Toro 78544, 78545 Operator's Manual

FormNo.3359-401RevA

60inand72inDFSE-ZVac
CollectionSystem

Z500SeriesZMasterMowers

ModelNo.78544—SerialNo.280000001andUp

ModelNo.78545—SerialNo.280000001andUp

Registeratwww.T oro.com.OriginalInstructions(EN)

Introduction

Readthisinformationcarefullytolearnhowtooperate
andmaintainyourproductproperlyandtoavoidinjury
andproductdamage.Youareresponsibleforoperating
theproductproperlyandsafely.

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

Wheneveryouneedservice,genuineToroparts,or
additionalinformation,contactanAuthorizedService
DealerorToroCustomerServiceandhavethemodel
andserialnumbersofyourproductready .Figure1
andFigure2identiesthelocationofthemodeland
serialnumbersontheproduct.Writethenumbersin
thespaceprovided.

Figure2

BaggerSerialNumber

1.Baggermodelandserialnumberlocation

ModelNo.

SerialNo.

Thismanualidentiespotentialhazardsandhas
safetymessagesidentiedbythesafetyalertsymbol
(Figure3),whichsignalsahazardthatmaycauseserious
injuryordeathifyoudonotfollowtherecommended
precautions.

Figure3

1.Safetyalertsymbol

Figure1

1.Blowermodelandserialnumberlocation

ModelNo.

SerialNo.

Thismanualuses2otherwordstohighlightinformation.
Importantcallsattentiontospecialmechanical
informationandNoteemphasizesgeneralinformation
worthyofspecialattention.

Contents

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

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

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

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

1PreparingtheMower.........................................6

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

3InstallingtheHandleAssembly..........................8

4TighteningallMountingBolts............................9

5InstallingtheBaggerAssembly...........................9

6RoutingtheBlowerBeltintotheBlower

Assembly.......................................................10

7InstallingtheBlowerAssembly.........................10

8SizingtheUpperTubefor60inchMowers

withGasEngines...........................................12

©2008—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

Contactusatwww.Toro.com.

2

PrintedintheUSA.

AllRightsReserved

9InstallingtheDischargeTubes..........................13

10InstallingtheBeltCover.................................15

11InstallingtheW eights.....................................16

12AdjustingtheParkingBrake...........................16

13CheckingtheTirePressure.............................17

Operation...................................................................18

PositioningtheAdjustableBafe........................18

EmptyingtheBagger..........................................19

ClearingObstructionsfromtheCollection

System............................................................19

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

UsingtheGrassDeector...................................20

TransportingMachines.......................................20

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

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

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

CleaningtheBaggerScreen.................................22

CleaningtheCollectionSystem...........................22

InspectingtheBlowerBelt..................................22

ReplacingtheBlowerBelt...................................22

CheckingandAdjustingtheBlower

Latch..............................................................23

GreasingtheIdlerArmandHandle

Pivot..............................................................23

InspectingtheCollectionSystem........................24

AdjustingtheDoorClosing................................24

AdjustingtheDoorOpening..............................25

AdjustingtheLatches.........................................25

InspectingtheMowerBlades..............................25

InstallingtheMowerBlades................................25

InstallingtheGrassDeector.............................26

Storage.......................................................................26

Troubleshooting.........................................................27

Safety

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.

•Thegrasscatchercanobstructtheviewtotherear.
Useextracarewhenoperatinginreverse.

•Usecarewhenloadingorunloadingthemachine
intoatrailerortruck.Ifthemachineistobedriven
ontoatruckortrailerwiththehopperfull,always
backuptheramp.

•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.

3

Frequentlycheckcomponentsandreplacewith
manufacturer’srecommendedparts,whennecessary.

SafetyandInstructionalDecals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof
potentialdanger.Replaceanydecalthatisdamagedorlost.

1-653554

106-3339

1-653558

98-5954

103-3507

4

Setup

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

ProcedureDescription

1

2

3

4

5

6

7

8

9

Nopartsrequired

Baggermountingbracket1
Baggersideplate2
Spacer
Bolt,(3/8x1-1/2inches)
Bolt,(3/8x1inch)(forZ593mowers

only)
FlangeNut,(3/8inch)
Curvedwasher
Handleassembly1
Washer2
Bolt(3/8x1-1/4inches)
Clevispinspring
Locknut(3/8inch)

Nopartsrequired

Baggerassembly1
Clevispin
Hairpincotter2

Blowerbelt(fromBlowerandDriveKit)

Blowerassembly(fromBlowerand
DriveKit)

Spring(fromBlowerandDriveKit)

Uppertube1

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

Qty.

14

14
14

Use

–

2

2

3
1
3

–

2

1

1

1

3
3
3

Preparethemower.

Installthebaggermountingbracket

Installthehoodassembly.

Tightenallmountingbolts

Installthebaggerassembly.

Routetheblowerbeltintotheblower
assembly.

Installtheblowerassembly.

Sizetheuppertubefor60inchmowers
withgasengines.

Installthedischargetubes.

10

11

Beltcover(fromBlowerandDriveKit)

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

only)

5

2

4
4

2

2

Installthebeltcover .

Installtheweights.

ProcedureDescription

Qty.

Use

12
13

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

Nopartsrequired

Nopartsrequired

1

PreparingtheMower

InstallingtheBaggerMounting

–

–

2

Bracket

NoPartsRequired

Partsneededforthisprocedure:

Procedure

Performthefollowingproceduretopreparethemower
forattachingtheblowerandnishingkit.

