Toro 48in and 52in E-Z Vac DFS Collection System, Z Master G3 Mower User manual

CV

FormNo.3438-500RevA

48in,52in,60in,or72inE-ZVac

™

DFSCollectionSystem

ZMaster

®

G3Mower

ModelNo.78556—SerialNo.400000000andUp

ModelNo.78566—SerialNo.405700000andUp

ModelNo.78567—SerialNo.405700000andUp

Registeratwww.Toro.com.

OriginalInstructions(EN)

*3438-500*A

Introduction

Readthisinformationcarefullytolearnhowtooperate

andmaintainyourproductproperlyandtoavoid

injuryandproductdamage.Youareresponsiblefor

operatingtheproductproperlyandsafely.

YoumaycontactT orodirectlyatwww.T oro.com

forproductsafetyandoperationtrainingmaterials,

accessoryinformation,helpndingadealer,orto

registeryourproduct.

Wheneveryouneedservice,genuineToroparts,or

additionalinformation,contactanAuthorizedService

DealerorT oroCustomerServiceandhavethemodel

andserialnumbersofyourproductready.Figure1,

Figure2andFigure3identiesthelocationofthe

modelandserialnumbersontheproduct.Writethe

numbersinthespaceprovided.

g003368

Figure1

1.Collectionsystemmodelandserialnumberlocation

ModelNo.

SerialNo.

g009233

Figure2

48-and52-inchbaggerserialnumber

1.Baggermodelandserialnumberlocation

g009213

Figure3

60-and72-inchbaggerserialnumber

1.Baggermodelandserialnumberlocation

ModelNo.

SerialNo.

Thismanualidentiespotentialhazardsandhas

safetymessagesidentiedbythesafetyalertsymbol

(Figure4),whichsignalsahazardthatmaycause

seriousinjuryordeathifyoudonotfollowthe

recommendedprecautions.

g000502

Figure4

1.Safetyalertsymbol

Thismanualuses2wordstohighlightinformation.

Importantcallsattentiontospecialmechanical

informationandNoteemphasizesgeneralinformation

worthyofspecialattention.

8111LyndaleAvenueSouth

Bloomington,MN55420

2

Contactusatwww.Toro.com.

