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8

Sizing the Upper Tube for
152 cm (60 inch) Mowers
with Gas Engines

Parts needed for this procedure:

1

Upper tube

Procedure

Note:

This procedure is for 152 cm (60 inch) mowers

with gas engines only.

1.

Measure up 89 mm (3-1/2 inches) from the
bottom of the upper tube. Use the existing 3
holes as marks and then mark it in several
places to create a line around the tube (

Figure

18

).

2.

Cut the 89 mm (3-1/2 inches) off the upper tube
(

Figure 18

).

Note:

Notice the three indentations in the tube.

This is where holes will be drilled in the following
procedure.

g003391

Figure 18

1.

Indentations for drilling
holes

4.

Use the existing holes to
create a line

2.

Upper tube

5.

Line to cut tube

3.

Cut off 89 mm (3-1/2
inches) for 152 cm (60
inch) mowers with gas
engines only

9

Installing the Discharge
Tubes

Parts needed for this procedure:

1

Upper tube

1

Lower tube

3

Bolt (#10 x 3/4 inches)

3

Locknut (#10)

3

Washer (7/32 inch)

Procedure

Important:

Make sure that the mower deck is in

the lowest height-of-cut position while installing
the discharge tubes.

13

 

Summary of Contents for Z Master Z500 Series

Page 1: ...Rev A 60in and 72in DFS E Z Vac Collection System Z500 Series Z Master Mowers Model No 78544 Serial No 280000001 and Up Model No 78545 Serial No 280000001 and Up Register at www Toro com Original Instructions EN 3440 329 A ...

Page 2: ...tion Model No Serial No This manual identifies potential hazards and has safety messages identified by the safety alert symbol Figure 3 which signals a hazard that may cause serious injury or death if you do not follow the recommended precautions g000502 Figure 3 1 Safety alert symbol This manual uses 2 words to highlight information Important calls attention to special mechanical information and ...

Page 3: ...turn the machine Slow down and use extra care on hillsides Be sure to travel in the recommended direction on hillsides Turf conditions can affect the machine s stability Use extreme caution while operating near drop offs Refer to the traction unit Operator s Manual for operation near slopes and drop offs Keep all movement on slopes slow and gradual Do not make sudden changes in speed directions or...

Page 4: ...Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger Replace any decal that is damaged or lost decal1 653554 1 653554 decal1 653558 1 653558 decal98 5954 98 5954 decal103 3507 103 3507 decal106 3339 106 3339 4 ...

Page 5: ... Hairpin cotter 2 Install the bagger assembly 6 Blower belt from the Blower and Drive Kit 1 Route the blower belt into the blower assembly Blower assembly from the Blower and Drive Kit 1 7 Spring from the Blower and Drive Kit 1 Install the blower assembly 8 Upper tube 1 Size the upper tube for 152 cm 60 inch mowers with gas engines Upper tube 1 Lower tube 1 Bolt 10 x 3 4 inches 3 Locknut 10 3 9 Wa...

Page 6: ... brackets and bagger mounting bracket are fit loose on the machine Refer to Tightening the Mounting Bolts for the correct procedure to tighten the bolts 1 Remove the bolts nuts and washers holding the roll bar to one side of the machine Discard the nuts bolts and washers Figure 4 Figure 5 and Figure 6 2 Install the bagger side plate and the roll bar section to the side of the machine using 4 bolts...

Page 7: ...ide plate 4 Spacer 9 Holes to use when installing the side bracket 5 Bagger side plate g003379 Figure 5 For Kubota Diesel Mowers 1 Bolt 3 8 x 1 inch 6 Bagger side plate 2 Curved washer 3 8 inch 7 ROPS 3 Bagger mounting bracket 8 Flange nut 3 8 inch 4 Bolt 3 8 x 1 1 2 inches 9 Side view of bagger side plate 5 Spacer 10 Holes to use when installing the side bracket 7 ...

Page 8: ...e Assembly Parts needed for this procedure 1 Handle assembly 2 Washer 3 Bolt 3 8 x 1 1 4 inches 1 Clevis pin spring 3 Locknut 3 8 inch Procedure 1 Position the handle assembly between the ROPS roll bar and the bagger mounting bracket Figure 8 2 Install the handle assembly to the bagger mounting bracket and the machine with 3 bolts 3 8 x 1 1 4 inches and 3 locknuts 3 8 inch Figure 7 and Figure 8 g0...