1.DisengagethePTO,movethemotioncontrollevers
totheneutrallockedpositionandsettheparking
brake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Repairallbentordamagedareasofmowerdeckand
replaceanymissingparts.

4.Cleanthemowerofanydebrisonthedeckorrear
partofthemowertoeaseinstallation.

1Baggermountingbracket

2Baggersideplate

2

Spacer

14

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

2

Bolt,(3/8x1inch)(forZ593mowersonly)

14

FlangeNut,(3/8inch)

14

Curvedwasher

Procedure

Important:Donottightenanyboltsuntilbothside

bracketsandbaggermountingbracketaretloose
onthemachine.

RefertoTighteningtheMountingBoltsforthe
correctproceduretotightenthebolts.

Adjusttheparkingbrake.

Checkthetirepressure.

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

2.Installthebaggersideplateandtherollbarsection
tothesideofthemachineusing4bolts(3/8x1-1/2
inches),4curvedwashers(3/8inch),and4ange
nuts(3/8inch)(Figure4,Figure5,andFigure6).

3.Repeatthestepsabovefortheoppositeside
(Figure4,Figure5,andFigure6).

Note:Makesurethecurvedwashersareinstalledas
showninFigure4,Figure5,andFigure6.

4.Installthebaggermountingbrackettotheleftand
rightsidebaggerbracketswith4bolts(3/8x1-1/2
inches),4curvedwashers(3/8inch),and4ange
nuts(3/8inch)(Figure4,Figure5,andFigure6).

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

6

2bolts(3/8x1inch)forZ593mowersasshownin
Figure5),2curvedwashers(3/8inch),and2ange
nuts(3/8inch)(Figure4,Figure5,andFigure6).

Figure4

ForZ500GasMowers

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

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

3.Baggermountingbracket

4.Spacer

5.Baggersideplate

8.Sideviewofbaggerside
plate

9.Holestowheninstalling
thesidebracket

Figure5

ForKubotaDieselMowers

1.Bolt,(3/8x1inch)

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

3.Baggermountingbracket

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

5.Spacer

6.Baggersideplate

8.Flangenut,(3/8inch)

plate

10.Holestowheninstalling
thesidebracket

7

3

InstallingtheHandleAssembly

Partsneededforthisprocedure:

1Handleassembly

2Washer

3

Bolt(3/8x1-1/4inches)

1

Clevispinspring

3

Locknut(3/8inch)

Procedure

1.PositionthehandleassemblybetweentheROPSroll
barandthebaggermountingbracket(Figure8).

2.Installthehandleassemblytothebaggermounting
bracketandthemachinewith3bolts(3/8x1-1/4
inches)and3locknuts(3/8inch)(Figure7and
Figure8).

Figure6

ForDaihatsuDieselMowers

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

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

3.Baggermountingbracket

4.Spacer

5.Baggersideplate

8.Sideviewofbaggerside
plate

9.Holestowheninstalling
thesidebracket

Note:ThemiddleboltisnotusedonKubota
poweredengines(Figure8).

Figure7

1.Handleassembly

2.Washer

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

4.Nut(3/8inch)

8

4

TighteningallMountingBolts

NoPartsRequired

Procedure

Thefollowingstepsarethecorrectsequencetotighten
thesidebracketsandthebaggermountingbracket.All
mountingboltsneedtobetorquedto35ft-lb(48N⋅m).

1.Tightenthebaggermountingbrackettotherear
framerst.

2.TightentheROPSandsidebracketstothesideof
themower.

3.Ifthebaggermountingbracketmovessidetosidean
1/8inchormore,installoneorbothofthespacers
betweenthebaggermountingbracketandmounting
plates(Figure4,Figure5,andFigure6).

4.Tightenthebaggermountingbrackettotheside
brackets.

Figure8

1.Handleassembly

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

3.Washer

3.Installthebaggerarmlinkagetothebaggerassembly
withaclevispinspring(Figure9).

4.Nut(3/8inch)

5.Thisboltisnotusedon
Kubotapoweredmachines

5

InstallingtheBagger
Assembly

Partsneededforthisprocedure:

1Baggerassembly

2

Clevispin

2Hairpincotter

Procedure

1.Installthebaggerassemblyontothebagger
mountingbracket(Figure10).

2.Installthe2clevispinsintothebaggerassemblyand
baggermountingbracket.Secureitwith2hairpin
cotters(Figure10).

1.Baggerarmlink

2.Baggerassembly

Figure9

3.Clevispinspring

9

Figure10

1.Hoodassembly3.Hairpincotter

2.Clevispin

4.Baggermountingbracket

6

RoutingtheBlowerBeltinto

Figure11

1.Idlerpulley4.Peg

2.Mowerdeckpulley5.Belt

3.Spring

7

InstallingtheBlowerAssembly

6.Blowerpulley

theBlowerAssembly

Partsneededforthisprocedure:

1

Blowerbelt(fromBlowerandDriveKit)

Procedure

1.Installthebeltaroundtheblowerpulley(Figure11).

2.Installthespringtotheidlerarmandthepegonthe
blowerassembly(Figure11).

Partsneededforthisprocedure:

1

Blowerassembly(fromBlowerandDriveKit)

1

Spring(fromBlowerandDriveKit)

Procedure

Anuncovereddischargeopeningcouldallow
thelawnmowertothrowobjectsinthe
operator’sorbystander’sdirectionandresult
inseriousinjury.Also,contactwiththeblade
couldoccur.