PrintedintheUSA

AllRightsReserved

Contents

Safety.......................................................................4

TowingSafety.....................................................4

SafetyandInstructionalDecals..........................5

Setup........................................................................8

1PreparingtheMower......................................10

2InstallingtheSideBumpers............................10

3InstallingtheBaggerMounting

Brackets........................................................10

4InstallingtheHandleAssemblyand

Bracket..........................................................11

5InstallingtheHandleAssemblyandBracket

for48-and52-inchMowers...........................12

6InstallingtheBaggerAssembly......................12

7InstallingtheMuferDeector........................14

8RoutingtheBlowerBeltintotheBlower

Assembly......................................................14

9InstallingtheBlowerAssembly.......................16

10InstallingtheDischargeTubes.....................18

11InstallingtheBeltCover................................22

12InstallingtheWeights...................................22

13InstallingtheBumpers.................................24

14AdjustingtheParkingBrake.........................25

15CheckingtheTirePressure..........................26

Operation................................................................26

AdjustingtheBafe...........................................27

EmptyingtheBagger........................................28

ClearingObstructionsfromtheCollection

System..........................................................28

RemovingtheBagger.......................................28

UsingtheGrassDeector.................................29

TransportingMachines.....................................29

OperatingTips.................................................29

Maintenance...........................................................31

RecommendedMaintenanceSchedule(s)...........31

CleaningtheBaggerScreen.............................31

CleaningtheCollectionSystem........................31

InspectingtheBlowerBelt................................32

ReplacingtheBlowerBeltfor60-and72-inch

Mowers.........................................................32

ReplacingtheBlowerBeltfor48-and52-inch

Mowers.........................................................32

CheckingandAdjustingtheBlower

Latch.............................................................33

GreasingtheIdlerArmandHandle

Pivot..............................................................33

InspectingtheCollectionSystem......................34

AdjustingtheClosedDoorfor60-and72-inch

Mowers.........................................................34

AdjustingtheOpenDoorfor60-and72-inch

Mowers.........................................................35

AdjustingtheLatchesfor60-and72-inch

Mowers.........................................................35

AdjustingtheArmPositionfor48-and

52-inchMowers.............................................35

AdjustingtheClosedDoorfor48-and52-inch

Mowers.........................................................36

AdjustingtheOpenDoorfor48-and52-inch

Mowers.........................................................37

AdjustingtheParkingBrake..............................39

InspectingtheMowerBlades............................39

InstallingtheMowerBlades..............................39

InstallingtheGrassDeector............................39

Storage...................................................................40

Troubleshooting......................................................41

3

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.Turfconditionscanaffectthestabilityof

themachine.Useextremecautionwhileoperating

neardrop-offs.

•Keepallmovementonslopesslowandgradual.

Donotmakesuddenchangesinspeed,direction,

orturning.

•Thegrasscatchercanobstructtheviewtothe

rear.Useextracarewhenoperatinginreverse.

•Usecarewhenloadingorunloadingthemachine

intoatrailerortruck.

•Neveroperatewiththedischargedeectorraised,

removedoraltered,unlessusingagrasscatcher.

•Keephandsandfeetawayfrommovingparts.Do

notmakeadjustmentswiththeenginerunning.

•Parkthemachineonlevelground,disengage

thedrives,chockthewheels,andshutoffthe

enginebeforeleavingtheoperator'spositionfor

anyreasonincludingemptyingthegrasscatcher

oruncloggingthechute.

•Ifyouremovethegrasscatcher,besuretoinstall

anydischargedeectororguardthatmighthave

beenremovedtoinstallthegrasscatcher.Donot

operatethemowerwithouteithertheentiregrass

catcherorthegrassdeectorinplace.

•Shutofftheenginebeforeremovingthegrass

catcheroruncloggingthechute.

•Donotleavegrassinthegrasscatcherfor

extendedperiodsoftime.

•Grasscatchercomponentsaresubjecttowear,

damageanddeterioration,whichcouldexpose

youtomovingpartsorallowobjectstobethrown.

Frequentlycheckcomponentsandreplacewith

themanufacturer'srecommendedparts,when

necessary.

TowingSafety

•Donotattachtowedequipmentexceptatthehitch

point.

•Followtheattachmentmanufacturer's

recommendationforweightlimitsfortowed

equipmentandtowingonslopes.

•Neverallowchildrenorothersinorontowed

equipment.

•Onslopes,theweightofthetowedequipmentmay

causelossoftractionandlossofcontrol.Reduce

towedweightandslowdown.

•Stoppingdistanceincreaseswiththeweightofthe

towedload.Travelslowlyandallowextradistance

tostop.

•Makewideturnstokeeptheattachmentclearof

themachine.

•Donottowaloadthatweighsmorethanthe

towingmachine.

4

SafetyandInstructionalDecals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyarea

ofpotentialdanger.Replaceanydecalthatisdamagedorlost.

decal1-653554

1-653554

decal1-653558

1-653558

decal98-5954

98-5954

decal106-5517

106-5517

1.Warning–Donottouchthehotsurface.

decal106-0871

106-0871

decal106-3339

106-3339

decal126-4659

126-4659

1.Warning—hotpulley;allowtocool.

decal126-9451

126-9451

1.Thrownobjectshazard—Donotruntheblowerwithoutthe

entirecollectionsysteminstalledandlatched.

2.Warning–ReadtheOperator’smanualaboutcounterbalance

weightinstallation.

