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