•Neveroperatethelawnmowerunlessyou
installacoverplate,amulchplate,oragrass
chuteandcatcher.

•Makesurethegrassdeectorisinstalled
whenthegrasschuteandcatcherare
removed.

1.Removethesidedischargechutefromthemower
deck(Figure12).

10

Figure12

1.Bolt

2.Spacer6.GrassDeector

3.Locknut

4.Spring8.Jhookendofspring

5.Springinstalled

7.Lendofspring,place

behinddeckedgebefore
installingbolt

2.Slidetheblowerassemblypegintothepivothole.
For60inchmowersrefertoFigure13andfor72
inchmowersrefertoFigure14.

Figure14

72inchMowerDeck

1.Blowerassembly3.Pivothole

2.Mowerdeck,72inch(183
cm)shown

4.Blowerassemblypeg

3.Closetheblowerassemblytoseeifthelatchesare
adjustedcorrectly.Loosenortightentheboltso
thelatchesrmlyholdtheblowerassemblyagainst
themowerdeck,butcanbereleasedbyhand
(Figure15).

Figure13

60inchMowerDeck

1.Blowerassembly3.Pivothole

2.Mowerdeck,60inch(152
cm)shown

4.Blowerassemblypeg

Figure15

1.Latch3.Blowerassembly

2.Bolt

4.InstallthespringasshowninFigure16.

Makesurethehooksareinthecorrectposition.

11

8

SizingtheUpperTubefor60
inchMowerswithGasEngines

Partsneededforthisprocedure:

1Uppertube

Procedure

Figure16

1.Springloadedidlerpulley

2.Shorthookend

5.Pullthespringloadedidlerpulleybackandroute
thebeltaroundthemowerdeckpulley .Ensurethe
beltisroutedaroundtheblowerpulleyscorrectly
(Figure17).

3.Longhookend

Note:Thisprocedureisfor60inchmowerswithgas
enginesonly .

1.Measureup3–1/2inches(89mm)fromthebottom
oftheuppertube.Usetheexisting3holesasmarks
andthenmarkitinseveralplacestocreatealine
aroundthetube(Figure18).

2.Cutthe3–1/2inches(89mm)offtheuppertube
(Figure18).

Note:Noticethethreeindentationsinthetube.
Thisiswhereholeswillbedrilledinthefollowing
procedure.

Figure17

1.Mowerdeckpulley3.Blower

2.SpringloadedIdlerpulley

12

Figure18

1.Indentationsfordrilling
holes

2.Uppertube5.Linetocuttube

3.Cutoff3–1/2inches(89
mm)for60inchmowers
withgasenginesonly

4.Usetheexistingholesto
createaline

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Lowerthemowerdecktothelowestheight-of-cut
position.

4.Installtheuppertubeintothebaggeropeningand
pullitbackoutsotherubbersealisprotrudingout
(Figure19).

Figure19

1.Uppertube3.Baggerhood

2.Baggeropening

5.Measurethedistancethetubeisinsidethehood.

Measurefromthehoodplatetotheedgeofthetube
asshowninFigure20.Thisdistanceneedstobe
3/4inch(19mm).

9

InstallingtheDischargeTubes

Partsneededforthisprocedure:

1Uppertube

1Lowertube

3

Bolt,(#10x3/4inches)

3

Locknut,(#10)

3

Washer,(7/32inch)

Procedure

Important:Makesurethemowerdeckisinthe

lowestheight-of-cutpositionwhileinstallingthe
dischargetubes.

Note:Remembertoreplacethegrassdeectorwhen
thebaggerisremovedfromthemower.Referto
ReplacingtheGrassDeector.

1.DisengagethePTOandsettheparkingbrake.

1.Hoodplate

2.Uppertube

3.Hoodinthedownposition

Figure20

4.3/4inch(19mm)

5.Edgeoftube

13

6.Oncethe3/4inch(19mm)measurementhasbeen
achieved,marktheuppertubeontheoutsidewhere
therubbersealprotrudesout.Thisismarkedto
ensurethecorrectpositionfortheuppertubewhen
drillingtheholesandconnectingtheupperand
lowertubes(Figure21).

Note:Therubbersealmustprotrudeoutfromthe
baggerhood.

Figure22

1.Lowertube2.Uppertube

8.Slidethelowertubeontothebootandlatchthem
together(Figure23).

Figure21

1.Uppertube3.Baggerhood

2.Rubbersealprotrudingout4.Markhereagainstthe
rubberseal

7.Installthelowertubeintotheuppertube(Figure22).

Note:Thereisalatchonthetopandbottomof
theblowerhousing.

1.Blowerassembly3.Latch

2.Lowertube

14

Figure23

9.Makesurethemowerdeckisinthelowest
height-of-cutpositionandthemarkontheupper
tubeisstillpositionedagainsttheprotrudingrubber
seal.

ChecktomakesurethemarkfromFigure21isstill
inplace.

10.Usingthethreeholesorindentationsintheupper
tubeasatemplate,drillthreeholes(7/32inch
diameter)wheretheupperandlowertubesjoin
together(Figure24).

1.Lowertube

2.Uppertube

3.Flatwasher,(7/32inch)

Figure25

4.Locknut,(#10)

5.Bolt,(#10x3/4inches)

Figure24

1.Baggerhood4.Lowertube

2.Uppertube5.Blowerassembly

3.Drill7/32inchdiameter
holeshere(useupper
tubeasatemplate)

11.Removethelowertubefromtheblower.

