Toro DFS Vac Collection System, 2005 and After 500 Series Z Master User manual

Brand: Toro

Model: DFS Vac Collection System, 2005 and After 500 Series Z Master

Category: Lawnmowers

Type: User manual

Operator’s Manual

Original Instructions (EN)

Form No. 3353–268 Rev A

DFS Vac Collection System

2005 and after 500 Series Z Master

Model No. 78513—Serial No. 250000001 and Up

W 2005 by The Toro Company

8111 Lyndale Avenue South

Bloomington, MN 55420-1196

Printed in the USA

Contents

Page

Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Safety and Instruction Decals 3. . . . . . . . . . . . . . . .

Setup 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loose Parts 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Bagger Mounting Bracket onto an Air

Cooled Machine 6. . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Bagger Mounting Bracket onto a Liquid

Cooled Machine 7. . . . . . . . . . . . . . . . . . . . . . . . .

Tightening all Mounting Bolts 9. . . . . . . . . . . . . . .

Removing the Mower Belt and the Right Rear Idler

Pulley 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Drive Pulley Assembly 10. . . . . . . . . .

Installing the Bagger 11. . . . . . . . . . . . . . . . . . . . . .

Installing the Bagger Tensioner Pulley and Belt 12.

Adjusting the Bagger Belt 14. . . . . . . . . . . . . . . . . .

Installing and Adjusting the Mower Belt 15. . . . . . .

Installing the Weights 16. . . . . . . . . . . . . . . . . . . . . .

Installing the Boot and Discharge Tubes 18. . . . . . .

Installing the Bagger Dump Handle 19. . . . . . . . . . .

Installing the Bagger Dump Lever Stop Bolt 19. . . .

Adjusting the Bagger Dump Lever 20. . . . . . . . . . . .

Checking the Tire Pressure 21. . . . . . . . . . . . . . . . . .

Operation 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Positioning the Adjustable Baffle 22. . . . . . . . . . . . .

Opening the Bagger 22. . . . . . . . . . . . . . . . . . . . . . .

Holding the Bagger Door Open 23. . . . . . . . . . . . . .

Clearing Obstructions From the Bagger System 23.

Removing the Discharge Tubes 23. . . . . . . . . . . . . .

Removing the Bagger 23. . . . . . . . . . . . . . . . . . . . . .

Replacing the Grass Deflector 24. . . . . . . . . . . . . . .

Operating and Bagging Tips 24. . . . . . . . . . . . . . . . .

Maintenance 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Maintenance Schedule 26. . . . . . . . .

Cleaning the Screens 26. . . . . . . . . . . . . . . . . . . . . .

Cleaning the Bagger 26. . . . . . . . . . . . . . . . . . . . . . .

Checking the Bagger Belt 26. . . . . . . . . . . . . . . . . . .

Greasing the Idler Arm 26. . . . . . . . . . . . . . . . . . . . .

Greasing the Fan Shaft Bearings 27. . . . . . . . . . . . .

Inspecting the Bagger 27. . . . . . . . . . . . . . . . . . . . . .

Inspecting the Mower Blades 27. . . . . . . . . . . . . . . .

Storage 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction

Read this manual carefully to learn how to operate and

maintain your product properly. The information in this

manual can help you and others avoid injury and product

damage. Although Toro designs and produces safe

products, you are responsible for operating the product

properly and safely.

Whenever you need service, genuine Toro parts, or

additional information, contact an Authorized Service

Dealer or Toro Customer Service and have the model and

serial numbers of your product ready. Figure 1 illustrates

the location of the model and serial numbers on the

product.

m–6984

Figure 1

1. Location of the model and serial numbers

Write the product model and serial numbers in the space

below:

Model No.

Serial No.

This manual identifies potential hazards and has special

safety messages that help you and others avoid personal

injury and even death. Danger, Warning, and Caution are

signal words used to identify the level of hazard. However,

regardless of the hazard, be extremely careful.

Danger signals an extreme hazard that will cause serious

injury or death if you do not follow the recommended

precautions.

Warning signals a hazard that may cause serious injury or

death if you do not follow the recommended precautions.

