Toro 78544 Operator's Manual

FormNo.3440-329RevA

60inand72inDFSE-ZVac
CollectionSystem

Z500SeriesZMaster

ModelNo.78544—SerialNo.280000001andUp
ModelNo.78545—SerialNo.280000001andUp

®

Mowers

™

Registeratwww.T oro.com.
OriginalInstructions(EN)

CV

*3440-329*A

Introduction

Readthisinformationcarefullytolearnhowtooperate
andmaintainyourproductproperlyandtoavoid
injuryandproductdamage.Youareresponsiblefor
operatingtheproductproperlyandsafely .

YoumaycontactT orodirectlyatwww.T oro.com
forproductsafetyandoperationtrainingmaterials,
accessoryinformation,helpndingadealer,orto
registeryourproduct.

g007732

Figure2

BaggerSerialNumber

1.Baggermodelandserialnumberlocation

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

Figure1

1.Blowermodelandserialnumberlocation

ModelNo.

SerialNo.

Thismanualidentiespotentialhazardsandhas
safetymessagesidentiedbythesafetyalertsymbol
(Figure3),whichsignalsahazardthatmaycause
seriousinjuryordeathifyoudonotfollowthe
recommendedprecautions.

g000502

Figure3

1.Safetyalertsymbol

Thismanualuses2wordstohighlightinformation.
Importantcallsattentiontospecialmechanical

g003368

informationandNoteemphasizesgeneralinformation
worthyofspecialattention.

ModelNo.

SerialNo.

©2020—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

Contents

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

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

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

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

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

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

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

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

6RoutingtheBlowerBeltintotheBlower

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

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

8SizingtheUpperTubefor152cm(60inch)

MowerswithGasEngines.............................12

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

10InstallingtheBeltCover...............................16

Contactusatwww.Toro.com.

2

PrintedintheUSA

AllRightsReserved

11InstallingtheWeights...................................17

12AdjustingtheParkingBrake.........................17

13CheckingtheTirePressure..........................18

Operation................................................................19

PositioningtheAdjustableBafe.......................19

EmptyingtheBagger........................................20

ClearingObstructionsfromtheCollection

System..........................................................20

RemovingtheBagger.......................................20

UsingtheGrassDeector.................................21

TransportingMachines.....................................21

OperatingTips.................................................21

Maintenance...........................................................23

RecommendedMaintenanceSchedule(s)...........23

CleaningtheBaggerScreen.............................23

CleaningtheCollectionSystem........................23

InspectingtheBlowerBelt................................23

ReplacingtheBlowerBelt.................................23

CheckingandAdjustingtheBlower

Latch.............................................................24

GreasingtheIdlerArmandHandle

Pivot..............................................................24

InspectingtheCollectionSystem......................25

AdjustingtheDoorClosing...............................25

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

AdjustingtheLatches.......................................26

InspectingtheMowerBlades............................26

InstallingtheMowerBlades..............................26

InstallingtheGrassDeector............................27

Storage...................................................................28

Troubleshooting......................................................29

Safety

Thefollowinglistcontainssafetyinformationspecic
toToroproductsandothersafetyinformationyou
mustknow.

•Becomefamiliarwiththesafeoperationofthe

equipment,withtheoperatorcontrols,andsafety
signs.

•Useextracarewithgrasscatchersorother

attachments.Thesecanchangetheoperating
characteristicsandthestabilityofthemachine.

•Followthemanufacturer'srecommendations

foraddingorremovingwheelweightsor
counterweightstoimprovestability.

•Donotuseagrasscatcheronsteepslopes.A

heavygrasscatchercouldcauselossofcontrol
oroverturnthemachine.

•Slowdownanduseextracareonhillsides.Be

suretotravelintherecommendeddirectionon
hillsides.Turfconditionscanaffectthemachine's
stability.Useextremecautionwhileoperatingnear
drop-offs.RefertothetractionunitOperator's
Manualforoperationnearslopesanddrop-offs.

•Keepallmovementonslopesslowandgradual.

Donotmakesuddenchangesinspeed,directions
orturning.