12.Jointheupperandlowertubeswith3bolts(#10
x3/4inches),3atwashers(7/32inch),and3
locknuts(#10)(Figure25).

13.Installthelowertubeontotheblowerhousingand
secureitwiththelatches.

10

InstallingtheBeltCover

Partsneededforthisprocedure:

Beltcover(fromBlowerandDriveKit)

Procedure

1.Lowerthemowerdecktothelowestheight-of-cut
position.

2.Installthenewbeltcoversothenotchesonboth
sidesgooverthebeltcoversupportsandsecurethe
latch(Figure26).

15

Figure26

1.Beltcover5.Latch

2.Blowerassembly6.Beltcovernotch

3.Pulleyassembly7.Beltcoversupport

4.Beltcoverbracket

2.Installplate,nuts(1/2inch)andlockwasher
(1/2inch)undertheframeandweight(Figure27).

3.Repeatforoppositeside.

Note:AllZMastermowersreceivethecaster
weights.

Figure27

1.Frontcasterweight4.Nut

2.U-bolt5.Frontcaster

3.Plate6.Lockwasher

11

InstallingtheWeights

Partsneededforthisprocedure:

2

Casterweight

2U-bolt

4

Nut,(1/2inch)

4

Lockwasher,(1/2inch)

2Plate

2

Topweight(for60inchmowerdecksonly)

2

Procedure

TocomplywithANSI/OPEIB71.4-2004Standard,
weightsmustbeaddedtothemachine.

Note:OnlyZMastermowerswith60inchmower
decksreceivethetopweights.

4.Installthetopweightsontopofeachcasterweight
for60inchmowerswith2bolts(1/2x2–1/2inches)
(Figure28).

Figure28

1.Topweight3.Frontcasterweight

2.Bolt,(1/2x2–1/2inches)

4.Frontcasterwheel

Thebaggeraddsalotofweighttotherear
ofthemachineandmaycauseanunstable
conditionwhichcouldresultinalossofcontrol.

1.Placecasterweightsonthefrontcasters.

16

12

13

AdjustingtheParkingBrake

NoPartsRequired

Procedure

Checktheparkingbrakeforproperadjustment.

1.Disengagebrakelever(leverdown).

2.Measurethelengthofthespring.

Themeasurementshouldbe2-3/4inch(70mm)
betweenwashers(Figure29).

CheckingtheTirePressure

NoPartsRequired

Procedure

Note:Increasethetirepressureduetotheadditional

weight.

Checkandincreasetheairpressureinthefrontcaster
wheelsandreartires(Figure30).

Pressure:Reartires-20psi(138kPa)

Frontcasterwheels-25psi(172kPa)

Figure29

1.Brakelever

2.Spring(2-3/4inches/70
mm)

3.Adjustingnuts7.Trunnionroller

4.Collaronbrakerod

3.Ifadjustmentisnecessary,loosenthejamnutbelow
thespringandtightenthenutdirectlybelowthe
yoke(Figure29).Turnthenutuntilthecorrect
measurementisobtained.Tightenthetwonuts
togetherandrepeatonoppositesideofunit.

4.Turnnutsclockwisetoshortenspringlengthand
turncounter-clockwisetolengthenthespring.

5.Engageparkingbrake,leverup.

6.Measurethedistancebetweenthetrunnionroller
andthecollaronbrakerod.

Themeasurementshouldbe3/16-1/4inch(5-7
mm)(Figure29).

7.Ifadjustmentisnecessary,loosenthejamnut
directlybelowtheyoke.Turnthebottomroduntil
thecorrectmeasurementisobtained(Figure29).
Tightenjamnutatyoke

5.3/16–1/4inch(5–7mm)

6.Jamnutandyoke

Figure30

17

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

Important:Settheparkingbrakewhenleavingthe
machineunattended,evenifjustforafewminutes.

Toavoidpersonalinjury,followthese
procedures:

•Becomefamiliarwithalloperatingand
safetyinstructionsintheoperator’smanual
foryourmowerbeforeusingthisattachment.

•Neverremovethebaggerorbaggertubes
whiletheengineisrunning.

•Alwaysshuttheengineoffandwaitforall
movingpartstostopbeforeclearingan
obstructionfromthebaggingsystem.

•Neverdomaintenanceorrepairswhilethe
engineisrunning.

Childrenorbystandersmaybeinjuredifthey
moveorattempttooperatethetractorwhileit
isunattended.

Alwaysremovetheignitionkeyandsetthe
parkingbrakewhenleavingthemachine
unattended,evenifjustforafewminutes.

PositioningtheAdjustable
Bafe

AdjustthebafetopositionB(middleposition)for
bagging.RefertothemachinesOperatorManualfor
thebafeadjustmentprocedure.

•Settheparkingbrake.

Withoutthegrassdeector,baggertubesor
completecollectionsystemmountedinplace,
youandothersareexposedtobladecontact
andthrowndebris.Contactwiththerotating
mowerblade(s)andthrowndebriswillcause
injuryordeath.

•Alwaysinstallthegrassdeectorwhen
removingthecollectionsystemand
changingtosidedischargemode.

•Ifthegrassdeectoriseverdamaged,
replaceitimmediately.Thegrassdeector
routesmaterialdowntowardtheturf.

•Neverputyourhandsorfeetunderthe
mower.