3.Lossoftractionandsteeringorreducedstabilityhazard–Ez

Vaccounterbalanceweight(s)installedwithouttheEzVac

maycauselossoftractionandsteeringcontrol.TheEzVac

installedwithouttheEzVaccounterbalanceweight(s)can

causereducedstability.Installweight(s)onlywhentheEz

Vacisinstalled.

5

decal126-9595

126-9595

1.Rotationindicator

2.Impeller/RotatingBladeshazard-Keephandsawayfrom

movingparts.Keepallsafetydevicesinplaceandworking.

Donotreachintotheblowerunlesstherotationindicator

hasstopped.DisengagethePTO,shutofftheengine,

removethekey,andwaitforallmovingpartstostop.

decal133-8061

133-8061

decal136-4164

136-4164

1.Warning—readtheOperator’sManual.4.Cutting/dismembermenthazard,impeller—keepawayfrom

movingparts;keepallguardsandcoversinplace.

2.Warning—hearingprotectionmustbeworn.

5.Cutting/dismembermenthazard,impeller—disengagethe

PTO,removethekey,andwaitforallmovingpartstostop.

3.Thrownobjecthazard—donotoperatetheblowerwithoutthe

entiresysteminstalledandlatched.

6.Warning;lossoftraction—donotoperatewithonly

counterbalanceweightsinstalled;donotoperatewithonly

E-ZVacinstalled;operateonlywithbothE-ZVacand

counterbalanceweightsinstalled.

6

decal103-3508

103-3508

48-inchand52-inchdecksonly

decal109-5890

109-5890

60-inchand72-inchdecksonly

7

Setup

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

ProcedureDescription

Qty.

Use

1

Nopartsrequired

–

Preparethemower.

Leftbumper

1

Rightbumper1

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

2

Flangenut(largeange–3/8inch)

6

Installthesidebumpers.

Uppermountingbracket1

Lowermountingbracket1

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

4

Carriagebolt(1/2x2–1/2inches)

2

Flangenut(largeange–3/8inch)

4

3

Flangenut(1/2inch)

2

Installthebaggermountingbrackets.

Handleassembly1

Handlebracket1

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

4

Clevis-pinspring

1

4

Flangenut(largeange–3/8inch)

4

Installthehandleassembly(for60-and

72-inchmowers).

Hoodassembly1

Knob1

5

Carriagebolt

1

Installthehoodassembly.

Baggerassembly1

6

Pinandhairpincotterassembly2

Installthebaggerassembly.

Muferdeector

1

Flangenut(smallange–3/8inch)

2

7

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

2

Installthemuferdeector.

8

Blowerbelt(fromtheBlowerandDrive

Kit)

1

Routetheblowerbeltintotheblower

assembly.

Blowerassembly(fromtheBlowerand

DriveKit)

1

9

Spring(fromtheBlowerandDriveKit)

1

Installtheblowerassembly.

Uppertube1

Lowertube1

Bolt(#10x3/4inches)

3

Locknut(#10)

3

10

Washer(7/32inch)

3

Installthedischargetubes.

11

Beltcover(fromtheBlowerandDrive

Kit)

1Installthebeltcover.

8

ProcedureDescription

Qty.

Use

Casterweight(ifneeded)

2

Clevispin

2

Hairpincotter2

Lockwasher(3/8inch)

6

Weight-mountbracket1

Bolt(3/8x1inch)

6

Flatwasher(3/8inch)

6

Flangenut(smallange–3/8inch)

3

Carriagebolt(5/16x3/4inch)

2

Flangenut(5/16inch)

2

Frontweight(48-inch,52-inch,and

60-inchdecks)

3

Frontweight[72-inchdecks(serial

number406294344andbelow)]

1

Frontweight[72-inchdecks(serial

number406294345andabove)]

2

Tapbolt(3/8x1-3/4inches)

2

12

Nut(3/8inch)

2

Installtheweights.

Bumper2

Spacer

2

13

Locknut(5/16inch)

2

Installthebumpers(formachineswith

MyRide™suspensionsystem).