Caution signals a hazard that may cause minor or moderate

injury if you do not follow the recommended precautions.

This manual uses two other words to highlight information.

Important calls attention to special mechanical

information and Note: emphasizes general information

worthy of special attention.

Safety

The following list contains safety information specific to

Toro products and other safety information you must know.

• Become familiar with the safe operation of the

equipment, with the operator controls, and safety signs.

• Use extra care with grass catchers or other attachments.

These can change the operating characteristics and the

stability of the machine.

• Follow the manufacturer’s recommendations for adding

or removing wheel weights or counterweights to

improve stability.

• Do not use a grass catcher on steep slopes. A heavy

grass catcher could cause loss of control or overturn 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.

• Keep all movement on slopes slow and gradual. Do not

make sudden changes in speed, directions or turning.

• The grass catcher can obstruct the view to the rear. Use

extra care when operating in reverse.

• Use care when loading or unloading the machine into a

trailer or truck

• Never operate with the discharge deflector raised,

removed or altered, unless using a grass catcher.

• Keep hands and feet away from moving parts. Do not

make adjustments with the engine running.

• Stop on level ground, disengage drives, chock or block

wheels, shut off engine before leaving the operator’s

position for any reason including emptying the grass

catcher or unclogging the chute.

• If you remove the grass catcher, be sure to install any

discharge deflector or guard that might have been

removed to install the grass catcher. Do not operate the

mower without either the entire grass catcher or the

grass deflector in place.

• Stop the engine before removing the grass catcher or

unclogging the chute.

• Do not leave grass in grass catcher for extended periods

of time.

• Grass catcher components are subject to wear, damage

and deterioration, which could expose moving parts or

allow objects to be thrown. Frequently check

components and replace with manufacturer’s

recommended parts, when necessary.

Safety and Instruction 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.

104-8569

106-3339

Setup

Note: Determine the left and right sides of the machine from the normal operating position.

Loose Parts

Note: Use the chart below to verify all parts have been shipped.

Step Description Qty. Use

Bagger mounting bracket

Side bracket—right

Side bracket—left

Long frame spacer—only two are

needed for air cooled machines

Short frame spacer

Bolt, 3/8 x 1–1/2 inch

Bolt, 3/8 x 1–1/4 inch

Flange Nut, 3/8 inch

Stiffener bracket

Bolts, 3/8 x 3/4 inch

Curved washer

Installing bagger mounting brackets

onto the machine

No parts needed Tightening all mounting bolts

No parts needed

Removing the mower belt and the right

rear idler pulley

Pulley assembly

Bolt, 1/2 x 1–1/4 inch

Lock nut,1/2 inch

Washer, 1/2 inch

Installing the drive pulley assembly

Bagger

Clevis pin

Hairpin cotter

Installing the bagger

Bagger tensioner pulley

Bolt, 3/8 x 2 inch

Lock Nut, 3/8 inch

Washer, 3/8 inch

Bagger belt

Installing the bagger tensioner pulley

and the bagger belt

No parts needed Adjusting the bagger belt

No parts needed Adjusting the mower belt tension

Step UseQty.Description

Caster weight

U–bolt

Nut, 1/2 inch

Lock washer, 1/2 inch

Plate

Top weight

Bolt, 1/2 x 3 inch

Installing the weights

Boot

Middle Tube

Upper Tube

Clamp

Installing the boot and the discharge

tubes

Bagger dump lever

Washer, 13/16 inch

Cotter pin

Installing the bagger dump lever

Bolt, 1/2 x 1–3/4 inch

Jam nut, 1/2 inch

Long clevis (liquid cooled only)

Installing the bagger dump lever stop

bolt

No parts needed Adjusting the bagger dump lever

No parts needed Checking the tire pressure

Step

Parts needed for this step:

• 1 Bagger mounting bracket

• 1 Side bracket—right

• 1 Side bracket—left

• 4 Long frame spacer—only two are needed for air

cooled machines

• 2 Short frame spacer

• 12 Bolt, 3/8 x 1–1/2 inch

• 4 Bolt, 3/8 x 1–1/4 inch

• 26 Flange Nut, 3/8 inch

• 2 Stiffener bracket

• 8 Bolts, 3/8 x 3/4 inch

• 8 Curved washer

If you have a liquid cooled machine, go to page 7 for

Installing the Bagger Mounting Bracket onto a Liquid

Cooled Machine.

