Toro 78569 Operator's Manual

FormNo.3373-452RevC

G018353

48in,52in,and60inE-ZVac™
TwinSoftBagger

ZMaster

ModelNo.78569—SerialNo.312000001andUp

®

2000SeriesMower

Registeratwww.T oro.com.
OriginalInstructions(EN)

*3373-452*C

Introduction

G018356

1

g018357

1

Readthisinformationcarefullytolearnhowtooperateand
maintainyourproductproperlyandtoavoidinjuryand
productdamage.Youareresponsibleforoperatingthe
productproperlyandsafely.

YoumaycontactTorodirectlyatwww .Toro.comforproduct
andaccessoryinformation,helpndingadealer,ortoregister
yourproduct.

Wheneveryouneedservice,genuineT oroparts,oradditional
information,contactanAuthorizedServiceDealerorToro
CustomerServiceandhavethemodelandserialnumbers
ofyourproductready .Figure1,andFigure2identifythe
locationofthemodelnumbersandserialnumbersonthe
product.Writethemodelnumberandserialnumberinthe
spaceprovided.

Figure2

1.Baggermodelandserialnumberlocation

ModelNo.

Figure1

1.Blowermodelandserialnumberlocation

SerialNo.

Thismanualidentiespotentialhazardsandhassafety
messagesidentiedbythesafety-alertsymbol(Figure3),

ModelNo.

SerialNo.

whichsignalsahazardthatmaycauseseriousinjuryordeath
ifyoudonotfollowtherecommendedprecautions.

Figure3

1.Safety-alertsymbol

Thismanualuses2wordstohighlightinformation.
Importantcallsattentiontospecialmechanicalinformation
andNoteemphasizesgeneralinformationworthyofspecial
attention.

©2012—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

Contactusatwww.Toro.com.

2

PrintedintheUSA

AllRightsReserved

Contents

Safety

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

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

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

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

2InstallingtheSideBumpersandSupport

Brackets.............................................................6

3InstallingtheTailpipeExtension.............................7

4DrillingtheExhaust-ShieldMounting

Holes.................................................................9

5InstallingtheExhaustShield..................................11

6InstallingtheHopperSupportFrameandHood

Rod...................................................................12

7InstallingtheHoodBafe.....................................13

8InstallingtheHoodAssemblyandBags...................14

9RoutingtheBlowerBeltintotheBlower

Assembly...........................................................16

10InstallingtheBlowerAssembly.............................17

11InstallingtheBeltCover......................................19

12InstallingtheDischargeTube...............................19

13InstallingtheWeights..........................................23

14CheckingtheTirePressure..................................25

Operation....................................................................25

EmptyingtheGrassBags.........................................26

ClearingObstructionsfromtheBagger

System..............................................................26

RemovingtheBagger..............................................26

UsingtheGrassDeector.......................................27

TransportingMachines............................................27

OperatingTips......................................................27

Maintenance.................................................................29

RecommendedMaintenanceSchedule(s)......................29

PreparingforMaintenance.......................................29

CleaningtheHoodScreen.......................................29

CleaningtheBaggerandBags...................................29

InspectingtheBlowerBelt.......................................29

ReplacingtheBlowerBelt........................................29

GreasingtheIdlerArm...........................................30

InspectingtheBagger.............................................30

InspectingtheMowerBlades...................................30

ChoosingtheMowerBlades.....................................30

ReplacingtheGrassDeector..................................30

Storage........................................................................31

Troubleshooting...........................................................32

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,shutofftheenginebeforeleavingtheoperator's
positionforanyreasonincludingemptyingthegrass
catcheroruncloggingthechute.

•Ifyouremovethegrasscatcher,besuretoinstallany

dischargedeectororguardthatmighthavebeen
removedtoinstallthegrasscatcher.Donotoperatethe
mowerwithouteithertheentiregrasscatcherorthegrass
deectorinplace.

•Shutofftheenginebeforeremovingthegrasscatcheror

uncloggingthechute.

•Useastick,notyourhands,toremoveanobstruction

fromtheblowertube.

•Donotleavegrassingrasscatcherforextendedperiods

oftime.

•Grasscatchercomponentsaresubjecttowear,damage

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

3

SafetyandInstructionalDecals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaofpotential
danger.Replaceanydecalthatisdamagedorlost.

1-653558

103–2076

121–3212

1.Warning—readthe

Operator’sManual.

106-0871

2.Warning—wearhearing
protection.

3.Cutting/dismemberment
hazard,impeller—keep
handsawayfrommoving
parts;keepallguardsin
place.

