Toro 78506 Operator's Manual
DFS Vac Collection System
500 Series Z Master
Model No. 78506—Serial No. 230000001 and Up
Form No. 3350–769
Operator ’s Manual
Domestic English (EN)
Contents
Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 3. . . . . . . . . . . . . . . .
Setup 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Drive Wheels 6. . . . . . . . . . . . . . . .
Removing the Roll Over Protection System
(ROPS) 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Bagger Mounting Bracket onto an
Air Cooled Machine 8. . . . . . . . . . . . . . . . . . . . . . .
Installing the Bagger Mounting Bracket onto a
Liquid Cooled Machine 9. . . . . . . . . . . . . . . . . . . .
Installing the Side Brackets to the Machine 10. . . . .
Tightening all Mounting Bolts 12. . . . . . . . . . . . . . .
Installing The Drive Wheels 13. . . . . . . . . . . . . . . . .
Removing the Mower Belt and the Right Rear Idler
Pulley 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Drive Pulley Assembly 14. . . . . . . . . .
Installing the Bagger 15. . . . . . . . . . . . . . . . . . . . . .
Installing the Bagger Tensioner Pulley and Belt 16.
Adjusting the Bagger Belt 18. . . . . . . . . . . . . . . . . .
Installing and Adjusting the Mower Belt 19. . . . . . .
Installing the Weights 20. . . . . . . . . . . . . . . . . . . . . .
Installing the Boot and Discharge Tubes 22. . . . . . .
Installing the Bagger Dump Handle 23. . . . . . . . . . .
Installing the Bagger Dump Lever Stop Bolt 23. . . .
Adjusting the Bagger Dump Lever 24. . . . . . . . . . . .
Checking the Tire Pressure 25. . . . . . . . . . . . . . . . . .
Operation 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Positioning the Adjustable Baffle 26. . . . . . . . . . . . .
Opening the Bagger 26. . . . . . . . . . . . . . . . . . . . . . .
Holding the Bagger Door Open 27. . . . . . . . . . . . . .
Adjusting the Bagger Door Opening and Cable 27. .
Clearing Obstructions From the Bagger System 27.
Removing the Discharge Tubes 28. . . . . . . . . . . . . .
Removing the Bagger 28. . . . . . . . . . . . . . . . . . . . . .
Replacing the Grass Deflector 28. . . . . . . . . . . . . . .
Operating and Bagging Tips 29. . . . . . . . . . . . . . . . .
Maintenance 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Maintenance Schedule 30. . . . . . . . .
Cleaning the Screens 30. . . . . . . . . . . . . . . . . . . . . .
Cleaning the Bagger 30. . . . . . . . . . . . . . . . . . . . . . .
Checking the Bagger Belt 30. . . . . . . . . . . . . . . . . . .
Greasing the Idler Arm 30. . . . . . . . . . . . . . . . . . . . .
Greasing the Fan Shaft Bearings 31. . . . . . . . . . . . .
Inspecting the Bagger 31. . . . . . . . . . . . . . . . . . . . . .
Page
Page
Inspecting the Mower Blades 31. . . . . . . . . . . . . . . .
Storage 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction
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–6984
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.
2003 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
All Rights Reserved
Printed in the USA
2
Caution signals a hazard that may cause minor or moderate
injury if you do not follow the recommended precautions.
• The grass catcher can obstruct the view to the rear. Use
extra care when operating in reverse.
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.
• Follow the manufacturer’s recommendations for adding
or removing wheel weights or counterweights to
improve stability.
• 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.
• Use care when loading or unloading the machine into a
trailer or truck
• Never operate with the discharge deflector raised,
removed or altered, unless using a grass catcher.
• Keep hands and feet away from moving parts. Do not
make adjustments with the engine running.
• Stop on level ground, disengage drives, chock or block
wheels, shut off 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.
• Stop the engine before removing the grass catcher or
unclogging the chute.
• 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.
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.