If you have an air cooled machine, use the following

instructions for Installing the Bagger Mounting Bracket

onto an Air Cooled Machine.

Installing the Bagger Mounting

Bracket onto an Air Cooled

Machine

Important Do not tighten any bolts until both side

brackets and bagger mounting bracket are fit loose on the

machine.

Refer to Tightening the Mounting Bolts, on page 9, for the

correct procedure to tighten the bolts.

Installing the Bagger Mounting Bracket to

the Side Brackets (Air Cooled)

Important When installing the bagger bracket for an

air cooled machine, use only 2 long frame spacers; 1 per

each side (Fig. 2).

1. Install the side brackets to the bagger mounting bracket

(Fig. 2).

2. In the top two holes, install 2 bolts (3/8 x 1–1/2 inch),

2 flange nuts (3/8 inch) one long frame spacer, and one

short frame spacer (Fig. 2).

Note: Make sure the long frame spacers are installed as

shown in figure 2.

3. In the bottom hole, install a bolt (3/8 x 1–1/4 inch) and

a flange nut (3/8 inch) (Fig. 2).

4. Install a bracket stiffener to the side bracket and bagger

mounting bracket. Use 4 bolts (3/8 x 3/4 inch) and

4 flange nuts (3/8 inch) (Fig. 2).

5. Repeat the previous steps for the opposite side (Fig. 2).

m–8040

Figure 2

1. Bagger mounting bracket

2. Bolt, 3/8 x 1–1/4 inch

3. Flange nut, 3/8 inch

4. Bracket stiffener

5. Left side bracket

6. Bolt, 3/8 x 3/4 inch

7. Long frame spacer

8. Bolt, 3/8 x 1–1/2 inch

9. Short frame spacer

10. Right side bracket

Installing the Side Brackets to an Air

Cooled Machine

Important Do not tighten any bolts until both side

brackets and bagger mounting bracket are fit loose on the

machine.

Important Install one side at a time.

1. Remove the bolts, nuts and washers holding the rollbar

to one side of the machine. Discard the bolts, nuts and

washers (Fig. 3).

2. Install the bagger side plate and the roll bar section to

the side of the machine using 4 bolts

(3/8 x 1–1/2 inch), 4 curved washer (3/8 inch) and 4

flange nuts (3/8 inch) (Fig. 3).

3. Repeat the previous step on the opposite side of the

machine.

Note: Make sure the curved washers are installed as shown

in Figure 3.

m–8044

Figure 3

1. Side bracket

2. Curved washer, 3/8 inch

3. Bolt, 3/8 x 1–1/2 inch

4. Flange nut, 3/8 inch

5. ROPS

Installing the Bagger Mounting Bracket

onto an Air Cooled Machine

Important When installing the bagger onto an air

cooled machine, use the air cooled spacer (Fig. 4).

1. Install the bagger mounting bracket to the rear frame of

the machine (Fig. 4).

2. In the top two holes, install 2 bolts (3/8 x 1–3/4 inch),

2 flange nuts (3/8 in.) and the air cooled frame spacer

(Fig. 4).

3. In the bottom two holes, install 2 bolts (3/8 x

1–1/4 inch) and 2 flange nuts (3/8 in.) (Fig. 4).

m–8041

Figure 4

1. Bagger mounting bracket

2. Bolt, 3/8 x 1–1/4 inch

3. Flange nut, 3/8 inch

4. Bumper

5. Air cooled frame spacer

6. Bolt, 3/8 x 1–3/4 inch

Installing the Bagger Mounting

Bracket onto a Liquid Cooled

Machine

Important Do not tighten any bolts until both side

brackets and bagger mounting bracket are fit loose on the

machine.

Refer to Tightening the Mounting Bolts, on page 9, for the

correct procedure to tighten the bolts.

Installing the Bagger Mounting Bracket to

the Side Brackets (Liquid Cooled)

Important When installing the bagger onto a liquid

cooled machine, the rear bumper plate must be removed.

