Toro 78534, 78535 Operator's Manual

FormNo.3395-266RevA

60inor72inE-ZVac

Z500SeriesZMaster

ModelNo.78534—SerialNo.315000001andUp
ModelNo.78535—SerialNo.315000001andUp

®

Mowers

™

Bagger

Registeratwww.T oro.com.
OriginalInstructions(EN)

*3395-266*A

WARNING

CALIFORNIA

Proposition65Warning

Thisproductcontainsachemicalorchemicals

knowntotheStateofCaliforniatocausecancer,

birthdefects,orreproductiveharm.

Introduction

Readthisinformationcarefullytolearnhowtooperateand
maintainyourproductproperlyandtoavoidinjuryand
productdamage.Youareresponsibleforoperatingthe
productproperlyandsafely.

YoumaycontactTorodirectlyatwww .Toro.comforproduct
safetyandoperationtrainingmaterials,accessoryinformation,
helpndingadealer,ortoregisteryourproduct.

Figure2

1.Baggermodelandserialnumberlocation

Wheneveryouneedservice,genuineT oroparts,oradditional
information,contactanAuthorizedServiceDealerorToro
CustomerServiceandhavethemodelandserialnumbersof
yourproductready.Figure1identiesthelocationofthe
modelandserialnumbersontheproduct.Writethenumbers
inthespaceprovided.

Figure1

1.Blowermodelandserialnumberlocation

ModelNo.

SerialNo.

Thismanualidentiespotentialhazardsandhassafety
messagesidentiedbythesafetyalertsymbol(Figure3),
whichsignalsahazardthatmaycauseseriousinjuryordeath
ifyoudonotfollowtherecommendedprecautions.

Figure3

1.Safetyalertsymbol

Thismanualuses2wordstohighlightinformation.
Importantcallsattentiontospecialmechanicalinformation
andNoteemphasizesgeneralinformationworthyofspecial
attention.

Contents

ModelNo.

SerialNo.

©2015—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

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

SafetyandInstructionalDecals.................................4

Setup............................................................................5

1PreparingtheMachine...........................................6

2InstallingtheBaggerMountingBracket....................6

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

4InstallingtheHoodAssemblyandBags....................8

5RoutingtheBaggerBeltintotheBlower

Assembly............................................................9

Contactusatwww.Toro.com.

2

PrintedintheUSA

AllRightsReserved

6InstallingtheBlowerAssembly...............................9

7SizingtheUpperTubefor60-inchMachineswith

GasEngines.......................................................11

8InstallingtheDischargeTubes...............................12

9InstallingtheBeltCover........................................15

10InstallingtheWeights..........................................15

11AdjustingtheParkingBrake.................................16

12CheckingtheTirePressure..................................16

Operation....................................................................17

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

EmptyingtheGrassBags.........................................17

ClearingObstructionsfromtheBagger

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

RemovingtheBagger..............................................18

UsingtheGrassDeector.......................................19

TransportingtheMachine........................................19

OperatingTips......................................................19

Maintenance.................................................................21

RecommendedMaintenanceSchedule(s)......................21

CleaningtheHoodScreen.......................................21

CleaningtheBaggerandBags...................................21

InspectingtheBaggerBelt.......................................21

ReplacingtheBaggerBelt........................................21

CheckingandAdjustingtheBlowerLatch..................22

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

InspectingtheBagger.............................................22

InspectingtheMowerBlades...................................22

InstallingtheMowerBlades.....................................22

InstallingtheGrassDeector...................................23

Storage........................................................................24

Safety

ThefollowinglistcontainssafetyinformationspecictoToro
productsandothersafetyinformationyoumustknow .

•Becomefamiliarwiththesafeoperationoftheequipment,

withtheoperatorcontrols,andsafetysigns.

•Useextracarewithgrasscatchersorotherattachments.

Thesecanchangetheoperatingcharacteristicsandthe
stabilityofthemachine.

•Followthemanufacturer'srecommendationsforadding

orremovingwheelweightsorcounterweightstoimprove
stability.

•Donotuseagrasscatcheronsteepslopes.Aheavy

grasscatchercouldcauselossofcontroloroverturnthe
machine.

•Slowdownanduseextracareonhillsides.Besureto

travelintherecommendeddirectiononhillsides.Turf
conditionscanaffectthemachine'sstability.Useextreme
cautionwhileoperatingneardrop-offs.