14

Nopartsrequired

–

Adjusttheparkingbrake.

15

Nopartsrequired

–

Checkthetirepressure.

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

9

1

PreparingtheMower

NoPartsRequired

Procedure

Performthefollowingproceduretopreparethemower

forattachingtheblowerandnishingkit.

1.DisengagethePTO,movethemotion-control

leverstotheNEUTRAL-LOCKEDpositionand

engagetheparkingbrake.

2.Shutofftheengine,removethekey,andwait

forallmovingpartstostopbeforeleavingthe

operatingposition.

3.Pullthesparkplugwires.

4.Repairallbentordamagedareasofmower

deckandreplaceanymissingparts.

5.Cleanthemowerofanydebrisonthedeckor

rearpartofthemowertoeaseinstallation.

2

InstallingtheSideBumpers

Partsneededforthisprocedure:

1

Leftbumper

1Rightbumper

2

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

6

Flangenut(largeange–3/8inch)

Procedure

1.Removethenutsandboltsholdingtheside

bumperstothemachine(Figure5).

Note:Discardallnutsandonlythe1bolt

removedfromeachside

Note:For60-and72-inchmowers,donot

installtheboltandangenutfortheleftbumper

neartheROPS.Youwillinstallthemwhen

youinstallthehandlebracketinafollowing

procedure.

2.Installthenewleftandrightbumperswith2

carriagebolts(3/8x1-1/4inches),4previously

removedcarriagebolts,and6angenuts(3/8

inch)asshowninFigure5.

g009214

Figure5

1.Flangenut(large

ange–3/8inch)

4.Leftbumper

2.Rightbumper

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

3.Useexistingbolts

10

3

InstallingtheBagger

MountingBrackets

Partsneededforthisprocedure:

1Uppermountingbracket

1Lowermountingbracket

4

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

2

Carriagebolt(1/2x2–1/2inches)

4

Flangenut(largeange–3/8inch)

2

Flangenut(1/2inch)

Procedure

Note:For60-and72-inchmowers,donotinstall

theboltandangenutfortheleftsideofthelower

mountingbracket.Thiswillbeinstalledwheninstalling

thehandlebracketinthefollowingprocedure.

1.Installthelowermountingbrackettothe

machineframewith4carriagebolts(3/8x1-1/4

inches)and4angenuts(largeange–3/8inch)

asshowninFigure6.

g017215

Figure6

1.Carriagebolt(1/2x2-1/2

inches)

4.Lowermountingbracket

2.Uppermountingbracket

5.Carriagebolt(3/8x1-1/4

inches)

3.Flangenut(1/2inch)6.Flangenut(large

ange–3/8inch)

2.Installtheuppermountingbrackettotheleftand

rightbumperswith2carriagebolts(1/2x2-1/2

inches)and2angenuts(1/2inch)asshown

inFigure6.

4

InstallingtheHandle

AssemblyandBracket

60-and72-inchMowers

Partsneededforthisprocedure:

1Handleassembly

1Handlebracket

4

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

1

Clevis-pinspring

4

Flangenut(largeange–3/8inch)

Procedure

1.Removetheclevis-pinspringfromthe

bagger-armassembly(seeFigure11).

2.Installthehandleassemblypinintothehandle

bracketandconnectthemtogetherwitha

carriagebolt(3/8x1-1/4inches)andaange

nut(largeange–3/8inch).

g009216

Figure7

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

ange–3/8inch)

2.Handlebracket5.Assembledhandleand

bracketassembly

3.Handleassembly

11

3.Installthehandleandbracketassemblytothe

sideofthemachinewith3carriagebolts(3/8x

1-1/4inches)and3angenuts(largeange–3/8

inch)asshowninFigure8.

