Toro 78500 Operator's Manual
DFS Vac Collection System
100 Series Z Master
Model No. 78500—Serial No. 230000001 and Up
Form No. 3350–765
Operator’s Manual
English (CE)
Contents
Introduction
Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 3. . . . . . . . . . . . . . . . .
Setup 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before Installation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Mower for Existing Holes 6. . . . . . . .
Checking for Holes in the Clutch 6. . . . . . . . . . . . . .
Drilling Holes in the Clutch 6. . . . . . . . . . . . . . . . . .
Installing the Clutch and Drive Pulley Assembly 7.
Removing the Drive Wheels 8. . . . . . . . . . . . . . . . .
Removing the Rear Heat Shield 9. . . . . . . . . . . . . . .
Drilling Holes for the Bagger 9. . . . . . . . . . . . . . . . .
Installing the Bagger Mounting Bracket 10. . . . . . . .
Installing the Bagger Idler Pulley and
the Skid Plate 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Bagger 12. . . . . . . . . . . . . . . . . . . . . . .
Installing the Bagger Belt 12. . . . . . . . . . . . . . . . . . . .
Checking/Adjusting the Bagger Belt Tension 13. . . .
Installing the Weights 14. . . . . . . . . . . . . . . . . . . . . . .
Installing the Front Weight 16. . . . . . . . . . . . . . . . . . .
Installing the Boot and Discharge Tubes 17. . . . . . . .
Installing the Bagger Dump Lever Stop Bolt 18. . . . .
Adjusting the Bagger Dump Lever 18. . . . . . . . . . . .
Checking the Tire Pressure 19. . . . . . . . . . . . . . . . . .
Operation 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Opening the Bagger 20. . . . . . . . . . . . . . . . . . . . . . . .
Holding the Bagger Door Open 21. . . . . . . . . . . . . . .
Clearing Obstructions From the Bagger System 21. .
Removing the Discharge Tubes 21. . . . . . . . . . . . . . .
Removing the Bagger 22. . . . . . . . . . . . . . . . . . . . . . .
Installing the Grass Deflector 22. . . . . . . . . . . . . . . . .
Operating and Bagging Tips 23. . . . . . . . . . . . . . . . .
Maintenance 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Maintenance Schedule 25. . . . . . . . .
Cleaning the Screen 25. . . . . . . . . . . . . . . . . . . . . . . .
Cleaning the Bagger 25. . . . . . . . . . . . . . . . . . . . . . . .
Checking the Bagger Belt 25. . . . . . . . . . . . . . . . . . .
Greasing the Idler Arm 25. . . . . . . . . . . . . . . . . . . . .
Greasing the Fan Shaft Bearings 26. . . . . . . . . . . . . .
Inspecting the Bagger 26. . . . . . . . . . . . . . . . . . . . . . .
Inspecting the Mower Blades and Baffles 26. . . . . . .
Storage 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
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 operating the product
properly and safely.
Whenever you need service, genuine Toro parts, or
additional information, contact an Authorized Service
Dealer or Toro Customer Service and have the model and
serial numbers of your product ready. Figure 1 illustrates
the location of the model and serial numbers on the
product.
1
m–60xx
Figure 1
1. Location of the model and serial numbers
Write the product model and serial numbers in the space
below:
Model No.
Serial No.
This manual identifies potential hazards and has special
safety messages that help you and others avoid personal
injury and even death. Danger, Warning, and Caution are
signal words used to identify the level of hazard. However,
regardless of the hazard, be extremely careful.
Danger signals an extreme hazard that will cause serious
injury or death if you do not follow the recommended
precautions.
Warning signals a hazard that may cause serious injury or
death if you do not follow the recommended precautions.
Caution signals a hazard that may cause minor or moderate
injury if you do not follow the recommended precautions.
2004 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
All Rights Reserved
Printed in the USA
2
This manual uses two other words to highlight information.
Important calls attention to special mechanical
information and Note: emphasizes general information
worthy of special attention.
Safety
The following list contains safety information specific to
Toro products and other safety information you must know.
• Become familiar with the safe operation of the
equipment, with the operator controls, and safety signs.
• Use extra care with grass catchers or other attachments.
These can change the operating characteristics and the
stability of the machine.
