Form No. 3350–164 60in TURBO FORCE Mower Finishing Kit Z500 Triple Soft Bagger Model No. 78502—Serial No. 230000001 and Up Operator’s Manual Register your product at www.Toro.
Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety and Instruction Decals . . . . . . . . . . . . . . . Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loose Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Before Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . Prepare the Mower . . . . . . . . . . . . . . . . . . . . .
• Do not use your hands to unclog the chute, blower or bagger. Caution signals a hazard that may cause minor or moderate injury if you do not follow the recommended precautions. • Do not leave grass in grass catcher for extended periods of time. 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 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. 79-0350 1-653554 79-0360 106-0871 80-8040 98-4387 1. Warning—wear hearing protection.
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 1 2 3 4 5 6 7 8 9 10 Description Qty.
Step 11 12 13 14 15 Description Qty.
Position B Before Installation Use this position when bagging. Prepare the Mower Middle Position Perform the following procedure to prepare the mower for attaching the blower and finishing kit. 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. Clean the mower of any debris on the deck or rear of mower to ease installation.
Installation Step Step 1 2 No Parts needed for this step. No Parts needed for this step. Removing the Existing Belt Cover Removing the Existing Anti-Scalp Roller and Bracket Note: Clean the area around the belt cover before removing. Note: Clean the area around the right, rear anti-scalp wheel 1. Unlatch and remove the right belt cover (Fig. 5). 1.
Step Step 3 4 Parts needed for this step: Parts needed for this step: • 1 Anti-scalp roller bracket • 1 Mounting plate • 1 Tapping screw • 2 Bolts, 3/8 x 1-1/4 inch • 2 Flange nuts, 3/8 inch Installing the New Bracket and Anti-Scalp Roller Installing the Mounting Plate 1. Install the new anti–scalp roller bracket using the three carriage bolts (3/8 x 3/4 inch) and flange nuts (3/8 inch) removed previously (Fig. 7). 1. Move the grass deflector into the upright position.
Step Note: If the pulley does not turn, loosen the bolts to raise the bolt heads and allow the pulley to lock into position. 5 4. After the new pulley assembly is in position, tighten the existing bolts to secure new pulley. Important Torque the nuts to 23 ft-lb ± 2 ft-lb (31 N⋅m ± 3 N⋅m). Step Parts needed for this step: • 1 Pulley assembly Installing the Pulley Assembly 1. Loosen, but do not remove, the tapping bolts on the existing pulley (Fig. 9). There should be a 1/4 inch (0.
Step Installing the Bagger Mounting Bracket 7 Important Do not tighten any bolts until both side brackets and bagger mounting bracket are fit loose on the machine. Important Make sure the bagger mounting bracket is installed in the position shown in Figure 12. 1. Remove the existing two bolts in the bottom of the rear frame (Fig. 12).
4. Install the drive wheels and torque to 95 ft-lb (128 N⋅M). Step 5. Lower the machine onto the drive wheels.
5. Position the bagger latch under the latch hook (Figures 17 and 18). 2. Install the 2 clevis pins into the hood assembly and bagger mounting bracket. Secure it with 2 hairpin cotter pins (Fig. 15). 1 3 3 4 2 4 m–6719 1 Figure 17 2 1. Hood 2. Bags 3 4 m–6741 6. Push down on the bagger latch until it locks into place (Fig. 18). Figure 15 1. Hood assembly 2. Bagger mounting bracket 3. Bagger latch 4. Latch hook 3. Hairpin cotter pin 4. Clevis pin 1 3.
Step Step 10 11 Parts needed for this step: Parts needed for this step: • 1 Blower assembly • 1 Blower belt cover • 1 Idler spring Installing the Blower Assembly • 1 Bagger belt Important Make sure the mounting plate is installed to the mower. • 1 Pulley cover 1. Move the grass deflector into the upright position. Installing the Bagger Belt and Idler Spring 2. Slide the blower assembly peg into the hole on the bracket (Fig. 19).
3 4 6 2 m–7007 7 1 5 Figure 21 1. Blower pulley 2. Mower 3. Blower assembly 4. Top pulley of mower pulley assembly 5. Spring loaded idler pulley (belt back side touching pulley) 6. Fixed idler pulley 7. Front latch (red) 4. Push down on the front latch (colored red) and open the blower assembly (Fig. 21). 5. Install the bagger belt on the top mower pulley (Fig. 21). 6. Route the bagger belt around the top pulley of the mower pulley assembly (Fig. 21). 7.
12. Adjust the bagger belt tension. Refer to Checking and Adjusting the Bagger Belt Tension on page 23. Step 12 13. Install the belt cover over the pulley assembly and secure the 3 cover latches into the blower (Fig. 23). 3 2 Parts needed for this step: • 1 Belt cover Installing the Belt Cover 1 1. Install the new belt cover over the pulley assembly and secure the latches (Fig. 24). 3 2 m–6236 Figure 23 1. Blower assembly 2. Blower belt cover 3. Latch 1 m–7020 Figure 24 1. Pulley assembly 2.
Step 4 13 1 3 4 5 Parts needed for this step: 2 • 1 Bagger tube • 1 Clamp • 2 Knobs m–6252 • 1 Blower adapter Figure 26 1. Tube 2. Blower assembly 3. Top blower stud Installing the Bagger Tube Note: To ease assembly of the bagger tube to the blower adapter, apply soapy water to both the bagger tube and the adapter. 4. Knob 5. Side blower stud Note: There are nubs on the inside of the bagger elbow that hold the upper end of the bagger tube (Fig. 27). 1.