104-8569
106-3339
3
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 Description Qty. Use
1
2
3
4
No parts needed Removing the Drive Wheels
No parts needed
Bagger mounting bracket
Side bracket—right
Side bracket—left
Long frame spacer—only two are
needed for air cooled machines
Short frame spacer
Bolt, 3/8 x 1–1/2 inch
Bolt, 3/8 x 1–1/4 inch
Flange Nut, 3/8 inch
Stiffener bracket
Bolts, 3/8 x 3/4 inch
Bolt, 3/8 x 1 inch
Flange Nut, 3/8 inch
Curved washer
Spacer
1
1
1
4
2
12
4
26
2
8
6
6
6
4
Removing the Roll Over Protection
System (ROPS)
Installing bagger mounting brackets
onto the machine
Installing the side brackets to the
machine
5
6
7
8
No parts needed Installing the Drive Wheels
No parts needed Tightening all mounting bolts
No parts needed
Pulley assembly
Bolt, 1/2 x 1–1/4 inch
Lock nut,1/2 inch
Washer, 1/2 inch
1
4
4
4
4
Removing the mower belt and the right
rear idler pulley
Installing the drive pulley assembly
Step UseQty.Description
9
10
11
12
13
Bagger
Clevis pin
Hairpin cotter
Bagger tensioner pulley
Bolt, 3/8 x 2 inch
Lock Nut, 3/8 inch
Washer, 3/8 inch
Bagger belt
No parts needed Adjusting the bagger belt
No parts needed Adjusting the mower belt tension
Caster weight
U–bolt
Nut, 1/2 inch
Lock washer, 1/2 inch
Plate
Top weight
Bolt, 1/2 x 3 inch
1
2
2
1
1
1
1
1
2
2
4
4
2
4
2
Installing the bagger
Installing the bagger tensioner pulley
and the bagger belt
Installing the weights
14
15
16
17
18
Boot
Middle Tube
Upper Tube
Clamp
Bagger dump lever
Washer, 13/16 inch
Cotter pin
Bolt, 1/2 x 1–3/4 inch
Jam nut, 1/2 inch
Long clevis (liquid cooled only)
No parts needed Adjusting the bagger dump lever
No parts needed Checking the tire pressure
1
1
1
1
1
2
1
1
2
1
Installing the boot and the discharge
tubes
Installing the bagger dump lever
Installing the bagger dump lever stop
bolt
5
Step
1
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 nuts.
2. Raise the rear of the machine and support with jack
stands (Fig. 2).
1
m–6859
Figure 3
1. Drive wheel
1
Figure 2
1. Jack stand
3. Remove the nuts and the drive wheels (Fig. 3).
1
6
Step
2
No parts needed for this step.
1
Removing the Roll Over
Protection System (ROPS)
1. Loosen the front handles securing the center roll bar
section to the right and left sections (Fig. 4).
2
1
m–6835
Figure 4
1. Front handle 2. Center roll bar section
2
m–6893
Figure 5
1. Pin 2. Hair pin cotter
3. Loosen the center roll bar bolts allowing the roll bar to
be pivoted to the down position (Fig. 6).
2
1
2. Remove the hair pin cotters and pins securing the center
roll bar section to the right and left sections (Fig. 5).
Figure 6
1. Bolt 2. Flange nut
4. Remove the 2 bolts and 2 flange nuts securing the
center roll bar section to the right and left sections
(Fig. 6). Remove the center roll bar section.
7
5. Remove the following fasteners (Fig. 7) securing each
(right and left) roll bar section to the frame:
• Lock nut (3/8 inch) and curved washer. Do not
remove bolt from frame.
Step
• Bolt (3/8 x 1 inch), curved washer and flange nut
(3/8 inch).
• Bolt (3/8 x 1 inch), curved washer and flange nut
(3/8 inch).
• Bolt (3/8 x 4-1/2 inches), curved washer and
flange nut (3/8 inch).
3
3
Parts needed for this step:
• 1 Bagger mounting bracket
• 1 Side bracket—right
• 1 Side bracket—left
• 4 Long frame spacer—only two are needed for air
cooled machines
• 2 Short frame spacer
• 12 Bolt, 3/8 x 1–1/2 inch
• 4 Bolt, 3/8 x 1–1/4 inch
• 26 Flange Nut, 3/8 inch
• 2 Stiffener bracket
• 8 Bolts, 3/8 x 3/4 inch
If you have a liquid cooled machine, go to page 9 for
Installing the Bagger Mounting Bracket onto a Liquid
Cooled Machine.