4.Cutting/dismemberment
hazard,
impeller—disengage
thePTO,removethekey
fromtheignition,waitfor
allmovingpartstostop.

5.Thrownobjecthazard—do
notruntheblowerwithout
thecollectionsystem
installedandlatched.

6.Warning;lossof
traction/control
hazard—ultravac
counterbalanceweight(s)
installedwithoutultravac
maycauselossoftraction
andsteeringcontrol;
ultravacinstalledwithout
ultravaccounterbalance
weight(s)willcause
reducedstability;install
theweight(s)onlywhen
ultravacisinstalled.

109–6809

1.Crushinghazardofhand—donotremovethewholebaggerfromthemachine:1.Openthebaggertop.2.Removethebag(s)
fromthebagger.3.Donotremovethebaggertopwhenitisclosed;openthebaggertopandthenremoveit.

4

Setup

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

ProcedureDescription

1

2

3

4

5

6

7

8

9

10

11

12

Nopartsrequired

Leftbumper
Leftframe-supportbracket
Rightbumper1
Rightframe-supportbracket
Carriagebolt(3/8x1-1/4inches)
Flangenut(3/8inch)
Tailpipeextension1
Washer-headscrew(#8x1/2inch,

self-threading)
Exhaustshield1
Flange-hex-headbolt(3/8x1inch)
Nut(3/8inch)
Exhaustshield1
Flange-hex-headbolt(3/8x1inch)
Nut(3/8inch)
Hopper-supportframe
Hairpin2
Hoodhold-downrod1
Baggerhood1
Bafe
Hairpin(small)
Hoodassembly1
Bag2
Blower(fromthebloweranddrivekit)
Blowerbelt(fromthebloweranddrive

kit)
Blowerassembly(fromtheblowerand

drivekit)
Spring(fromthebloweranddrivekit)
Beltcover(fromthebloweranddrivekit)
Coverknob
Upperdischargetube1
Screw(1/4x3/4inch)
Locknut(1/4inch)
Lowerdischargetube1

Qty.

Use

–

1
1

1
6
6

1

2
2

3
3
1

1
2

1

1

1

1
1
1

3
3

Preparethemower.

Installthesidebumpersandsupport
brackets.

Installthemuferextension.

Drilltheexhaust-shieldmountingholes.

Installtheexhaustheatshield.

Installthebaggermountingbrackets.

Installthehoodbafe.

Installthehoodassemblyandbags.

Routetheblowerbeltintotheblower
assembly.

Installtheblowerassembly .

Installthebeltcover.

Installthedischargetubes.

5

ProcedureDescription

13

Weight-mountbracket1
Carriagebolt(5/16x3/4inch)
Flangenut(5/16inch)
Frontweight3
Bolt(3/8x1inch)
Lockwasher6
Flatwasher6
Flangenut(3/8inch)

Qty.

Use

2
2

6

3

Installtheweights.

14

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

1

PreparingtheMower

Nopartsrequired

2

InstallingtheSideBumpers andSupportBrackets

NoPartsRequired

Partsneededforthisprocedure:

Procedure

Performthefollowingproceduretopreparethemowerfor
attachingtheblowerandbaggerkit.

1.DisengagethePTO,movethemotion-controllevers
totheNEUTRALlockedposition,andsettheparking
brake.

2.Shutofftheengine,removethekey ,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Repairallbentordamagedareasofthemowerdeck
andreplaceanymissingparts.

4.Cleanthemowerofanydebrisonthedeckorrearpart
ofthemowertoeaseinstallation.

1

1

1Rightbumper

1

6

6

Procedure

1.Removetheleftandrightbumpersasfollows:

A.Removethenutsandboltssecuringtheleftside

–

Leftbumper

Leftframe-supportbracket

Rightframe-supportbracket

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

Flangenut(3/8inch)

Checkthetirepressure.

bumperandmufershieldtothechassisand
centerengineguardasshowninFigure4.

6

G018358

1

3

5

6

7

8

8

7

8

2

4

Figure4

SideBumperandBracketInstallation

1.Leftsidebumper

2.Centerengineguard6.Rightframe-support

3.Leftframe-supportbracket7.Carriagebolt(3/8x1-1/4

4.Mufershield8.Flangenut(3/8inch)

5.Rightsidebumper

bracket

inches)

F.Aligntheholesfortheleftframe-supportbracket,

leftsidebumperandmuferguardtotheupper
holeinthecenterengineguard(Figure4).