•Keepallmovementonslopesslowandgradual.Donot

makesuddenchangesinspeed,directionsorturning.

•Thegrasscatchercanobstructtheviewtotherear.Use

extracarewhenoperatinginreverse.

•Usecarewhenloadingorunloadingthemachineintoa

trailerortruck.

•Neveroperatewiththedischargedeectorraised,

removedoraltered,unlessusingagrasscatcher.

•Keephandsandfeetawayfrommovingparts.Donot

makeadjustmentswiththeenginerunning.

•Stoponlevelground,disengagedrives,chockorblock

wheels,shutoffenginebeforeleavingtheoperator's
positionforanyreasonincludingemptyingthegrass
catcheroruncloggingthechute.

•Ifyouremovethegrasscatcher,besuretoinstallany

dischargedeectororguardthatmighthavebeen
removedtoinstallthegrasscatcher.Donotoperatethe
machinewithouteithertheentiregrasscatcherorthe
grassdeectorinplace.

•Stoptheenginebeforeremovingthegrasscatcheror

uncloggingthechute.

•Donotleavegrassingrasscatcherforextendedperiods

oftime.

•Grasscatchercomponentsaresubjecttowear,damage

anddeterioration,whichcouldexposemovingpartsor
allowobjectstobethrown.Frequentlycheckcomponents
andreplacewithmanufacturer'srecommendedparts,
whennecessary.

3

SafetyandInstructionalDecals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaofpotential
danger.Replaceanydecalthatisdamagedorlost.

1-653558

98-5954

109-5890

106-3339

4

Setup

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

ProcedureDescription

1

2

3

4

5

6

7

8

9

10

Nopartsrequired

Baggermountingbracket1
Baggersideplate2
Spacer
Bolt(3/8x1-1/2inches)
Bolt(3/8x1inch)(forZ593machines

only)
FlangeNut(3/8inch)
Curvedwasher

Nopartsrequired

Hoodassembly1
Bags3
Clevispin
Hairpincotter2

Baggerbelt(fromtheBlowerandDrive
Kit)

Blowerassembly(fromtheBlowerand
DriveKit)

Spring(fromtheBlowerandDriveKit)

Uppertube1

Uppertube1
Lowertube1
Bolt(#10x3/4inches)
Locknut(#10)
Washer(7/32inch)

Beltcover(fromtheBlowerandDrive
Kit)

Casterweight
U-bolt2
Nut(1/2inch)
Lockwasher(1/2inch)
Plate2
Topweight(for60inchmowerdecks

only)
Bolt,1/2x2–1/2inch-fortopweights

Qty.

–

2

14

2

14
14

–

2

1

1

1

3
3
3

1Installthebeltcover.

2

4
4

2

2

Preparethemachine.

Installthebaggermountingbracket.

Tightenallmountingbolts.

Installthehoodassemblyandbags.

Routethebaggerbeltintotheblower
assembly.

Installtheblowerassembly .

Sizetheuppertubefor60-inch
machineswithgasengines.

Installthedischargetubes.

Installtheweights.

Use

11
12

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

Nopartsrequired

Nopartsrequired

5

–

–

Adjusttheparkingbrake.

Checkthetirepressure.

3.Repeatthestepsabovefortheoppositeside(Figure

4,Figure5,andFigure6).

1

PreparingtheMachine

NoPartsRequired

Procedure

1.DisengagethePTO,movethemotioncontrollevers
totheNEUTRAL-LOCKEDpositionandsettheparking
brake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Repairallbentordamagedareasofmowerdeckand
replaceanymissingparts.

4.Cleanthemachineofanydebrisonthedeckorrear
partofthemachinetoeaseinstallation.

2

Note:Makesurethecurvedwashersareinstalledas

showninFigure4,Figure5,andFigure6.

4.Installthebaggermountingbrackettotheleftandright
sidebaggerbracketswith4bolts(3/8x1-1/2inches),
4curvedwashers(3/8inch),and4angenuts(3/8
inch)asshowninFigure4,Figure5,andFigure6.

5.Installthebaggermountingbrackettotherearframe
ofthemachinewith2bolts(3/8x1-1/2inches)(use
2bolts(3/8x1inch)forZ593machinesasshownin

Figure5),2curvedwashers(3/8inch),and2ange

nuts(3/8inch)asshowninFigure4,Figure5,and

Figure6.