•Nevertrytoclearthedischargeareaor
mowerbladesunlessyoumovethepower
takeoff(PTO)tooffandrotatetheignition
keytooff.Alsoremovethekeyandpullthe
wireoffofthesparkplug(s).

Figure31

•Turnofftheenginebeforeuncloggingthe
dischargechute.

18

EmptyingtheBagger

1.DisengagethePTOandsettheparkingbrake.

2.Liftuponthehandletoopenthedoorandempty
thehopper.

3.Pushthehandledowntoclosethedoor(Figure32).

Note:Ifthemachineistobedrivenontoatruck
ortrailerwiththehopperfull,alwaysbackupthe
ramp.Thiswillreducethechanceofrearwardtip.

Figure32

Note:Inmostcases,thedebriscanbeshakenout

ofthetubes.

7.Iftheblowerassemblyisplugged,unlatchthe
blowerassembly,removethebelt,andswingitopen.

8.Usingastickorsimilarobject,notyourhands,to
removeandcleartheobstructionfromtheblower
assembly.

9.Afteryouremovetheobstruction,installthe
completecollectionsystemandresumeoperation.

RemovingtheBagger

Componentsaroundenginewillbehotifthe
machinehasbeenrunning.Touchinghot
componentscancauseburns.

•Donottouchenginecomponentswhenhot.

ClearingObstructionsfrom
theCollectionSystem

Whenthecollectionsystemisinoperation,the
blowercanberotatingandcutofforinjure
hands.

•Beforeadjusting,cleaning,repairing
andinspectingtheblower,andbefore
uncloggingthechute,turnofftheengine
andwaitforallmovingpartstostop.
Removethekey .

•Useastick,notyourhands,toremovean
obstructionfromtheblowerandtube.

•Keepface,hands,feet,andanyotherpartof
yourbodyorclothingawayfromconcealed,
moving,orrotatingparts.

1.DisengagethePTOandsettheparkingbrake.

2.Turnofftheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Emptythebagger.

4.Unlatchthelowertube.

5.Removethetubesfromthebagger.

6.Usingastickorsimilarobject,notyourhands,to
removeandcleartheobstructionfromthetube
assembly.

•Allowenginetocoolbeforeremovingthe
bagger.

1.DisengagethePTO ,settheparkingbrake,and
chockorblockthetires.

2.Turnofftheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Unlatchthelowertubefromtheblowerandremove
thetubefromtheblowerassembly.

4.Removethetubefromthebaggerhood.

5.Lowerthemowerdecktothelowestheight-of-cut
position.

6.Unlatchthebeltcoveroverthemowerpulley
assembly.

7.Removetheblowerbeltfromthemowerpulley
assembly.

8.Opentheblowerassembly .

9.Removetheblowerassemblyfromthepivothole.

10.Ifyouarechangingtosidedischargemode,ensure
thegrassdeectorisinstalledandcanbelowered
intoworkingposition.

11.Removethecollectionsystemassembly.

19

UsingtheGrassDeector

Withoutthegrassdeector,dischargecover,
orcompletegrasscatcherassemblymounted
inplace,youandothersareexposedtoblade
contactandthrowndebris.Contactwith
rotatingmowerblade(s)andthrowndebriswill
causeinjuryordeath.

•Alwaysinstallthegrassdeectorwhen
removingthecollectionsystemand
changingtosidedischargemode.

•Ifthegrassdeectoriseverdamaged,
replaceitimmediately.Thegrassdeector
routesmaterialdowntowardtheturf.

•Neverputyourhandsorfeetunderthe
mower.

CuttingHeight

Foroptimumbaggingperformance,setthedeck
height-of-cuttoremovenomorethat2to3inches(51
to76mm)or1/3ofthegrassheight,whicheverisless.
Cuttingoffmorethanthiswillreducethecapacityof
thevacuumsystem.

CuttingFrequency

Cutthegrassoften,especiallywhenitgrowsrapidly.
Youwillhavetocutyourgrasstwiceifitgetsexcessively
long(refertoBaggingLongGrass).

CuttingTechnique

Forbestlawnappearance,besuretoslightlyoverlap
themowerintothepreviouslycutarea.Thishelps
reducetheloadontheengineandreducesthechance
ofpluggingtheblowerassemblyandtubes.

•Nevertrytoclearthedischargeareaor
mowerbladesunlessyoumovethepower
takeoff(PTO)totheoffposition,rotatethe
ignitionkeytooffandremovethekey .

TransportingMachines

Donotleavegrassordebrisinthebaggerwhile
transportingthemachineonatrailerortruck.

Transportingthemachinewithgrassordebris
inthebaggercandamagethemachine.

Donotleavegrassordebrisinthebaggerwhile
transportingthemachineonatrailerortruck.

OperatingTips

BaggingSpeed

Thebaggingsystemmayplugifyoudrivetoofastand
theenginespeedgetstooslow .Onhillsitmaybe
necessarytoslowthemachinesgroundspeed.Mow
downhillwheneverpossible.

Asthebaggerlls,extraweightisaddedto
thebackofthemachine.Ifyoustopandstart
suddenlyonhills,youmaylosesteeringcontrol
orthemachinemaytip.

•Donotstartorstopsuddenlywhengoing
uphillordownhill.Avoiduphillstarts.

•Ifyoudostopthemachinewhengoing
uphill,disengagethePTO.Thenbackdown
thehillusingaslowspeed.

•Donotchangespeedsorstoponslopes.