G.Looselysecurethebracket,bumperandmufer

guardtothecenterengineguardattheupperhole
withacarriagebolts(3/8x1-1/4inches)anda
angenut(3/8inch)(Figure4).

H.Alignthefrontholesintheleftsidebumperand

themuferguardwiththeforward-mounting
pointonthechassis.(Figure4).

I.Securethebumperandguardtothemounting

pointwithacarriagebolt(3/8x1-1/4inches)and
aangenut(3/8inch)(Figure4).

J.Tightenthehardwarethatsecuresthebracket,

bumperandmuferguardtothecenterengine
guard.

3.Installthenewrightsidebumperasfollows:

A.Alignthenewrightsidebumperwiththe

forward-mountingpointonthechassisandthe
bumper-mountingpointsonthecenterengine
guard(Figure4).

B.Alignthemountingange(theangewith2

holes)oftherightframe-supportbrackettothe
leftasshowninFigure4.

B.Removetheleftbumperandmufershieldfrom

themachine.

Note:Retainthemufershieldforinstallation
withthenewleftsidebumper.

C.Removethenutsandboltssecuringtherightside

bumpertothechassisandcenterengineguard.

Note:Discardthecarriageboltsandangenuts
thatsecuretheoriginalleftandrightsidebumpers
tothemachine.

2.Installthenewleftsidebumperasfollows:

A.Alignthenewleftsidebumperwiththe

forward-mountingpointonthechassisandthe
bumper-mountingpointsonthecenterengine
guard(Figure4).

B.Alignthemountingange(theangewith2

holes)oftheleftframe-supportbrackettotheleft

C.Aligntheholesoftherightframe-supportbracket

andbackholesoftherightsidebumperwiththe
back,centerengineguard(Figure4).

D.Looselysecurethebracketandbumpertothe

centerengineguardwith2carriagebolts(3/8x
1-1/4inches)and2angenut(3/8inch)(Figure

4).

E.Alignthefrontholeinthenewrightsidebumper

withtheforwardmountingpointonthechassis
(Figure4).

F.Securethebumpertothemountingpointwith

acarriagebolt(3/8x1-1/4inches)andaange
nut(3/8inch)(Figure4).

G.Tightenthehardwarethatsecuresthebracketand

bumpertothecenterengineguard.

asshowninFigure4.

C.Aligntheholesoftheleftframe-supportbracket

andthebackholesoftheleftsidebumperwith
theholesinthecenterengineguard(Figure4).

D.Looselysecurethebracketandbumpertothe

centerengineguardatthelowerholewitha
carriagebolt(3/8x1-1/4inches)andaangenut
(3/8inch)(Figure4).

E.Positionthemuferheatshieldwiththemounting

angesinsidetheleftsidebumper(Figure4).

7

3

4

3

5

3

62

4

3

3

5

61

G018372

InstallingtheTailpipe
Extension

Partsneededforthisprocedure:

1Tailpipeextension

1

Washer-headscrew(#8x1/2inch,self-threading)

Procedure

Installthetailpipeextensionasfollows:

1.Locatethemufertailpipeatthelowerleftcornerof
theengine.

Note:Ifyouneedadditionalroomtoinstallthe
tailpipeextension,dothefollowingsteps:

A.Removethe3angenutsthatsecurelower-left

engineguardtothemachine(Figure5).

Note:Retaintheseparts.

Figure5

1.Lower-leftengineguard
(USdomesticmowers)

2.Lower-leftengineguard
(Internationalmowers)

3.Carriagebolt(frontmount
point)

Lower-LeftEngineGuard

4.Flangenut

5.Carriagebolt(center
engineguard)

6.Mufertailpipe

B.Removethe2carriageboltsatthefront-mount

2.Measure19mm(3/4inch)alongtheoutsideofthe

pointandthelower-leftengineguard.(Figure5).

Note:Retaintheseparts.Donotremovethe
carriageboltatthecenterengineguard.

mufertailpipe,fromtheoutletendmovingtowardthe
muferasillustratedinFigure6,andmarkthesurface
ofthetailpipeatthismeasurement.

8

G018366

1

2

3

4

3

4

1

8.Securethetailpipeextensionwiththeself-threading
screw(#8x1/2inch)(Figure6).

Note:Dothefollowingstepstoinstalltheengine
guardifremovedinstep1:

A.Aligntheholesintheguardwithbacksideofthe

front-mountingpointandthecenterengineguard
(Figure5).

B.Looselysecurethelowerengineguardtothe

carriageboltatthecenterengineguardwithone
ofthepreviouslyretainedangenuts(Figure5).