Page 9: ...Procedure The following steps are the correct sequence to tighten the side brackets and the bagger mounting bracket All mounting bolts need to be torqued to 48 N m 35 ft lb 1 Tighten the bagger mounting bracket to the rear frame first 2 Tighten the ROPS and side brackets to the side of the mower 3 If the bagger mounting bracket moves side to side an 1 8 inch or more install one or both of the spac...

Page 10: ...ith 2 hairpin cotters Figure 10 g007702 Figure 10 1 Hood assembly 3 Hairpin cotter 2 Clevis pin 4 Bagger mounting bracket 6 Routing the Blower Belt into the Blower Assembly Parts needed for this procedure 1 Blower belt from the Blower and Drive Kit Procedure 1 Install the belt around the blower pulley Figure 11 2 Install the spring to the idler arm and the peg on the blower assembly Figure 11 g003...

Page 11: ...atcher Make sure that the grass deflector is installed when you remove the grass chute and catcher 1 Remove the side discharge chute from the mower deck Figure 12 g002519 Figure 12 1 Bolt 5 Spring installed 2 Spacer 6 Grass deflector 3 Locknut 7 L end of spring Place it behind the deck edge before installing the bolt 4 Spring 8 J hook end of the spring 2 Slide the blower assembly peg into the pivo...

Page 12: ... be released by hand Figure 15 g003400 Figure 15 1 Latch 3 Blower assembly 2 Bolt 4 Install the spring as shown in Figure 16 Note Make sure that the hooks are in the correct position g003638 Figure 16 1 Spring loaded idler pulley 3 Long hook end 2 Short hook end 5 Pull the spring loaded idler pulley back and route the belt around the mower deck pulley Figure 17 Note Ensure that the belt is routed ...

Page 13: ...upper tube Figure 18 Note Notice the three indentations in the tube This is where holes will be drilled in the following procedure g003391 Figure 18 1 Indentations for drilling holes 4 Use the existing holes to create a line 2 Upper tube 5 Line to cut tube 3 Cut off 89 mm 3 1 2 inches for 152 cm 60 inch mowers with gas engines only 9 Installing the Discharge Tubes Parts needed for this procedure 1...

Page 14: ...opening 5 Measure the distance the tube is inside the hood Note Measure from the hood plate to the edge of the tube as shown in Figure 20 This distance needs to be 19 mm 3 4 inch g003388 Figure 20 1 Hood plate 4 19 mm 3 4 inch 2 Upper tube 5 Edge of tube 3 Hood in the down position 6 Once the 19 mm 3 4 inch measurement has been achieved mark the upper tube on the outside where the rubber seal prot...

Page 15: ... Figure 23 Note There is a latch on the top and bottom of the blower housing g003423 Figure 23 1 Blower assembly 3 Latch 2 Lower tube 9 Make sure that the mower deck is in the lowest height of cut position and the mark on the upper tube is still positioned against the protruding rubber seal Check to make sure that the mark from Figure 21 is still in place 15 ...

Page 16: ...with 3 bolts 10 x 3 4 inches 3 flat washers 7 32 inch and 3 locknuts 10 as shown in Figure 25 g003392 Figure 25 1 Lower tube 4 Locknut 10 2 Upper tube 5 Bolt 10 x 3 4 inches 3 Flat washer 7 32 inch 13 Install the lower tube onto the blower housing and secure it with the latches 10 Installing the Belt Cover Parts needed for this procedure 1 Belt cover from the Blower and Drive Kit Procedure 1 Lower...

Page 17: ... cause an unstable condition which could result in a loss of control 1 Place caster weights on the front casters 2 Install plate nuts 1 2 inch and lock washer 1 2 inch under the frame and weight Figure 27 3 Repeat for opposite side Note All Z Master mowers receive the caster weights g001366 Figure 27 1 Front caster weight 4 Nut 2 U bolt 5 Front caster 3 Plate 6 Lock washer Note Only Z Master mower...

Page 18: ...wo nuts together and repeat on opposite side of unit 4 Turn nuts clockwise to shorten spring length and turn counter clockwise to lengthen the spring 5 Engage parking brake lever up 6 Measure the distance between the trunnion roller and the collar on brake rod The measurement should be 5 7 mm 3 16 1 4 inch Figure 29 7 If adjustment is necessary loosen the jam nut directly below the yoke Turn the b...