Use 4 long frame spacers for this installation, 2 per each

side (Fig. 5).

1. Install the side brackets to the bagger mounting bracket

(Fig. 5).

2. In the top two holes, install 2 bolts (3/8 x 1–1/2 inch),

2 flange nuts (3/8 in.), 2 long frame spacers, and one

short frame spacer (Fig. 5).

Note: Make sure the long frame spacers are installed as

shown in figure 5.

3. In the bottom hole, install a bolt (3/8 x 1–1/4 inch) and

a flange nut (3/8 in.) (Fig. 5).

4. Install a bracket stiffener to the side bracket and bagger

mounting bracket. Use 4 bolts (3/8 x 3/4 inch) and

4 flange nuts (3/8 in.) (Fig. 5).

5. Repeat the previous steps for the opposite side (Fig. 5).

m–8042

Figure 5

1. Bagger mounting bracket

2. Bolt, 3/8 x 1–1/4 inch

3. Flange nut, 3/8 inch

4. Bracket stiffener

5. Left side bracket

6. Bolt, 3/8 x 3/4 inch

7. Long frame spacer

8. Bolt, 3/8 x 1–1/2 inch

9. Short frame spacer

10. Right side bracket

Installing the Side Brackets to a Liquid

Cooled Machine

Important Do not tighten any bolts until both side

brackets and bagger mounting bracket are fit loose on the

machine.

Important Install one side at a time.

1. Remove the bolts, nuts and washers holding the rollbar

to one side of the machine. Discard the bolts, nuts and

washers (Fig. 6).

2. Install the bagger side plate and the roll bar section to

the side of the machine using 4 bolts

(3/8 x 1–1/2 inch), 4 curved washer (3/8 inch) and 4

flange nuts (3/8 inch) (Fig. 6).

3. Repeat the previous step on the opposite side of the

machine.

Note: Make sure the curved washers are installed as shown

in Figure 6.

m–8044

Figure 6

1. Side bracket

2. Curved washer, 3/8 inch

3. Bolt, 3/8 x 1–1/2 inch

4. Flange nut, 3/8 inch

5. ROPS

Installing the Bagger Mounting Bracket

onto a Liquid Cooled Machine

1. Install the bagger mounting bracket to the rear frame of

the machine (Fig. 7).

2. In the top two holes, install 2 bolts (3/8 x 1–3/4 inch)

and 2 flange nuts (3/8 inch) (Fig. 7).

3. In the bottom two holes, install 2 bolts (3/8 x

1–1/4 inch) and 2 flange nuts (3/8 inch) (Fig. 7).

m–8043

2 5

Figure 7

1. Bagger mounting bracket

2. Bolt, 3/8 x 1–1/4 inch

3. Flange nut, 3/8 inch

4. Bumper

5. Bolt, 3/8 x 1–3/4 inch

Step

No parts needed for this step.

Tightening all Mounting Bolts

The following steps are the correct sequence to tighten the

side brackets and the bagger mounting bracket.

All 3/8 inch mounting bolts need to be torqued to 35 ft–lb

(48 Nwm).

1. Tighten the bagger mounting bracket to the rear frame

first (Figures 4 or 7).

2. Tighten the bagger mounting bracket to the side

brackets (Figures 4 or 7).

3. Tighten the bracket stiffeners to both the side plates and

the bagger mounting bracket (Figures 2 or 5).

4. Tighten the side brackets to the side of the mower

(Fig. 3 or 6).

5. Lower the machine onto the drive wheels.

Step

No parts needed for this step.