MachineSize

Rememberthatthemachineislongerandwiderwith
thisattachmentinstalled.Byturningtoosharplyin
connedplacesyoumaydamagetheattachmentor
otherproperty.

Trimming

Alwaystrimwiththeleftsideofthemower.Donot
trimwiththerightsideofthemowerbecauseyoucould
damagethebaggingtubes.

BaggingLongGrass

Ifthegrassiseverallowedtogrowlongerthannormal,
orifitcontainsahighdegreeofmoisture,raisethe
cuttingheighthigherthanusualandcutandbagthe
grassatthissetting.Thencutandbagthegrassagain
usingthelower,normalsetting.

Excessivelylonggrassisheavyandmaynotbe
propelledcompletelyintothebagger.Ifthishappens,
thetubeandblowermayplug.Toavoidpluggingthe
baggingsystem,mowthegrassatahighheight-of-cut,

20

thenlowerthemowertoyournormalcuttingheight
andrepeatthebaggingprocess.

BaggingWetGrass

Ifpossible,alwaystrytocutgrasswhenitisdry.Wet
grasscancauseplugging.

ReducingPlugging

Toavoidpluggingthebaggingsystem,reduceground
speedandmowthegrassatahighheight-of-cut,then
lowerthemowertoyournormalcuttingheightand
repeatthebaggingprocess.

SignsofPlugging

Asyouarebagging,asmallamountofgrassclippings
normallyblowoutthefrontofthemower.Anexcessive
amountofclippingblow-outindicatesthatthebagger
isfullorthetubeisplugged.

BaggingBlades

Inmostmowingconditions,thestandardhighlift
bladeswillprovidethebestbaggingperformance.

TheT oroAtomicbladeisrecommendedforbagging
leavesindryconditions.Indrydustyconditions,the
mediumliftorlowliftbladeswillreducedustanddirt
blowoutwhileprovidingeffectivebaggingairow .

ContactanAuthorizedServiceDealerfortheproper
bladesfordifferentmowingconditions.

CurbClimbingandLoading

Alwaysliftthedecktothehighestpositionwhenloading
themachineontrailersorascending/descendinga
curb.Leavingthemowerinalowerpositioncancause
damagetothemowerwhileloadingandgoingovera
curb.Ifacurbishigherthan6inches(152mm),crossit
atasharpanglewiththedeckfullyraised.Useextreme
cautionwhenloadingontoatrailer.

21

Maintenance

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst8hours

Beforeeachuseordaily

Every25hours

Every50hours

Every100hours

MaintenanceProcedure

•Inspecttheblowerbelt.

•Inspectthecollectionsystem.

•Cleanthehoodscreen.

•Cleanthecollectionsystem.

•Inspecttheblowerbelt.

•Greasetheidlerarm.

•Greasethehandlepivot.

•Inspectthecollectionsystem.

CleaningtheBaggerScreen

ServiceInterval:Beforeeachuseordaily

Thescreensneedtobecleanedbeforeeachuse.Inwet
grasstheywillneedtobecleanedmoreoften.

1.Disengagethepowertakeoff(PTO)andsetthe
parkingbrake.

2.Turnofftheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Openthebagger.

4.Cleanthedebrisfromthescreen.

5.Closethebagger.

ReplacingtheBlowerBelt

1.DisengagethePTO,movethemotioncontrollevers
totheneutrallockedposition,andsettheparking
brake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Pullbackonthespringloadedidlerpulleytorelieve
thebelttension(Figure33).

4.Removetheexistingblowerbeltfromthemower
deckpulleyandthentheblowerpulleys.

5.Installthenewbeltaroundtheblowerpulleysand
themowerdeckpulley(Figure33).

CleaningtheCollection
System

ServiceInterval:Beforeeachuseordaily

1.Washtheinsideandoutsideofthebaggerhood,
tube,andtheundersideofthemower.Useamild
automotivedetergenttoremovedirt.

2.Makesureyouremovemattedgrassfromallparts.

3.Afterwashingallparts,letthemdrythoroughly.

Note:Withallpartsinstalled,startandrunthemachine
foraminutetoassistindrying.

InspectingtheBlowerBelt

ServiceInterval:Aftertherst8hours

Every25hours

Checkbeltsforcracks,frayededges,burnmarksorany
otherdamage.Replacedamagedbelts.

22

Figure33

1.Idlerpulley4.Peg

2.Mowerdeckpulley5.Belt

3.Spring

Figure35

1.Latch3.Blowerassembly

2.Bolt

6.Blowerpulley

GreasingtheIdlerArmand

6.InstallthespringasshowninFigure34.

Figure34

1.Springloadedidlerpulley

2.Shorthookend

3.Longhookend

7.Pullbackonthespringloadedidlerpulleyand
installthebeltontothespringloadedidlerpulley
(Figure33).

HandlePivot

ServiceInterval:Every50hours—Greasetheidler

arm.

Every100hours—Greasethehandle
pivot.

Greasetheblowerbeltidlerarm(Figure36).

Figure36

CheckingandAdjustingthe
BlowerLatch

Closetheblowerassemblytoseeifthelatchesare
adjustedcorrectly.Loosenortightentheboltssothe
latchesrmlyholdtheblowerassemblyagainstthe
mowerdeck,butcanbereleasedbyhand.

23

Greasethehandlepivot(Figure37).

Figure37

InspectingtheCollection
System

ServiceInterval:Aftertherst8hours

Every100hours

1.DisengagethePTO,movethemotioncontrollevers
totheneutrallockedposition,andsettheparking
brake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Checktheuppertube,lowertube,bagger,andthe
blowerassembly.Replacethesepartsiftheyare
crackedorbroken.