2
2
1
Figure 7
1. Lock nut, 3/8 inch &
curved washer
2. Bolt, 3/8 x 1 inch, curved
washer & flange nut,
3/8 inch (2)
6. Remove the roll bar section from frame (Fig. 7). Repeat
the procedure on the other roll bar section
3. Bolt, 3/8 x 4–1/2 inches,
curved washer & flange
nut, 3/8 inch
m–6854
If you have an air cooled machine, use the following
instructions for Installing the Bagger Mounting Bracket
onto a Air Cooled Machine.
Installing the Bagger Mounting
Bracket onto an Air Cooled
Machine
Important Do not tighten any bolts until both side
brackets and bagger mounting bracket are fit loose on the
machine.
Refer to Tightening the Mounting Bolts, on page 12, for the
correct procedure to tighten the bolts.
Installing the Bagger Mounting Bracket to
the Side Brackets (Air Cooled)
Important When installing the bagger bracket for an
air cooled machine, use only 2 long frame spacers; 1 per
each side (Fig. 8).
1. Install the side brackets to the bagger mounting bracket
(Fig. 8).
8
2. In the top two holes, install 2 bolts (3/8 x 1–1/2 inch),
2 flange nuts (3/8 in.) one long frame spacer, and one
short frame spacer (Fig. 8).
Note: Make sure the long frame spacers are installed as
shown in figure 8.
3. In the bottom hole, install a bolt (3/8 x 1–1/4 inch) and
a flange nut (3/8 in.) (Fig. 8).
4. Install a bracket stiffener to the side bracket and bagger
mounting bracket. Use 4 bolts (3/8 x 3/4 inch) and
4 flange nuts (3/8 in.) (Fig. 8).
5. Repeat the previous steps for the opposite side (Fig. 8).
6
5
4
3
7
4
3
10
3
4
5
3
3
1
3
6
2
6
2
m–5863
Figure 9
1. Bagger mounting bracket
2. Bolt, 3/8 x 1–1/4 inch
3. Flange nut, 3/8 inch
4. Bumper
5. Air cooled frame spacer
6. Bolt, 3/8 x 1–3/4 inch
Installing the Bagger Mounting
1
9
8
2
6
m–5978
Figure 8
1. Bagger mounting bracket
2. Bolt, 3/8 x 1–1/4 inch
3. Flange nut, 3/8 inch
4. Bracket stiffener
5. Left side bracket
6. Bolt, 3/8 x 3/4 inch
7. Long frame spacer
8. Bolt, 3/8 x 1–1/2 inch
9. Short frame spacer
10. Right side bracket
Installing the Bagger Mounting Bracket
onto an Air Cooled Machine
Important When installing the bagger onto an air
cooled machine, use the air cooled spacer (Fig. 9).
1. Install the bagger mounting bracket to the rear frame of
the machine (Fig. 9).
2. In the top two holes, install 2 bolts (3/8 x 1–3/4 inch),
2 flange nuts (3/8 in.) and the air cooled frame spacer
(Fig. 9).
3. In the bottom two holes, install 2 bolts (3/8 x
1–1/4 inch) and 2 flange nuts (3/8 in.) (Fig. 9).
Bracket onto a Liquid Cooled
Machine
Important Do not tighten any bolts until both side
brackets and bagger mounting bracket are fit loose on the
machine.
Refer to Tightening the Mounting Bolts, on page 12, for the
correct procedure to tighten the bolts.
Installing the Bagger Mounting Bracket to
the Side Brackets (Liquid Cooled)
Important When installing the bagger onto a liquid
cooled machine, the rear bumper plate must be removed.
Use 4 long frame spacers for this installation, 2 per each
side (Fig. 10).
1. Install the side brackets to the bagger mounting bracket
(Fig. 10).
2. In the top two holes, install 2 bolts (3/8 x 1–1/2 inch),
2 flange nuts (3/8 in.), 2 long frame spacers, and one
short frame spacer (Fig. 10).
Note: Make sure the long frame spacers are installed as
shown in figure 10.