Removing the Mower Belt and

the Right Rear Idler Pulley

1. Loosen the idler plate bolts and loosen the mower idler

plate (Fig. 8).

m–6826

Figure 8

1. Mower idler plate

2. Square hole

3. Ratchet or breaker bar

4. Idler plate bolt

2. Remove the mower belt from the mower and the rear

fixed idler pulley (Fig. 9).

m–6825

Figure 9

1. Clutch

2. Mower belt

3. Right rear fixed idler

pulley

4. Belt guide

5. Mower spindle pulley

6. Mower idler pulley

3. Remove the fixed idler pulley from the right rear frame

of the machine (Fig. 10).

m–7055

Figure 10

1. Fixed idler pulley

2. Right rear of the machine

3. Bolt

4. Nut

5. Spacer

6. Washer

Step

Parts needed for this step:

• 1 Pulley assembly

• 4 Bolt, 1/2 x 1–1/4 inch

• 4 Lock nut, 1/2 inch

• 4 Washer, 1/2 inch

• 1 Template

Installing the Drive Pulley

Assembly

1. Install the mower belt onto the drive pulley assembly

(Figures 12 and 19).

Note: Make sure the cut–out in the pulley plate is on the

left–hand side of the machine (Fig. 11). This cut–out allows

room for the mower spring loaded idler pulley.

m–8045

Figure 11

1. Rear frame

2. Drive pulley assembly

3. Bolt, 1/2 x 1–1/4 inch

4. Nut, 1/2 inch

5. Washer, 1/2 inch

6. Cut–out

7. Pulley plate

2. Install the pulley assembly under the rear frame, and

loosely install 4 bolts (1/2 x 1–1/4 inch), 4 washers

(1/2 in.) and 4 locknuts (1/2 inch) (Fig. 11). Do not

tighten bolts now.

Positioning the Drive Pulley Assembly on

an Air Cooled Machine

1. Push the drive pulley assembly all the way forward and

then rearward a 1/4 inch (6 mm) (Fig. 11).

Note: The bolt head on the drive pulley assembly, should

be approximately centered horizontally, in the frame slot

(Fig. 12). View this from the right–hand side of the

machine.

2. Tighten the 4 bolts (1/2 x 1–1/4 inch), 4 washers

(1/2 in.) and 4 locknuts (1/2 inch) (Fig. 11).

Important A final adjustment may be needed when

installing the bagger belt.

Positioning the Drive Pulley Assembly on

a Liquid Cooled Machine

1. Push the drive pulley assembly all the way rearward and

then forward a 1/4 inch (6 mm) (Fig. 11).

Note: The bolt head on the drive pulley assembly, should

be approximately a 1/4 inch (6mm) rearward of the center

in the frame slot (Fig. 12). View this from the right–hand

side of the machine.

m–5861

Figure 12

1. Drive pulley assembly

2. Bolt head—air cooled

machine only

3. Mower drive belt

4. Bolt head—liquid cooled

machine only

5. Frame slot

6. 1/4 inch—liquid cooled

2. Tighten the 4 bolts (1/2 x 1–1/4 inch), 4 washers

(1/2 in.) and 4 locknuts (1/2 inch) (Fig. 11).

Important A final adjustment may be needed when

installing the bagger belt.

Step

Parts needed for this step:

• 1 Bagger

• 2 Clevis pin

• 2 Hairpin cotter

Installing the Bagger

1. Install the bagger onto the bagger mounting bracket

(Fig. 13).

2. Install clevis pins into the bagger and bagger bracket.

Secure with hairpin cotters (Fig. 13).

m–8046

Figure 13

1. Bagger

2. Bagger mounting bracket

3. Hairpin cotter

4. Clevis pin

Installing Bagger onto a Liquid Cooled

Machine

Note: The following instructions are for liquid cooled

machines only.

1. Loosen bolts that hold the engine shroud.

2. Move the engine shroud forward as far as possible.

3. Tighten bolts that hold the engine shroud.

4. Remove the cable guide and bolt from the frame of the

bagger (Fig. 14).

5. Install the cable guide, bolt, and nut with the cable

behind the cable guide (Fig. 14).

Note: Make sure the cable guide can rotate.

6. Locate template number 1 in the back of this manual.

Cut out template number 1 as indicated on the template

(Fig. 14).

7. Position the template on the right–hand side of the

engine shroud (Fig. 14).

8. Line up the mark on the template where the bagger

dump lever hits the engine shroud and the template

bottom is flush with the bottom of shroud (Fig. 14).

9. Tape the template to the engine shroud. Mark the outer

edge of the template. (Fig. 14).

10. Cut the engine shroud at the marked line. This will

prevent damage to the engine shroud while using the

bagger dump lever (Fig. 14).

