebolt

2.Removetheidlerarmandpulleyfromthebagger
andstoreit(Figure4).

3.Removethe2clevispinsand2hairpincotterpins
fromthebaggerandbaggermountingbracket
(Figure5).Savethishardware.

4.Removethebaggerfromthebaggermounting
bracketFigure5

5

Figure5

1.Bagger3.Hairpincotter

2.Baggermountingbracket

4.Clevispin

5.Removetheexistingbaggermountingbracket
hardwarefromthebackoftheexistingZMaster.
Discardthishardware(Figure6).

Figure7

1.Baggermountingbracket

2.Curvedwasher,(3/8inch)5.ROPS

3.Bolt,(3/8x1-1/2inches)

4.Flangenut,(3/8inch)

6.Foraircooledmachinesonly,removetheframe
spacerandstoreit(Figure6).

Figure6

1.Baggermountingbracket4.Bumper

2.Bolt,(3/8x1-1/4inches)5.Aircooledframespacer

3.Flangenut,(3/8inch)6.Bolt,(3/8x1-3/4inches)

7.RemovetheROPS,baggermountingbracket,and
sidebracketsbyremovingthebolts,curvedwashers,
andnuts(Figure7).

8.Retainthishardware.Thishardwarewillbeused
againwheninstallingthebaggerontoaZ593Z
Master.

9.Removethesidebracketsfromthebaggermounting
bracketandstorethem.Donotremovethe
bracketstiffenerfromthebaggermountingbracket
(Figure8).

10.Retainthishardware.Thishardwarewillbeused
againwheninstallingthebaggerontoaZ593Z
Master.

Figure8

1.Leftsidebracket

2.Bolt,(3/8x1-1/4inches)7.Longframespacer

3.Bracketstiffener8.Bolt,(3/8x1-1/2inches)

4.Flangenut,(3/8inch)9.Shortframespacer

5.Baggermountingbracket

6.Rightsidebracket

10.Bolt,(3/8x3/4inch)

11.Removeboltandthe2smalltopweightsfromeach
frontcasterweight(Figure9).

6

Figure9

1.Topweight3.Frontcasterweight

2.Bolt,(1/2x4inches)

4.Frontcasterwheel

2

InstallingtheBaggerMounting
Bracket

Partsneededforthisprocedure:

1

Sidebracket—right

1

Sidebracket—left

2

Bolt,(3/8x2–1/2)

2

Bolt,(3/8x3/4inch)

4

FlangeLocknut,(3/8inch)

2

Spacers

12.Removetheplate,nuts(1/2inch),andlockwasher
(1/2inch)undertheframeandweight(Figure10).

13.Removethecasterweightsonthefrontcasters.

Figure10

1.Frontcasterweight4.Nut

2.U-bolt5.Frontcaster

3.Plate6.Lockwasher

Procedure

Important:Donottightenanyboltsuntilbothside

bracketsandbaggermountingbracketaretloose
onthemachine.

RefertoTighteningtheMountingBoltsforthe
correctproceduretotightenthebolts.

Important:Usetheexistinghardwarewhenthe
baggermountingbracketwasremoved.

1.Installthesidebracketstothebaggermounting
bracket(Figure11).

2.Inthetoptwoholes,install2bolts(3/8x1-1/2
inches),2angenuts(3/8inch),2longframe
spacers,andoneshortframespacer(Figure11).

Note:Makesurethelongframespacersareinstalled
asshowninFigure11).

3.Inthebottomhole,installabolt(3/8x1-1/4inches)
andaangenut(3/8inch)(Figure11).

4.Installabracketstiffenertothesidebracketand
baggermountingbracket.Use4bolts(3/8x3/4
inch)and4angenuts(3/8inch)(Figure11).

5.Repeatthepreviousstepsfortheoppositeside
(Figure11).

7

Figure11

1.Baggermountingbracket

2.Bolt,(3/8x1-1/4inches)8.Bolt,(3/8x1-1/2inches)

3.Flangenut,(3/8inch)9.Shortframespacer

4.Bracketstiffener

5.Leftsidebracket

6.Bolt,(3/8x3/4inch)

7.Longframespacer

10.Rightsidebracket

11.Usetheseholesinthe
bracketstiffener

Figure12

1.Sidebracket4.Flangenut,3/8inch

2.Curvedwasher,3/8inch5.ROPS

3.Bolt,3/8x1-1/2inch

9.Installthebaggermountingbrackettotherearframe
ofthemachine(Figure13).

10.Inthetoptwoholes,install2bolts(3/8x2-1/2),2
roundspacers,and2angenuts(3/8inch).

6.Removethebolts,nuts,andwashersholdingtheroll
bartoonesideofthemachine.Discardthenuts,
bolts,andwashers(Figure12).

7.Installthebaggersideplateandtherollbarsection
tothesideofthemachineusing4bolts(3/8x1-1/2
inches),4curvedwashers(3/8inch),and4ange
nuts(3/8inch)(Figure12).

8.Repeatthestepsabovefortheoppositeside
(Figure12).

Note:Makesurethecurvedwasherareinstalled
asshowninFigure.

11.Inthebottomtwoholes,install2bolts(3/8x3/4
inch)anda2angenuts(3/8inch)(Figure13).

Figure13

1.Baggermountingbracket4.Bumper

2.Bolt,(3/8x3/4inch)

3.Flangenut,(3/8inch)6.Bolt,(3/8x2-1/2)

5.Roundspacer

8

4.Installthegearboxpulleyandbaggerdrivepulley
tothegearboxwith2setscrewsandasquarekey

3

(Figure14).Thepulleyhubneedstobeushwith
theendofthegearboxshaft.

TighteningallMountingBolts

NoPartsRequired

Procedure

Thefollowingstepsarethecorrectsequencetotighten
thesidebracketsandthebaggermountingbracket.

All3/8inchmountingboltsneedtobetorquedto
35ft-lb(48N⋅m).

1.Tightenthebaggermountingbrackettotherear
framerst(Figure13).

2.Tightenthebaggermountingbrackettotheside
brackets(Figure11).

3.Tightenthebracketstiffenerstoboththesideplates
andthebaggermountingbracket(Figure11).

4.Tightenthesidebracketstothesideofthemower
(Figure12).

5.Installthemowerbeltbackontotheuppergearbox
pulley(Figure14).

4

InstallingtheBaggerDrive
Pulley

Partsneededforthisprocedure:

1Baggerdrivepulley

3Pulleyspacer

4

Bolt,(3/8x1-3/4inches)

4

Flangenut,(3/8inch)

Procedure

1.Removethemowerbeltfromthegearboxpulley
assembly(Figure14).

2.Removethe2setscrews,squarekey,andgearbox
pulleyfromthegearbox.

Note:Makesurethepulleythatisremovedhas4
holesaroundthecenterhole.Ifitdoesnot,contact
anAuthorizedServiceDealerforthecorrectpulley.

Figure14

1.Gearbox5.Spacer

2.Flangenut,3/8inch

3.Gearboxdrivepulley7.Bolt,1/2x1-3/4inch

4.Setscrew

6.Baggerdrivepulley

3.Installthebaggerdrivepulleytothegearboxpulley
with3bolts(3/8x1-3/4inches),3spacers,and
3angenuts(3/8inch)(Figure14).

9