Note:Ensurethattheboltsgothroughthe

leftbumperandthelowerbaggerbracketand

connectthemtothesideofthemachine.

g009217

Figure8

1.Handleandbracket

assembly

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

2.Flangenut(large

ange–3/8inch)

5

InstallingtheHandle

AssemblyandBracketfor

48-and52-inchMowers

Partsneededforthisprocedure:

1Hoodassembly

1Knob

1

Carriagebolt

Procedure

Pivotthehandleoutintothehandlebracketand

secureitwithacarriageboltandknob(Figure9).

g009418

Figure9

1.Knob

3.Carriagebolt

2.Handlebracket

12

6

InstallingtheBagger

Assembly

Partsneededforthisprocedure:

1Baggerassembly

2Pinandhairpincotterassembly

Procedure

1.Positionthebaggeronitsback(Figure10).

2.Slidethehooksontothelowermountingbracket

(Figure10).

3.Rotatethebaggeruponthelowerbagger

mountingbracket.

4.Aligntheholeinthebaggerwiththeupper

mountingbracket(Figure10).

5.Installthepinandsecureitwiththehairpin

cotteronbothsides(Figure10).

g009219

Figure10

1.Lowermountingbracket4.Rotatebaggerup

2.Hook5.Hairpincotterconnected

tolanyard

3.Bagger6.Pinconnectedtolanyard

6.Rotatethebagger-handlelinkageuptothe

baggerassemblyandsecureitwithaclevis-pin

spring(Figure11).

Note:Loosenandrotatetheyokeifneededto

alignitwiththebaggerassembly.

13

g009218

Figure11

1.Bagger-armassembly

3.Clevis-pinspring

2.Bagger-handlelinkage4.Yoke

7

InstallingtheMufer

Deector

Partsneededforthisprocedure:

1

Muferdeector

2

Flangenut(smallange–3/8inch)

2

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

Procedure

Installthemuferdeectortothesideofthebagger

frame(Figure12).

Note:Ensurethatthemuferdeectorispositioned

overthetailpipeonthemufer.

g009221

Figure12

60-and72-inchbaggershown

1.Muferdeector3.Carriagebolt(3/8x1-1/4

inches)

2.Flangenut(small

ange–3/8inch)

14

8

RoutingtheBlowerBelt

intotheBlowerAssembly

Partsneededforthisprocedure:

1

Blowerbelt(fromtheBlowerandDriveKit)

Procedure

1.For60-and72-inchmowers,installthebelt

aroundtheblowerpulley(Figure13).

g003398

Figure13

Blowerfor60-and72-inchMowers

1.Idlerpulley4.Peg

2.Mower-deckpulley5.Belt

3.Spring

6.Blowerpulley

2.For48-and52-inchmowers,loosenthebelt

guide(Figure14).

3.Installthebeltaroundtheblowerpulleyand

xed-idlerpulley(Figure14).

4.Tightenthebeltguide.

g010508

Figure14

Blowerfor48-and52-inchmowers

1.Spring-loadedidlerpulley

5.Beltguide

2.Mower-deckpulley6.Fixed-idlerpulley

3.Spring

7.Blowerpulley

4.Peg8.Belt

15

9

InstallingtheBlower

Assembly

Partsneededforthisprocedure:

1

Blowerassembly(fromtheBlowerandDriveKit)

1

Spring(fromtheBlowerandDriveKit)

Procedure

WARNING

Anuncovereddischargeopeningcouldallow

thelawnmowertothrowobjectsatyouor

bystanders,resultinginseriousinjury.Also,

contactwiththebladecouldoccur.

•Neveroperatethelawnmowerunlessyou

installacoverplate,amulchplate,ora

grasschuteandcatcher.

•Makesurethatthegrassdeectoris

installedwhenyouremovethegrasschute

andcatcher.

1.Removetheside-dischargechutefromthe

mowerdeck(Figure15).