Note: Make sure to follow the template outline. Do not

create any sharp corners.

m–8048

Figure 14

1. Bagger dump lever

2. Engine shroud

3. Template

4. Cable guide

5. Mark on template

6. Template bottom

7. Shroud bottom

Step

Parts needed for this step:

• 1 Bagger tensioner pulley

• 1 Bolt, 3/8 x 2 inch

• 1 Lock Nut, 3/8 inch

• 1 Washer, 3/8 inch

• 1 Bagger belt

Installing the Bagger Tensioner

Pulley and Belt

1. Remove the four bolts in the skid plate (Fig. 15).

2. Remove the skid plate (Fig. 15). This will make it easier

to install the bagger belt.

m–6984

Figure 15

1. Bolts 2. Skid plate

3. Install the bagger tensioner pulley onto the idler arm

with a bolt (3/8 x 2 inch), washer (3/8 inch), and lock

nut (3/8 inch) (Fig. 16).

M–6908

Figure 16

1. Bolt, 3/8 x 2 inch

2. Idler arm

3. Lock nut, 3/8 inch

4. Washer, 3/8 inch

5. Bagger tensioner pulley

6. Bagger

4. Install the bagger belt onto the drive pulley

(Fig. 18 and 19).

5. Route the bagger belt onto the bagger pulley

(Figures 17 and 18).

m–5887

Figure 17

1. Tensioner spring

2. Eye bolt

3. Bagger tensioner pulley

4. Bagger pulley

5. Belt

6. Shortest space between

belt strands, 1 inch

±1/8 inch

Note: There should be a 1/4 twist in the belt when it is

installed onto the bagger tensioner pulley

6. Install the spring onto the idler arm (Fig. 17).

7. Install the tensioner spring onto the eyebolt attached to

the bagger (Fig. 17 and 20).

8. Adjust the bagger belt for proper tension. Refer to

Adjusting the Bagger Belt on page 14.

9. Adjust the Mower belt tension. Refer to Adjusting the

Mower Belt Tension on page 15.

10. Install the skid plate (Fig. 15).

m–5773

Figure 18

1. Drive pulley

2. Bagger tensioner pulley

3. Bagger pulley

4. 1/4 twist

m–5892

Figure 19

1. Drive pulley assembly

2. Mower belt

3. Bagger belt

4. Mounting bolts

5. Back of machine

Step

No parts needed for this step

Adjusting the Bagger Belt

1. Check the belt tension (Fig 20).

2. Measure the gap, at the bagger tensioner pulley,

between the tight and slack side of the belt when the

bagger tensioner pulley and spring are installed

(Fig. 20).

m–5887

Figure 20

1. Tensioner spring

2. Eye bolt

3. Bagger tensioner pulley

4. Bagger pulley

5. Belt

6. Shortest space between

belt strands, 1 inch

±1/8 inch

3. There must be a gap of 1 inch ± 1/8 inch (26mm ±

3 mm) between the belt strands (Fig 20).

4. If the gap is not correct, remove the tensioner spring

from the eyebolt and remove the tension on the mower

spring loaded idler (Fig 23).

5. If the gap measurement is too large:

A. Loosen the 4 mounting bolts holding the drive

pulley assembly (Fig 19).

B. Pull the pulley assembly rearward slightly

[1/8–3/16 inch (3–5 mm)] from the original set–up

position (Fig 19).

C. Tighten the 4 mounting bolts holding the drive

pulley assembly to the machine frame (Fig 19).

6. If the gap measurement is too small:

A. Loosen the 2 nuts on the lower fan shaft pillow

block (Fig. 21).

B. Insert a spacer behind the pillow block (Fig. 21).

C. Tighten the nuts.

D. Check the belt gap and repeat procedure as required.

Figure 21

1. Pillow block

2. Fan shaft

3. Spacer

7. Install the tensioner spring to the eyebolt and apply the

tension on the mower spring loaded idler.

8. Measure the bagger belt tension. There must be a gap of

1 inch ± 1/8 inch (26mm ± 3 mm) between the belt

strands (Fig 20).