InstallingtheBaggerMounting Bracket

Partsneededforthisprocedure:

1Baggermountingbracket

2Baggersideplate

2

Spacer

14

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

2

Bolt(3/8x1inch)(forZ593machinesonly)

14

FlangeNut(3/8inch)

14

Curvedwasher

Procedure

Important:Donottightenanyboltsuntilbothside

bracketsandbaggermountingbracketaretlooseon
themachine.

Referto3TighteningallMountingBolts(page8)forthe
correctproceduretotightenthebolts.

1.Removethebolts,nuts,andwashersholdingtheroll
bartoonesideofthemachine.Discardthenuts,bolts,
andwashers(Figure4,Figure5,andFigure6).

Figure4

ForZ500GasMowers

1.Bolt(3/8x1-1/2inches)6.ROPS

2.Curvedwasher(3/8inch)7.Flangenut(3/8inch)

3.Baggermountingbracket

4.Spacer9.Holesforinstallingthe

5.Baggersideplate

8.Sideviewofbaggerside
plate

sidebracket

2.Installthebaggersideplateandtherollbarsection
tothesideofthemachineusing4bolts(3/8x1-1/2
inches),4curvedwashers(3/8inch),and4angenuts
(3/8inch)asshowninFigure4,Figure5,andFigure6.

6

Figure5

ForZ593DieselMowers

1.Bolt(3/8x1inch)

2.Curvedwasher(3/8inch)7.ROPS

3.Baggermountingbracket

4.Bolt(3/8x1-1/2inches)9.Sideviewofbaggerside

5.Spacer10.Holesforinstallingthe

6.Baggersideplate

8.Flangenut(3/8inch)

plate

sidebracket

Figure6

ForZ597DieselMowers

1.Bolt(3/8x1-1/2inches)6.ROPS

2.Curvedwasher(3/8inch)7.Flangenut(3/8inch)

3.Baggermountingbracket

4.Spacer9.Holesforinstallingthe

5.Baggersideplate

8.Sideviewofbaggerside
plate

sidebracket

7

3

TighteningallMountingBolts

NoPartsRequired

Procedure

Note:Allmountingboltsneedtobetorquedto48N-m

(35ft-lb).

1.Tightenthebaggermountingbrackettotherearframe
rst.

2.TightentheROPSandsidebracketstothesideofthe
machine.

3.Ifthebaggermountingbracketmovessidetoside

0.32cm(1/8inch)ormore,installoneorbothofthe
spacersbetweenthebaggermountingbracketand
mountingplates(Figure4,Figure5,andFigure6).

4.Tightenthebaggermountingbrackettotheside
brackets.

4

InstallingtheHoodAssembly andBags

Partsneededforthisprocedure:

1Hoodassembly

3Bags

2

Clevispin

2Hairpincotter

Figure7

1.Hoodassembly2.Baggermountingbracket

2.Installthe2clevispinsintothehoodassemblyand
baggermountingbracket.Securethemwith2hairpin
cotters(Figure8).

Procedure

1.Installthehoodassemblyontothebaggermounting
bracket(Figure7).

Figure8

1.Hoodassembly3.Hairpincotter

2.Baggermountingbracket

3.Installthebagtabintothenotchinthehoodassembly.
Dothisforallbags(Figure9).

Note:Thebagswillrestonthebaggerframe.

8

4.Clevispin

Figure11

Figure9

1.Hoodassembly4.Notch

2.Bag

3.Bagtab

4.Lowerthebaggerhoodoverthebags(Figure10).

5.Baggerframe

1.Baggerlatch2.Latchhook

5

RoutingtheBaggerBeltinto theBlowerAssembly

Partsneededforthisprocedure:

1

Baggerbelt(fromtheBlowerandDriveKit)

Procedure

1.Installthebeltaroundtheblowerpulley(Figure12).

2.Installthespringtotheidlerarmandthepegonthe
blowerassembly(Figure12).

Figure10

1.Hood3.Baggerlatch

2.Bag4.Latchhook

5.Positionthebaggerlatchunderthelatchhook(Figure

11).

6.Pushdownonthebaggerlatchuntilitlocksintoplace
(Figure11).

1.Idlerpulley4.Peg

2.Mower-deckpulley5.Belt

3.Spring

9

Figure12

6.Blowerpulley