4.Checkthebaggerframe.Replaceanypartsthatare
crackedorbroken.

5.Tightenallnutsboltsandscrews.

5.Afterthestopboltshavebeenadjusted,thelengthof
thehingelinkscanbeadjustedtoprovidecomplete
closingofthedoorandreasonableforceonthe
handle.Lengthenthelinkstoreducetheforce.
Shortenthelinkstoincreasetheforce(Figure38
andFigure39).

6.Makesureboththeleftandrightsidesareadjusted
thesamedistance.Withthedoorclosed,thelinks
shouldbeslightlytighttominimizerattling.

7.Tightenthenuts.

Figure38

1.Contactarmstraightup
anddown

2.Stopbolt

3.Hingelinks

AdjustingtheDoorClosing

Thetwohingelinksandtwostopscrewscanbeadjusted
toprovidecompleteclosingofthedoor.

1.DisengagethePTO,movethemotioncontrollevers
totheneutrallockedposition,andsettheparking
brake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Withthedoorclosed,thestopboltsneedtobe
adjustedsothatthecontactarmisstraightupand
down(Figure38andFigure39).

4.Ifadjustmentisneed,loosenthenutsandadjustthe
stopbolts(Figure38andFigure39).

24

1.Contactarm

2.Stopbolt

Figure39

3.Hingelinks

AdjustingtheDoorOpening

Performthisafteradjustingthedoorclosing.

Adjustthehandlelinktoobtainthemaximumdoor
opening.Lengthenthehandlelinktoopenthedoor
farther.Shortenthehandlelinktoopenthedoorless
(Figure40).

Note:Themaximumdooropeningiscontrolledbythe
contactarmhittingthestop.Thestopisnotadjustable
andpreventsthedoorfrombeingopenedtoofar.

Figure40

1.Handle

2.Handlelink

3.Stop

Figure41

1.Latchlink2.Latchrod

InspectingtheMowerBlades

1.Inspectthemowerbladesregularlyandwhenevera
bladestrikesaforeignobject.

2.Ifbladesarebadlywornordamaged,installnew
blades.RefertoyourmowerOperator’ sManualfor
completeblademaintenance.

InstallingtheMowerBlades

AdjustingtheLatches

Thelatchescanbeadjustaftertheopenandcloseddoor
positionshavebeenset.

1.DisengagethePTO,movethemotioncontrollevers
totheneutrallockedposition,andsettheparking
brake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Closethedoor.

4.Checkthetoensurethelatchescompletelyengage
andcontactsthelatchrodweldedtothedoor
(Figure41).

5.Thelatchesneedtobetightagainstthelatchrod.
Theyneedtobelooseenoughtomoveorwiggle.

Inmostmowingconditions,thestandardhighliftblades
willprovidethebestbaggingperformance.

TheToroAtomicbladeisrecommendedforbagging
leavesindryconditions.Indrydustyconditions,the
mediumliftorlowliftbladeswillreducedustanddirt
blowoutwhileprovidingeffectivebaggingairow .

ContactanAuthorizedServiceDealerfortheproper
bladesfordifferentmowingconditions.

RefertothemowerOperator’ sManualformore
informationoninstallingblades.

25

InstallingtheGrassDeector

Storage

1.Cleanthebagger.RefertoCleaningtheBagger.

Anuncovereddischargeopeningcouldallow
thelawnmowertothrowobjectsinthe
operator’sorbystander’sdirectionandresult
inseriousinjury.Also,contactwiththeblade
couldoccur.

•Neveroperatethelawnmowerunlessyou
installacoverplate,amulchplate,oragrass
chuteandcatcher.

•Makesurethegrassdeectorisinthedown
position.

1.Removethelocknut,bolt,springandspacerholding
thedeectortothepivotbrackets(Figure42).

2.Removethedamagedorworngrassdeector.

3.Placethespacerandspringontothegrassdeector.
PlacetheLendofthespringbehindthedeckedge.

Note:MakesuretheLendofthespringisinstalled
behindthedeckedgebeforeinstallingtheboltas
showninFigure42

4.Installtheboltandnut.

5.PlacetheJhookendofthespringaroundthegrass
deector(Figure42).

2.Inspectthebaggerfordamage.RefertoInspecting
theCollectionSystem.

3.Makesurethebaggerisemptyandthoroughlydry.

4.Checkthebeltforwearorcracks.

5.Storethemachineinaclean,dryplace,outofdirect
sunlight.Ifyoumuststorethemachineoutside,
coveritwithaweatherproofcover.Thisprotectsthe
plasticpartsandextendsthelifeofthemachine.

Important:Thegrassdeectormustbeableto
lowerdownintoposition.Liftthedeectorup
totestthatitlowersintothefulldownposition.

Figure42

1.Bolt

2.Spacer6.GrassDeector

3.Locknut

4.Spring8.Jhookendofspring

5.Springinstalled

7.Lendofspring,place

behinddeckedgebefore
installingbolt

26

Troubleshooting

Problem

Abnormalvibration.

Reducedbaggingperformance.

Blowerandtubesplugtoofrequently.

PossibleCauseCorrectiveAction

1.Cuttingblade(s)is/arebentor
unbalanced.

2.Blademountingboltisloose.2.Tightentheblademountingbolt.

3.Looseblowerpulleyorpulleyassembly.3.Tightentheappropriatepulley.