Page 19: ...ll cause injury or death Always install the grass deflector when you remove the collection system and change to side discharge mode If the grass deflector is ever damaged replace it immediately The grass deflector routes material down toward the turf Never put your hands or feet under the mower Never try to clear the discharge area or mower blades unless you move the power take off PTO to off and ...

Page 20: ...tion from the tube assembly Note In most cases the debris can be shaken out of the tubes 7 If the blower assembly is plugged unlatch the blower assembly remove the belt and swing it open 8 Use a stick or similar object not your hands to remove and clear the obstruction from the blower assembly 9 After you remove the obstruction install the complete collection system and resume operation Removing t...

Page 21: ...whichever is less Cutting off more than this will reduce the capacity of the vacuum system Cutting Frequency Cut the grass often especially when it grows rapidly You need to cut your grass twice if it gets excessively long refer to Bagging Long Grass page 21 Cutting Technique For best lawn appearance be sure to slightly overlap the mower into the previously cut area This helps reduce the load on t...

Page 22: ...commended for bagging leaves in dry conditions In dry dusty conditions the medium lift or low lift blades reduces dust and dirt blowout while providing effective bagging air flow Contact an Authorized Service Dealer for the proper blades for different mowing conditions Curb Climbing and Loading Always lift the deck to the highest position when loading the machine on trailers or ascending descendin...

Page 23: ...side of the bagger hood tube and the underside of the mower Use a mild automotive detergent to remove dirt 2 Make sure you remove matted grass from all parts 3 After washing all parts let them dry thoroughly Note With all parts installed start and run the machine for a minute to assist in drying Inspecting the Blower Belt Service Interval After the first 8 hours Every 25 hours Check the belts for ...

Page 24: ... blower assembly to see if the latches are adjusted correctly Loosen or tighten the bolts so the latches firmly hold the blower assembly against the mower deck but can be released by hand g003400 Figure 35 1 Latch 3 Blower assembly 2 Bolt Greasing the Idler Arm and Handle Pivot Service Interval Every 50 hours Grease the idler arm Every 100 hours Grease the handle pivot Grease the blower belt idler...

Page 25: ... closed loosen the nuts and adjust the stop bolts so that the contact arm is straight up and down Figure 38 and Figure 39 4 Adjust the length of the hinge links to so that the door completely closes and reasonable force is on the handle Figure 38 and Figure 39 Note Lengthen the links to reduce the force Shorten the links to increase the force Note Make sure that both the left and right sides are a...

Page 26: ...le g008027 Figure 41 1 Latch link 2 Latch rod Inspecting the Mower Blades 1 Inspect the mower blades regularly and whenever a blade strikes a foreign object 2 If blades are badly worn or damaged install new blades Refer to your mower Operator s Manual for complete blade maintenance Installing the Mower Blades In most mowing conditions the standard high lift blades will provide the best bagging per...

Page 27: ...r worn grass deflector 3 Place the spacer and spring onto the grass deflector Note Place the L end of the spring behind the deck edge Note Make sure that the L end of the spring is installed behind the deck edge before installing the bolt as shown in Figure 42 4 Install the bolt and nut 5 Place the J hook end of the spring around the grass deflector Figure 42 Important The grass deflector must be ...

Page 28: ...efer to Inspecting the Collection System page 25 3 Make sure that the bagger is empty and thoroughly dry 4 Check the belt for wear or cracks 5 Store the machine in a clean dry place out of direct sunlight If you must store the machine outside cover it with a weatherproof cover This protects the plastic parts and extends the life of the machine 28 ...

Page 29: ...Empty the bagger 1 The bagger is too full 1 Dump the bagger more frequently 2 The engine speed is low 2 Always operate the collection system at full throttle 3 Grass is too wet 3 Cut grass when it is dry 4 Grass is too long 4 Cut no more than 51 76 mm 2 3 inches or 1 3 of the grass height whichever is less 5 The screen in the bagger hood is plugged 5 Remove debris leaves or grass clippings from th...

Page 30: ...Notes ...

Page 31: ...Notes ...

Page 32: ... the Service Dealer s analysis or with the assistance provided contact us at RLC Customer Care Department Toro Warranty Company 8111 Lyndale Avenue South Bloomington MN 55420 1196 888 865 5676 U S Customers 888 865 5691 Canada customers Owner Responsibilities You must maintain your Toro Product by following the maintenance procedures described in the Operator s Manual Such routine maintenance whet...

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