• Never operate with the discharge deflector raised or
removed and never altered, unless using a grass catcher
or mulching baffles.
• Keep hands and feet away from 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. Do not operate the
mower without either the entire grass catcher or the
grass deflector in place.
• Do not use a grass catcher on steep slopes. A heavy
grass catcher could cause loss of control or overturn the
machine.
• Slow down and use extra care on hillsides. Be sure to
travel in the recommended direction on hillsides. Turf
conditions can affect the machine’s stability. Use
extreme caution while operating near drop–offs.
• Keep all movement on slopes slow and gradual. Do not
make sudden changes in speed, directions or turning.
• The grass catcher can obstruct the view to the rear. Use
extra care when operating in reverse.
• Use care when loading or unloading the machine into a
trailer or truck
Safety and Instruction 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.
• Turn off the engine and wait for all moving parts to
stop before removing the grass catcher or
unclogging the chute.
• Do not use your hands to unclog the chute, blower or
bagger.
• Do not leave grass in grass catcher for extended periods
of time.
• Grass catcher components are subject to wear, damage
and deterioration, which could expose moving parts or
allow objects to be thrown. Frequently check
components and replace with manufacturer’s
recommended parts, when necessary.
106-5855
1. Warning—read the
2. Tipping and lose of control hazard—add weight to the front of
the machine.
Operator’s Manual.
106-5856
1. Thrown object hazard—do not operate the mower with the
deflector up or removed; keep the deflector or grass collector in
place.
2. Cutting/dismemberment hazard of hand or foot, mower
blade—stay away from moving parts.
3
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
1
2
3
4
5
Description Qty. Use
Template
Bolt, #6 x1/2 inch
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
No parts needed Removing the drive wheels
No parts needed Removing the heat shield
Template 1 Drilling the holes for the bagger
1
1
1
1
1
1
Drilling holes for the clutch
Installing the clutch and drive pulley
assembly
6
7
Bagger mounting bracket
Bolt, 5/16 x 1 inch
Flange nut, 5/16 inch
Flat washer, 5/16 inch
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
1
16
16
6
1
5
5
1
1
1
4
Installing the bagger mounting bracket
Installing the bagger idler pulley and
skid plate
Step UseQty.Description
8
9
10
11
Bagger
Clevis pin
Hairpin cotter
Spring
Bagger belt
Spacer 3
Weight—left
Weight—right
Weight bracket—left
Weight bracket—right
Support plate
Bolt, 3/8 x 6–1/2 inch
Bolt, 5/16 x 1 inch
Nut, 3/8 inch
Lock washer, 3/8 inch
Flat washer, 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
16
1
2
2
1
1
1
1
2
2
1
4
2
8
8
4
2
1
Installing the bagger
Installing the bagger belt
Checking/adjusting the bagger belt
tension
Installing the weights
12
13
14
15
16
Weight
Weight bracket
Large Washer
Locknut, 5/16 inch
Bolt, 5/16 x 1–1/4 inch
Washer, 11/32 inch
Bagger bracket
Carriage bolt, 5/16 x 1 inch
Flange nut, 5/16 inch
Bolt, 1/2 x 1–3/4 inch
Jam nut, 1/2 inch
No parts needed Adjusting the bagger dump lever
No parts needed Checking the tire pressure
1
2
2
2
2
2
1
8
8
1
2
Installing the front weight
Installing the boot and discharge tubes
Installing the bagger dump lever stop
bolt
5
Before Installation
Checking the Mower for
Existing Holes
Check the mower for existing holes. Use any existing holes
in the mower that align with any of the parts to be installed
in their correct positions.
Step
1
Parts needed for this step:
• 1 Template
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
4
2
m–4119
1. Clutch strap
2. Bolt
3
Figure 3
3. Clutch connector
4. Clutch
• 1 Bolt, #6 x 1/2 inch
Checking for Holes in the
Clutch
Look under the engine to view the clutch. Check to see if
there are existing holes in the clutch as shown in Figure 2.
• If there are no existing holes, proceed to Drilling Holes
in the Clutch below.
• If there are existing holes in the clutch, proceed to
Installing the Clutch and Drive Pulley Assembly on
page 7.