•Thegrasscatchercanobstructtheviewtothe

rear.Useextracarewhenoperatinginreverse.

•Usecarewhenloadingorunloadingthemachine

intoatrailerortruck.Ifthemachineistobedriven
ontoatruckortrailerwiththehopperfull,always
backuptheramp.

•Neveroperatewiththedischargedeectorraised,

removedoraltered,unlessusingagrasscatcher.

•Keephandsandfeetawayfrommovingparts.Do

notmakeadjustmentswiththeenginerunning.

•Stoponlevelground,disengagedrives,chock

orblockwheels,shutoffenginebeforeleaving
theoperator'spositionforanyreasonincluding
emptyingthegrasscatcheroruncloggingthe
chute.

•Ifyouremovethegrasscatcher,besuretoinstall

anydischargedeectororguardthatmighthave
beenremovedtoinstallthegrasscatcher.Donot
operatethemowerwithouteithertheentiregrass
catcherorthegrassdeectorinplace.

•Stoptheenginebeforeremovingthegrasscatcher

oruncloggingthechute.

•Donotleavegrassingrasscatcherforextended

periodsoftime.

•Grasscatchercomponentsaresubjecttowear,

damageanddeterioration,whichcouldexpose
movingpartsorallowobjectstobethrown.
Frequentlycheckcomponentsandreplace

3

withmanufacturer'srecommendedparts,when
necessary.

SafetyandInstructionalDecals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyarea
ofpotentialdanger.Replaceanydecalthatisdamagedorlost.

1-653554

decal1-653554

decal106-3339

106-3339

decal1-653558

1-653558

decal98-5954

98-5954

decal103-3507

103-3507

4

Setup

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

ProcedureDescription

1

2

3

4

5

6

7

8

9

10

11

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)
Clevis-pinspring
Locknut(3/8inch)

Nopartsrequired

Baggerassembly1
Clevispin
Hairpincotter2

Blowerbelt(fromtheBlowerandDrive
Kit)

Blowerassembly(fromtheBlowerand
DriveKit)

Spring(fromtheBlowerandDriveKit)

Uppertube1

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

Beltcover(fromtheBlowerandDrive
Kit)

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

only)

Qty.

–

2

14

2

14
14

3
1
3

–

2

1

1

1

3
3
3

1Installthebeltcover.

2

4
4

2

Preparethemower.

Installthebaggermountingbracket.

Installthehandleassembly .

Tightenallmountingbolts.

Installthebaggerassembly .

Routetheblowerbeltintotheblower
assembly.

Installtheblowerassembly .

Sizetheuppertubefor152cm(60inch)
mowerswithgasengines.

Installthedischargetubes.

Installtheweights.

Use

12
13

Nopartsrequired

Nopartsrequired

5

–

–

Adjusttheparkingbrake.

Checkthetirepressure.

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

1

PreparingtheMower

NoPartsRequired

Procedure

Performthefollowingproceduretopreparethemower
forattachingtheblowerandnishingkit.

1.DisengagethePTO,movethemotion-control
leverstotheNEUTRAL-LOCKEDpositionandset
theparkingbrake.

2.Stoptheengine,removethekey ,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition.

3.Repairallbentordamagedareasofmower
deckandreplaceanymissingparts.

4.Cleanthemowerofanydebrisonthedeckor
rearpartofthemowertoeaseinstallation.

2

InstallingtheBagger
MountingBracket

Partsneededforthisprocedure:

1Baggermountingbracket

2Baggersideplate

2

Spacer

14

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

2

Bolt(3/8x1inch)(forZ593mowersonly)

14

Flangenut(3/8inch)

14

Curvedwasher

Procedure

Important:Donottightenanyboltsuntilboth

sidebracketsandbaggermountingbracketaret
looseonthemachine.

RefertoTighteningtheMountingBoltsforthe
correctproceduretotightenthebolts.

1.Removethebolts,nuts,andwashersholding
therollbartoonesideofthemachine.Discard
thenuts,bolts,andwashers(Figure4,Figure

5,andFigure6).