Step 2 14 1 3 1 6 4 Parts needed for this step: 5 • 2 Caster weights • 2 Top weights • 2 U–bolts m–5882 • 4 Nuts, 1/2 inch Figure 28 • 2 Plates 1. Front caster weight 2. U–bolt 3. Plate • 4 Lock washers, 1/2 inch 4. Nut 5. Front caster 6. Lock washer • 2 Bolts, 1/2 x 3 inch Installing the Extra Top Weight Installing the Weights 1. Install the top weight on top of the caster weight with a bolt (1/2 x 3 inch) (Fig. 29). To comply with ANSI/OPEI B71.
Checking the Tire Pressure 5. Tighten the two nuts, below the spring, together and repeat on the opposite side of the machine. Check and adjust the air pressure in the front and rear tires. 6. Engage the parking brake (lever up). Pressure: 13 psi (90 kPa) drive wheels and caster wheels (Fig. 29). 7. Measure the distance between the trunnion roller and the collar on brake rod. The measurement needs be 5/16 inch (8 mm) (Fig. 31). 4 5 7 1 6 1 m–1872 Figure 30 3 1.
Operation Note: Determine the left and right sides of the machine from the normal operating position. Caution Important Set the parking brake when leaving the machine unattended, even for just a few minutes. Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. Warning Always remove the ignition key and set the parking brake when leaving the machine unattended, even for just a few minutes.
8. Lower the bagger hood over the bags (Fig. 17). Trimming 9. Latch the bagger hood (Fig. 18). Always trim with the left side of the mower. Do not trim with the right side of the mower because you could damage the blower assembly and bagging tube. Clearing Obstructions From the Bagger System Cutting Height For optimum bagging performance, set the deck height–of–cut to remove no more that 2 to 3 inches (51 to 76 mm) or 1/3 of the grass height, whichever is less.
Bagging Wet Grass If possible, always try to cut grass when it is dry. Wet grass can cause plugging. Reducing Plugging To avoid plugging the bagging system, reduce ground speed and mow the grass at a high height-of-cut, then lower the mower to your normal cutting height and repeat the bagging process. Signs of Plugging As you are bagging, a small amount of grass clippings normally blow out the front of the mower.
Maintenance Important If the machine is on a slope and set the parking brake to prevent the machine from slowly rolling.
3. Close the blower assembly and measure between the spring coil ends. See Figure 33 for measuring the spring length and eye hook orientation. 6. Adjust the fixed idler towards the rear to lengthen the spring and increase belt tension (Fig. 34). 7. Adjust the fixed idler towards the front to shorten the spring and decrease belt tension (Fig. 34). 8. Tighten the two bolts that hold the fixed idler to the blower assembly (Fig. 34). 5 9. Close the blower assembly and measure the spring length again.
2. The blower latch must engage over the front peg (Fig. 36). If it does not, proceed to step 3 and lengthen the latch. 4. To lengthen the latch turn the hex nut counterclockwise to loosen the nut. (Fig. 37). 5. To shorten the latch turn the hex nut clockwise to tighten the nut. (Fig. 37). 6. When the desired latch length is correct, tighten both nuts. (Fig. 37). Replacing the Blower Belt Check the bagger belt for wear and cracks after the first 8 hours and then every 25 hours. 1.
7. Remove the bagger belt from the blower assembly pulley (Fig. 39). 3 2 4 3 4 6 5 7 2 1 m–7007 1 m–6244 5 Figure 40 Figure 39 1. 2. 3. 4. Blower pulley Mower Blower assembly Top mower pulley 1. Blower 2. Liner 3. Bolt 5. Spring loaded idler pulley 6. Fixed idler pulley 7. Front latch 4. Washer 5. Nut 6. Remove any debris from the blower. Do not use your hands to remove the debris. 8. Install the new bagger belt. Refer to Installing the Bagger Belt and Idler Spring on page 14. 7.
Greasing the Blower 10. Push the top 2 bolts down, toward the front of blower, until the blower liner conforms to the inside of the blower (Fig. 42). This will provide clearance between the impeller and the liner. Grease the bagger belt idler arm every 25 hours (Fig. 43). Grease the blower pivot after installing the blower into the mounting hole (Fig. 43). 11. Rotate the blower pulley to verify that the blower fan does not hit the liner (Fig. 42). Adjust the liner if necessary. 12.
Storage 1. Clean the bagger attachment. Refer to Cleaning the Bagger on page 23. 2. Inspect the bagger attachment for damage. Refer to Inspecting the Bagger on page 27. 3. Make sure the bags are 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.
Troubleshooting Problem Abnormal vibration. Reduced bagging performance. Blower and tube plug g too f frequently. tl Debris blowout. Blower impeller does not spin freely. Possible Causes Corrective Action 1. Cutting blade(s) bent or unbalanced. 1. Install new cutting blade(s). 2. Blade mounting bolt is loose. 2. Tighten blade mounting bolt. 3. Loose blower pulley or pulley assembly. 3. Tighten the appropriate pulley. 4. Blower belt is worn or damaged. 4. Replace the blower belt. 5.