9. Repeat this procedure if a gap of 1 inch ± 1/8 inch

(26mm ± 3 mm) was not achieved (Fig 20).

Step

No parts needed for this step.

Installing and Adjusting the

Mower Belt

1. Disengage the PTO, move the motion control levers to

the neutral locked position and set the parking brake.

2. Stop the engine, remove the key, and wait for all

moving parts to stop before leaving the operating

position.

3. Raise the mower to the transport position.

4. Ensure the mower belt is installed on all mower pulleys

(Fig 22).

Important Check the amount of twist in the belt

between the pulleys. Make sure it is only what is specified

in Figure 22.

m–6825

Figure 22

1. Clutch

2. Mower belt

3. 1/4 turn belt twist

4. Belt guide

5. Mower spindle pulley

6. Mower idler pulley

Important Check and make sure the belt is installed

into both the front and rear belt guides (Fig 23).

5. Check the belt tension. The spring loaded idler center

bolt needs to be near the top alignment hole in left

support plate (Fig 23).

M–4417

Figure 23

1. Center bolt

2. Alignment hole

3. Left support plate

4. Spring loaded idler

6. If adjustment is required, loosen the mower idler plate

and adjust it (Fig. 24).

7. Insert a ratchet or breaker bar into the square hole in the

mower idler plate to adjust the tension (Fig. 24).

8. To increase belt tension, rotate the mower idler plate

until resistance is felt and rotation stops. Do not go past

when it stops (Fig. 24).

9. Tighten the idler plate bolts (Fig. 24).

m–6826

Figure 24

1. Mower idler plate

2. Square hole

3. Ratchet or breaker bar

4. Idler plate bolt

10. Check the distance from the rubber stop and the arm of

the spring loaded idler pulley when the idler plate is

tightened. It needs to be 0 to 1/4 inch (0 to 6 mm) from

the rubber stop (Fig. 25).

m–6825

Figure 25

1. Spring loaded idler pulley

2. Top alignment hole

3. 0 to 1/4 inch gap

(0 to 6 mm)

4. Idler pulley arm

5. Belt

6. Rubber bumper

11. Adjust the belt tension and the idler plate, if necessary,

and tighten all hardware securely (Fig. 24).

Step

Parts needed for this step:

• 2 Caster weight

• 2 U–bolt

• 4 Nut, 1/2 inch

• 4 Lock washer, 1/2 inch

• 2 Plate

• Top weight

• 2 Bolt, 1/2 x 3 inch— for two top weights

Installing the Weights

To comply with ANSI/OPEI B71.4–1999 Standard, top

weights must be added to the machine.

Installing the Caster Weights

The bagger adds a lot of weight to the rear of the

machine and may cause an unstable condition

which could result in a loss of control.

• Install the front caster weights and top weights.

Caution

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 (Fig. 26).

3. Repeat for opposite side.

Note: On Z–Master mowers with 52 inch mower decks and

liquid cooled Z–Master mowers with 60 inch mowers

additional weights are required.

m–5882

Figure 26

1. Front caster weight

2. U–bolt

3. Plate

4. Nut

5. Front caster

6. Lock washer

Installing the Extra Top Weights

1. Install 2 top weights on top of each caster weight and

secure them with a bolt (1/2 x 3 inch) (Fig. 27).

m–5882

Figure 27

1. Top weight

2. Bolt, 1/2 x 3 inches

3. Front caster weight

4. Front caster wheel

Step

Parts needed for this step:

• 1 Boot

• 1 Middle tube

• 1 Upper tube

• 1 Clamp

Installing the Boot and

Discharge Tubes

Note: Remember to replace the L or the straight end of the

spring when in side discharge mode. Refer to Replacing the

Grass Deflector on page 24.

1. Disengage the PTO and set the parking brake.

2. Stop the engine, remove the key, and wait for all

moving parts to stop before leaving the operating

position.

3. To relieve the spring tension on the grass deflector,

place the L or the straight end of the spring in front of

the mounting bracket (Fig. 38).

4. Lift the grass deflector all the way back.

5. Position the boot’s front hook into the front slot on the

mounting bracket (Fig. 29).