2.Installthebaggersideplateandtherollbar
sectiontothesideofthemachineusing4bolts
(3/8x1-1/2inches),4curvedwashers(3/8
inch),and4angenuts(3/8inch)(Figure4,

Figure5,andFigure6).

3.Repeatthestepsabovefortheoppositeside
(Figure4,Figure5,andFigure6).

Note:Makesurethecurvedwashersare

installedasshowninFigure4,Figure5,and

Figure6.

4.Installthebaggermountingbrackettotheleft
andrightsidebaggerbracketswith4bolts(3/8
x1-1/2inches),4curvedwashers(3/8inch),
and4angenuts(3/8inch)(Figure4,Figure

5,andFigure6).

5.Installthebaggermountingbrackettothe
rearframeofthemachinewith2bolts(3/8x
1-1/2inches)(use2bolts(3/8x1inch)for
Z593mowersasshowninFigure5),2curved
washers(3/8inch),and2angenuts(3/8inch)
(Figure4,Figure5,andFigure6).

6

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.Holestousewhen
installingthesidebracket

g003379

g003380

ForKubotaDieselMowers

1.Bolt(3/8x1inch)

2.Curvedwasher(3/8inch)

3.Baggermountingbracket

Figure5

6.Baggersideplate

7.ROPS

8.Flangenut(3/8inch)

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

5.Spacer

10.Holestousewhen
installingthesidebracket

7

Figure6

ForDaihatsuDieselMowers

3

InstallingtheHandle
Assembly

Partsneededforthisprocedure:

1Handleassembly

2Washer

3

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

1

Clevis-pinspring

3

Locknut(3/8inch)

Procedure

1.Positionthehandleassemblybetweenthe
ROPSrollbarandthebaggermountingbracket
(Figure8).

2.Installthehandleassemblytothebagger
mountingbracketandthemachinewith3bolts

g003378

(3/8x1-1/4inches)and3locknuts(3/8inch)
(Figure7andFigure8).

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.Holestousewhen
installingthesidebracket

1.Handleassembly

2.Washer

g008105

Figure7

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

4.Nut(3/8inch)

8

Figure9

g007701

Figure8

1.Handleassembly

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

3.Washer

3.Installthebaggerarmlinkagetothebagger
assemblywithaclevispinspring(Figure9).

4.Nut(3/8inch)

5.Thisboltisnotusedon
Kubotapoweredmachines

1.Baggerarmlink

2.Baggerassembly

3.Clevispinspring

4

TighteningallMounting
Bolts

g007703

NoPartsRequired

Procedure

Thefollowingstepsarethecorrectsequenceto
tightenthesidebracketsandthebaggermounting
bracket.Allmountingboltsneedtobetorquedto48
N⋅m(35ft-lb).

1.Tightenthebaggermountingbrackettotherear
framerst.

2.TightentheROPSandsidebracketstotheside
ofthemower.

3.Ifthebaggermountingbracketmovessideto
sidean1/8inchormore,installoneorboth
ofthespacersbetweenthebaggermounting
bracketandmountingplates(Figure4,Figure

5,andFigure6).

4.Tightenthebaggermountingbrackettotheside
brackets.

9

5

6

InstallingtheBagger
Assembly

Partsneededforthisprocedure:

1Baggerassembly

2

Clevispin

2Hairpincotter

Procedure

1.Installthebaggerassemblyontothebagger
mountingbracket(Figure10).

2.Installthe2clevispinsintothebaggerassembly
andbaggermountingbracket.Secureitwith2
hairpincotters(Figure10).

RoutingtheBlowerBelt
intotheBlowerAssembly

Partsneededforthisprocedure:

1

Blowerbelt(fromtheBlowerandDriveKit)

Procedure

1.Installthebeltaroundtheblowerpulley(Figure

11).

2.Installthespringtotheidlerarmandthepegon
theblowerassembly(Figure11).

Figure10

1.Hoodassembly3.Hairpincotter

2.Clevispin

4.Baggermountingbracket

g003398

Figure11

1.Idlerpulley4.Peg

2.Mower-deckpulley5.Belt

g007702

3.Spring

6.Blowerpulley

10