Note:Saveallthehardwareandthe

side-dischargechute.Installtheside-discharge

chutewhenthebaggerandblowerareremoved.

g002519

Figure15

1.Bolt

5.Springinstalled

2.Spacer6.Grassdeector

3.Locknut

7.L-endofspring(Place

itbehindthedeckedge

beforeinstallingthebolt)

4.Spring8.J-hookendofthespring

16

2.Slidetheblower-assemblypegintothepivot

hole(Figure16orFigure17).

g009420

Figure16

48-and52-inchmowerdeckshown

1.Blowerassembly3.Pivothole

2.Mowerdeck4.Blower-assemblypeg

g009220

Figure17

60-and72-inchmowerdeckshown

1.Blowerassembly3.Pivothole

2.Mowerdeck4.Blower-assemblypeg

3.Closetheblowerassemblytoseeifthelatches

areadjustedcorrectly(Figure18).

Note:Loosenortightentheboltsothelatches

rmlyholdtheblowerassemblyagainstthe

mowerdeckbutcanbereleasedbyhand

g003400

Figure18

1.Latch3.Blowerassembly

2.Bolt

4.InstallthespringasshowninFigure19.

Note:Makesurethatthehooksareinthe

correctposition.

g003638

Figure19

1.Spring-loadedidlerpulley

3.Long-hookend

2.Short-hookend

17

5.Pullthespring-loadedidlerpulleybackand

routethebeltaroundthemower-deckpulley

(Figure20).

Note:Ensurethatthebeltisroutedaroundthe

blowerpulleyscorrectly

g003399

Figure20

1.Mower-deckpulley3.Blower

2.Spring-loadedIdlerpulley

10

InstallingtheDischarge

Tubes

Partsneededforthisprocedure:

1Uppertube

1Lowertube

3

Bolt(#10x3/4inches)

3

Locknut(#10)

3

Washer(7/32inch)

Procedure

Important:Makesurethatthemowerdeckisin

thelowestheight-of-cutpositionwhileinstalling

thedischargetubes.

Note:Remembertoreplacethegrassdeectorwhen

thebaggerisremovedfromthemower.Referto

InstallingtheGrassDeector(page39).

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwait

forallmovingpartstostopbeforeleavingthe

operatingposition.

3.Lowerthemowerdecktothelowestheight-of-cut

position.

4.Installtheuppertubeintothebaggeropening

andpullitbackoutsothattherubbersealis

protrudingout(Figure21).

g009223

Figure21

1.Uppertube3.Baggerhood

2.Baggeropening

5.Measurethedistancethetubeisinsidethe

hood.

18

Note:Measurefromthehoodplatetotheedge

ofthetubeasshowninFigure22.Thisdistance

needstobe19mm(3/4inch).

g003388

Figure22

1.Hoodplate

4.3/4inch(19mm)

2.Uppertube

5.Edgeoftube

3.Hoodinthedownposition

6.Oncethe19mm(3/4inch)measurementhas

beenachieved,marktheuppertubeonthe

outsidewheretherubbersealprotrudesout

(Figure23).

Note:Thisismarkedtoensurethecorrect

positionfortheuppertubewhendrillingthe

holesandconnectingtheupperandlowertubes.

Note:Therubbersealmustprotrudeoutfrom

thebaggerhood.

g003393

Figure23

1.Uppertube3.Baggerhood

2.Rubbersealprotrudingout4.Markhereagainstthe

rubberseal.

19

7.Installthelowertubeintotheuppertube(Figure

24).

g003424

Figure24

1.Lowertube2.Uppertube

8.Slidethelowertubeontothebootandlatch

themtogether(Figure25orFigure26).

Note:Thereisalatchonthetopandbottom

oftheblowerhousing.

Note:Makesurethatthemowerdeckisin

thelowestheight-of-cutpositionandthemark

ontheuppertubeisstillpositionedagainstthe

protrudingrubberseal.

MakesurethatthemarkfromFigure23isstill

inplace.

g030596

Figure25

1.Blowerassembly3.Latch

2.Lowertube

20

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