4.Wornblowerbelt.4.Replacebelt.

5.Blowerfanblade(s)is/arebentor
unbalanced.

1.Lowenginespeed.1.Alwaysoperatethecollectionsystem

2.Pluggedscreeninbaggerhood.2.Removedebris,leavesorgrass

3.Looseblowerbelt.3.Replacetheblowerbelt.

4.Apluggedtubeorblower.4.Locateandremovepluggeddebris.

5.Fullbagger .5.Emptythebagger.

1.Baggeristoofull.1.Dumpmorefrequently.

2.Lowenginespeed.2.Alwaysoperatethecollectionsystem

3.Grassistoowet.3.Cutgrasswhenitisdry.

4.Grassistoolong.4.Cutnomorethan2-3inches(51-76

5.Pluggedscreeninhood.5.Removedebris,leavesorgrass

6.Groundspeedistoofast.6.Drivesloweratfullthrottle.

7.Wornblowerbelt.7.Replacebelt.

1.Installnewcuttingblade(s).

5.ContactanAuthorizedServiceDealer.

atfullthrottle.

clippingsfromthescreen.

atfullthrottle.

mm)or1/3ofthegrassheight,which
everisless.

clippingsfromthescreen.

Debrisblowout.

Blowerimpellerdoesnotspinfreely .

1.Baggeristoofull.1.Dumpmorefrequently.

2.Groundspeedistoofast.2.Drivesloweratfullthrottle.

3.Mowerdeckisnotleveled.

1.Pluggedblower .1.Removedebris,leavesorgrass

2.Impellernotaligned.

3.Seethemoweroperator’smanualfor
levelingthemowerdeck.

clippingsfromtheblowerimpeller.

2.ContactanAuthorizedServiceDealer.

27

Landscape
Contractor

Equipment (LCE)

The Toro Total Coverage Guarantee

A Limited Warranty

Conditions and Products Covered

The Toro® Company and its afliate, Toro Warranty Company, pursuant to an
agreement between them, jointly promise to repair the listed Toro Products if
defective in materials or workmanship. The following time periods apply from
the date of purchase:

This warranty applies to:

•

ProLine Mid-Size Mowers and Attachments

•

Z Master Mid-Mount ZRTs and Attachments

Components

Traction Unit Frame and Carrier Frame
All Spindles

Engines* and /Hydraulic System
Deck Shells (34 ″ -72 ″ )
Z500 Series Electric Clutch
Remaining Components

* S o m e e n g i n e s u s e d o n T o r o L C E P r o d u c t s a r e w a r r a n t e d b y t h e e n g i n e m a n u f a c t u r e r .

This warranty includes the cost of parts and labor, but you must pay
transportation costs.

Warranty Period

1 year
1 year

2 year

3 years Parts

2 years Labor

2 years
2 years
2 years

1 year

Instructions for Obtaining Warranty Service

If you think that your Toro Product contains a defect in materials or
workmanship, follow this procedure:

1. Contact any Toro Authorized or Master Service Dealer to arrange service at
their dealership. To locate a dealer convenient to you, access our website at
www.Toro.com. You may also call our Toro Customer Care Department
toll free at 888–865–5676 (U.S. Customers) or 888–865–5691 (Canada
customers).

2. Bring the product and your proof of purchase (sales receipt) to the Service
Dealer.

If for any reason you are dissatised with the Service Dealer’s analysis or with
the assistance provided, contact us at:

LCB Customer Service Department

Toro Warranty Company

8111 Lyndale Avenue South

Bloomington, MN 55420-1196

Owner Responsibilities

You must maintain your Toro Product by following the maintenance procedures
described in the operator’s manual. Such routine maintenance, whether
performed by a dealer or by you, is at your expense.

Items and Conditions Not Covered

There is no other express warranty except for special emission system coverage
on some products. This express warranty does not cover the following:

• Cost of regular maintenance service or parts, such as lters, fuel, lubricants,

tune-up parts, blade sharpening, brake and clutch adjustments.

• Any product or part which has been altered or misused or required

replacement or repair due to normal wear, accidents, or lack of proper
maintenance.

• Repairs necessary due to improper fuel, contaminants in the fuel system, or

failure to properly prepare the fuel system prior to any period of non-use
over three months.

• Pickup and delivery charges.

General Conditions

All repairs covered by this warranty must be performed by an Authorized Toro
Service Dealer using Toro approved replacement parts.

Neither The Toro® Company nor Toro Warranty Company is liable for
indirect, incidental or consequential damages in connection with the
use of the Toro Products covered by this warranty, including any
cost or expense of providing substitute equipment or service during
reasonable periods of malfunction or non-use pending completion
of repairs under this warranty.

Some states do not allow exclusions of incidental or consequential
damages, or limitations on how long an implied warranty lasts, so
the above exclusions and limitations may not apply to you.

All implied warranties of merchantability (that the product is t
for ordinary use) and tness for use (that the product is t for
a particular purpose) are limited to the duration of the express
warranty.

This warranty gives you specic legal rights, and you may also have
other rights which vary from state to state.

Countries Other than the United States or Canada

Customers who have purchased Toro products exported from the United States or Canada should contact their Toro Distributor (Dealer) to obtain guarantee
policies for your country, province, or state. If for any reason you are dissatised with your Distributor’s service or have difculty obtaining guarantee information,
contact the Toro importer. If all other remedies fail, you may contact us at Toro Warranty Company.

374-0037 Rev F