Note: If the grass deflector interferes with the boot, grind

off part of the grass deflector frame. See Figure 28 for the

correct part to grind off.

m–7056

Figure 28

1. Grass deflector frame 2. Grind this part off

6. Place the rear hook over the rear of the mounting

bracket (Fig. 29).

7. Install the upper tube into the bagger (Fig. 29).

8. Slide the clamp onto the middle tube (Fig. 29).

9. Align the knob on the middle tube with the notch in the

upper tube. Slide the middle tube into the upper tube

and twist the middle tube 60 degrees (Fig. 29).

10. Tighten the clamp around the upper and middle tube

connection (Fig. 29).

11. Slide the middle tube onto the boot and latch them

together (Fig. 29).

M–6910

Figure 29

1. Boot

2. Middle tube

3. Knob

4. Upper tube

5. Latch

6. Notch in upper tube

7. Mounting bracket

8. Front slot

9. Rear hook

10. Front hook

11. Clamp

Step

Parts needed for this step:

• 1 Dump handle

• 2 Washers, 13/16 inch

• 1 Cotter pin

Installing the Bagger Dump

Handle

1. Unfasten the dump handle from the crate.

2. Install a washer onto the bagger dump handle and install

the bagger dump handle into the bagger frame (Fig. 31).

3. Fasten the bagger with a washer ( inch) and a cotter

pin (Fig. 31).

m–8047

Figure 30

1. Dump handle

2. Washer

3. Cotter pin

4. Bagger frame

Step

Parts needed for this step:

• 1 Bolt, 1/2 x 1–3/4 inch

• 2 Jam nuts, 1/2 inch

• 1 Long clevis, liquid cooled machines only

Installing the Bagger Dump

Lever Stop Bolt

1. Move the bagger dump lever rearward to increase the

slack in the bagger cable (Fig. 31).

2. Remove the cotter pin and clevis pin securing the

bagger cable clevis to the bagger dump handle

(Fig. 31).

m–6985

Figure 31

1. Bagger dump lever

2. Bagger cable

3. Bagger cable clevis

4. Bolt, 1/2 x 1–3/4 inch

5. Jam nut, 1/2 inch

6. Stop bracket

3. Thread a jam nut (1/2 inch) all the way onto the bolt

(1/2 x 1–3/4 inch) (Fig. 31).

4. Move the bagger dump lever forward to move the

bottom of the lever away from the stop bracket

(Fig. 31).

5. Insert the bolt into the stop bracket hole and thread

another jam nut (1/2 inch) onto the bolt. Do not tighten.

Note: Install the long cable clevis onto the bagger dump

handle if it is for a liquid cooled machine (Fig. 32).

6. Secure the bagger cable clevis to the bagger dump

handle with the clevis pin and cotter pin previously

removed (Fig. 31 or Fig. 32).

m–6986

Figure 32

1. Bagger dump lever

2. Bagger cable

3. Long cable clevis—liquid

cooled machines only

4. Bolt, 1/2 x 1–3/4 inch

5. Jam nut, 1/2 inch

6. Stop bracket

7. Clevis pin

8. Cotter pin

7. Adjust the handle stop, refer to Adjusting the Bagger

Dump Lever, page 20.

Step

No parts needed for this step.

Adjusting the Bagger Dump

Lever

The bagger lever needs to be adjusted to remove slack in

the bagger cable.

1. Loosen the nuts on both sides of the stop bracket

(Fig. 33).

2. Adjust the stop bolt until there is no slack in the bagger

cable (Fig. 33).

3. Tighten the nuts on both sides of the stop bracket

(Fig. 33).

1 5 25

m–6990

Figure 33

1. Bagger dump lever

2. Stop bracket

3. Stop bolt

4. Bagger cable

5. Nut

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Toro DFS Vac Collection System, 2005 and After 500 Series Z Master User manual

Brand: Toro

Model: DFS Vac Collection System, 2005 and After 500 Series Z Master

Category: Lawnmowers

Type: User manual

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Toro DFS Vac Collection System, 2005 and After 500 Series Z Master User manual

Toro DFS Vac Collection System, 2005 and After 500 Series Z Master User manual

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