1
2
2
Figure 2
1. Clutch 2. Holes in clutch
2
3. Remove the existing deck belt from the clutch.
4. Remove the existing clutch from the machine (Fig. 4).
Discard the bolt that was installed in the clutch.
5. Remove the existing drive spacer from the clutch
(Fig. 4).
1
2
5
3
4
Figure 4
1. Engine
2. Clutch
3. Curved washers
6. Position the template into the clutch pulley so the
outside diameter is flush with the inside of the clutch
flange (Fig. 5).
4. Clutch bolt—discard
5. Drive spacer
m–6024
6
Note: Before drilling holes, place a piece of metal between
the clutch and pulley. This will prevent drilling into the
clutch.
7. Using the template, drill one 1/8 inch pilot hole into the
pulley (Fig. 5).
8. Install the screw (#6 x 1/2 inch) into the 1/8 inch hole
(Fig. 5). This will hold the template in place while
drilling the other two holes.
Step
2
9. Using the template, drill the remaining two 1/8 inch
pilot holes into the pulley (Fig. 5).
10.Remove the template and the screw (#6 x 1/2 inch) and
discard (Fig. 5).
11. Drill 3 holes, 3/8 inch diameter, into the 1/8 inch pilot
holes. (Fig. 5).
5
2
1. Clutch pulley
2. Template
3. Hole to drill
6
3
Figure 5
4. Clutch flange
5. Screw, #6 x 1/2 inch
6. Drive spacer
1
4
3
m–6006
Parts needed for this step:
• 1 Bolt, 7/16 x 4–1/2 inch—Kawasaki engines only
• 1 Bolt, 7/16 x 4 inch—Kohler engines only
• 1 Drive pulley assembly
• 1 Clutch spacer
Installing the Clutch and Drive
Pulley 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 holes
drilled into the clutch pulley (Fig. 6).
5. Install the drive spacer into the drive pulley assembly
(Fig. 6).
Note: There are two different size bolts for installing the
clutch. The size is determined by the type of engine on the
machine.
6. If the machine has a Kawasaki
clutch with a bolt (7/16 x 4–1/2 inch) and 2 existing
curved washers (Fig. 6).
7. If the machine has a Kohler
clutch with a bolt (7/16 x 4 inch) and 2 existing curved
washers (Fig. 6).
engine, then install the
engine, then install the
8. Torque the clutch bolt to 55 ft–lb (75 Nm) (Fig. 6).
9. If needed, install the existing deck belt onto the clutch.
10.If needed, install the clutch strap (Fig. 3).
11. If needed, plug in the clutch connector (Fig. 3).
7
1
Step
2
3
4
8
5
6 or 7
1. Clutch
2. Clutch connector
3. Pulley spacer
4. Drive pulley assembly
5. Curved washers
Figure 6
5
6 or 7
m–6007
6. Bolt, 7/16 x 4–1/2 inch for
Kawasaki engines
7. Bolt, 7/16 x 4 inch for
Kohler engines
8. Drive spacer
3
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.
8
Step
Step
4
No parts needed for this step.
Removing the Rear Heat Shield
1. Remove the 8 bolts and nuts securing the rear of the
heat shield to the engine straps and the rear bumper
(Fig. 7).
2. Remove the 4 bolts, the washers and the nuts securing
the sides of the heat shield to the engine straps, the
tailpipe guard and the bumper (Fig. 7). Save the heat
shield and all the hardware.
3
2
1
5
Parts needed for this step:
• 1 Template
Drilling Holes for the Bagger
1. Check if there is a large opening in the rear bumper.
(Fig. 8). 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).
3
4
1. Heat shield
2. Engine straps
Figure 7
2
4
3. Tailpipe guard
4. Frame
m–6809
4
1
4
2
Figure 8
1. Template
2. Rear bumper
3. Mark and center punch the 3 holes to be drilled (Fig. 8).
4. Mark the outline of the large opening in the template
(Fig. 8).
5. Remove the bolts, nuts, and template from the rear
bumper.
6. Drill 1/8 inch pilot holes at the 3 marked locations and
then drill 3/8 inch diameter holes.
7. Cut out the large opening marked on the rear bumper
(Fig. 8). This opening is needed to allow the bagger belt
to pass through the rear bumper.
3. Large opening in bumper
4. Holes to drill
8. File the metal burrs from the drilled holes and opening.
9
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