C.Securethelowerengineguardtothefront

mountingpointwiththepreviouslyretained
carriageboltsandangenuts(Figure5).

D.Tightenallthemountinghardwaretosecurethe

lower-leftengineguard.

4

DrillingtheExhaust-Shield

Figure6

TailpipeExtensionInstallation

1.Mufertailpipe

2.3/4inch(19mm)4.Washerheadscrew(#8x

3.Slipthepre-drilledendofthetailpipeextensionover
themufertailpipe,andaligntheendoftheextension
withthemarkcreatedinstep2.Rotatethetailpipe
extensionuntilthepre-drilledholeintheextensionis
alignedoutwardandhorizontal(Figure6).

4.Marktheoutlineoftheholeinthetailpipeextension
ontothemufertailpipe,andremovethetailpipe
extension.

5.Locatethecenterofthemarkonthemufertailpipe
surface,andcenter-punchthelocation.

6.Drilla1.5mm(1/16inch)holeinthemufertailpipe
atthecenter-punchmark.

7.Slipthetailpipeextensiononthemufertailpipeand
aligntheholes.

3.Tailpipeextension

1/2inch,self-threading)

MountingHoles

Partsneededforthisprocedure:

1Exhaustshield

2

Flange-hex-headbolt(3/8x1inch)

2

Nut(3/8inch)

Procedure

Note:Iftheexhaust-shieldmountingholesarepresentin

thelower-leftengineguard,skiptotheinstructionsinsection

5InstallingtheExhaustShield(page11).

Note:Installthetailpipeextensionandthelower-leftengine
guardbeforeinstallingtheexhaust-heatshield.

Drilltheholesinthelower-leftbumperholesfortheexhaust
shieldasfollows:

1.Locatethemufertailpipeandtailpipeextensionatthe
left-rearcorneroftheengine,andlocatethelower-left
engineguard.

2.Aligntheexhaustshieldtothelower-leftengineguard
asfollows:

A.Centerthearchedpartoftheshieldtothetailpipe

extension.

B.Locateandmarktheheat-shieldmountingholes

asfollows:

•ForDomestic(US)Mowers

9

i.Aligntherightangeoftheexhaust

G018637

G018638

1

shield(theangewith2holes)tothe
rearsurfaceofthelower-leftengine
guard(Figure7).

tothetwoleft-most-verticalslotsin
thelower-leftengineguard(Figure8).

Figure7

HeatShieldInstallationonUSDomesticMower

ii.Alignthebottomedgeofthe

exhaust-shieldrightangetothe
bottomedgeoftheengineguard
(Figure7).

iii.Aligntheleftangeoftheexhaust

shield(theangewith1hole)tothe
surfaceofthesmall,angularareaof
thelower-leftengineguard.(Figure7).

Note:Ensuretheleftange(the
angewith1hole)oftheexhaust
shieldisushwiththeengine-guard
surface.

iv .Alignthetopedgeofthe

exhaust-shieldleftangeand
thetopedgeofthelower-leftengine
guardsothattheangeedgeandthe
guardedgeareparallel(Figure7).

v.Marktheoutlineofallholesinthe

exhaust-shieldangesontothe
lower-leftengineguard,andremove
theexhaustshieldfromtheengine
guard.

•ForInternational(TE)Mowers

i.Aligntheholesoftheexhaust-shield

rightange(theangewith2holes)

Figure8

HeatShieldInstallationonInternational(TE)Mower

1.Flange-hex-headbolt(3/8x1inch)andNut(3/8inch)

ii.Alignthebottomedgeoftheright

angeoftheoftheexhaustshieldto
thebottomedgeoftheengineguard
(Figure8).

iii.Looselysecuretherightangeofthe

exhaustshieldtotheengineguard
with2ange-hex-headbolts(3/8x1
inch)and2angenuts(3/8inch).

iv .Aligntheleftangeoftheexhaust

shield(theangewith1hole)to
angularareaofthelower-leftengine
guard(Figure8).

Note:Ensurethattheleftange
(theangewith1hole)oftheexhaust
shieldisushwiththeengine-guard
surface.

v.Marktheoutlineoftheholeintheleft

angeoftheexhaustshieldontothe
lower-leftengineguard.

vi.Removethefastenersandexhaust

shieldfromtheengineguard.

3.Locatethecenterofthemarksonthelower-left
engine-guardsurface,andcenter-punchthelocations.

4.Drilla10mm(3/8inch)holeintheengineguardat
thecenter-punchmarkcreatedinstep3.

10