3. In the bottom hole, install a bolt (3/8 x 1–1/4 inch) and
a flange nut (3/8 in.) (Fig. 10).
4. Install a bracket stiffener to the side bracket and bagger
mounting bracket. Use 4 bolts (3/8 x 3/4 inch) and
4 flange nuts (3/8 in.) (Fig. 10).
5. Repeat the previous steps for the opposite side (Fig. 10).
9
6
5
4
10
3
7
4
3
3
7
Step
4
1
9
8
1. Bagger mounting bracket
2. Bolt, 3/8 x 1–1/4 inch
3. Flange nut, 3/8 inch
4. Bracket stiffener
5. Left side bracket
2
Figure 10
6. Bolt, 3/8 x 3/4 inch
7. Long frame spacer
8. Bolt, 3/8 x 1–1/2 inch
9. Short frame spacer
10. Right side bracket
6
m–5979
Installing the Bagger Mounting Bracket
onto a Liquid Cooled Machine
1. Install the bagger mounting bracket to the rear frame of
the machine (Fig. 11).
2. In the top two holes, install 2 bolts (3/8 x 1–3/4 inch)
and 2 flange nuts (3/8 in.) (Fig. 11).
3. In the bottom two holes, install 2 bolts (3/8 x
1–1/4 inch) and 2 flange nuts (3/8 in.) (Fig. 11).
4
1
3
3
Parts needed for this step:
• 6 Bolt, 3/8 x 1–1/2 inch
• 6 Flange Nut, 3/8 inch
• 6 Curved washer
• 4 Spacer
Installing the Side Brackets to
the Machine
Important Do not tighten any bolts until both side
brackets and bagger mounting bracket are fit loose on the
machine.
Refer to Tightening the Mounting Bolts, on page 12, for the
correct procedure to tighten the bolts.
1. Install the bagger side plates and the roll bar sections
(Fig. 12) to each side of the mower using the following
fasteners:
• Lock nut (3/8 inch) and curved washer (Previously
removed).
• Bolt (3/8 x 4-1/2 inches), curved washer, spacer and
flange nut (3/8 inch) (Previously removed).
• Bolt (3/8 x 1–1/2 inch), curved washer, spacer and
flange nut (3/8 inch) (New).
• Bolt (3/8 x 1–1/2 inch), curved washer and
flange nut (3/8 inch) (New).
• Bolt (3/8 x 1–1/2 inch), curved washer and
flange nut (3/8 inch) (New).
5
2
5
2
1. Bagger mounting bracket
2. Bolt, 3/8 x 1–1/4 inch
3. Flange nut, 3/8 inch
Note: Make sure the curved washers and spacers are
installed as shown in figure 12.
Note: Hydraulic lines may need to be adjusted when
installing the side brackets onto the machine. This will
allow for fastener clearance.
m–5864
Figure 11
4. Bumper
5. Bolt, 3/8 x 1–3/4 inch
10
3
Note: Make sure the bolts are installed on the outside of the
roll bar.
Note: Make sure the lanyard tab is installed as shown and
4
6
5
32
points forward.
6
1
2
Figure 12
1. Side bracket
2. Curved washer, 3/8 inch
3. Bolt, 3/8 x 1–1/2 inch
4. Flange nut, 3/8 inch
5. ROPS
6. Spacer
2. Make sure the lanyard clips are on the 2 bolts
(1/2 x 3-1/4 inches) (Fig. 13).
1
1
2
m–6891
Figure 14
1. Center roll bar section
5. Raise the roll bar into the upright position and secure it
with the pins and hairpin cotter pins fastened to the
lanyards (Fig. 15).
m–6892
Figure 13
1. Lanyard clip
Note: Make sure the bent tab points toward the head of the
bolt.
3. Lightly oil the ends of the center roll bar section
(Fig. 14).
4. Loosely install the center roll bar section, using 2 bolts
(1/2 x 3-1/4 inches) and 2 flange nuts (1/2 inch)
(Fig. 14).
1
2
m–6893
Figure 15
1. Pin 2. Hair pin cotter
6. Tighten the center roll bar bolts (1/2 x 3-1/4 inches) so
it rotates freely with some resistance (Fig. 16).
11
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