Form No. 3351–547 Rev A 72in TURBO FORCE Mower Finishing Kit Z500 Triple Soft Bagger Model No. 78504—Serial No. 230000001 and Up Operator’s Manual Register your product at www.Toro.
Contents Replacing the Blower Liner . . . . . . . . . . . . . . . . . Inspecting the Bagger . . . . . . . . . . . . . . . . . . . . . Greasing the Blower . . . . . . . . . . . . . . . . . . . . . . Inspecting the Mower Blades and Baffles . . . . . . Installing Mower Blades . . . . . . . . . . . . . . . . . . . Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page Introduction . . . . . . . . . . . . . . . .
• Stop on level ground, disengage drives, set the parking brake, shut off the engine before leaving the operator’s position for any reason including emptying the grass catcher or unclogging the chute. 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.
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 16 17 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). 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 6 No parts needed for this step. 1 m–6859 Removing the Drive Wheels (For Gasoline Engines Only) Figure 11 1. Drive wheel Danger Mechanical or hydraulic jacks may fail to support machine and cause a serious injury. • Use jack stands when supporting machine. • Do not use hydraulic jacks. 1. Loosen the drive wheel nuts. 2. Raise the rear of the machine and support with jack stands (Fig. 10). 1 1 Figure 10 1. Jack stand 3. Remove the nuts and the drive wheels (Fig. 11).
Step 7 1 No parts needed for this step. Removing the Roll Over Protection System (ROPS) (For Gasoline Engines Only) 2 1. Loosen the front handles securing the center roll bar section to the right and left sections (Fig. 12). m–6893 Figure 13 1. Pin 2. Hair pin cotter 3. Loosen the center roll bar bolts allowing the roll bar to be pivoted to the down position (Fig. 14). 2 1 2 m–6835 Figure 12 1. Front handle 1 2. Center roll bar section 2.
5. Remove the following fasteners (Fig. 15) securing each (right and left) roll bar section to the frame: Step • Lock nut (3/8 inch) and curved washer. Do not remove bolt from frame. • Bolt (3/8 x 1 inch), curved washer and flange nut (3/8 inch). 8 • Bolt (3/8 x 1 inch), curved washer and flange nut (3/8 inch). No parts needed for this step. • Bolt (3/8 x 4-1/2 inches), curved washer and flange nut (3/8 inch).
Step 9 5 4 7 6 3 2 2 7 5 Parts needed for this step: • 1 Left side bagger bracket • 1 Right side bagger bracket • 6 Bolt, 3/8 x 1–1/2 inch m–7628 • 6 Flange Nut, 3/8 inch 2 5 1 Figure 17 • 4 Spacer 1. Bagger bracket-(right side shown) 2. Bolt, 3/8 x 1–1/2 inch 3. Flange nut, 3/8 inch 4. Machine side frame Installing the Side Brackets to the Machine (For Gasoline Engines Only) 2. Make sure the lanyard clips are on the 2 bolts (1/2 x 3-1/4 inches) (Fig. 18).
1 2 1 m–6891 m–6891 Figure 19 Figure 21 1. Center roll bar section 1. Bolt 2. Flange nut 5. Raise the roll bar into the upright position and secure it with the pins and hairpin cotter pins fastened to the lanyards (Fig. 20). 7. Torque all lower fasteners, attached to the machine frame, to 30 ft–lb. 8. Tighten the front handles against the center roll bar ends. 1 2 m–6893 Figure 20 1. Pin 2. Hair pin cotter 1 6.
Step 5 2 10 3 1 2 4 Parts needed for this step: • 1 Bagger mounting bracket 6 • 6 Bolts, 3/8 x 1 inch • 6 Flange nuts, 3/8 inch 3 4 2 m–6743 • 6 Belleville washers, 3/8 inch Figure 23 Installing the Bagger Mounting Bracket (For Gasoline Engines Only) 1. Bagger mounting bracket 2. Bolt, 3/8 x 1 inch 3. Flange nut, 3/8 inch Note: For diesel engines, contact an Authorized Service Dealer for a Triple Bagger Mounting Kit. Installing the Side Brackets 2.
Step Step 11 12 Parts needed for this step: Parts needed for this step: • 1 Tube support • 1 Hood assembly • 1 Elbow • 3 Bags • 4 Bolts, 1/4 x 1-1/2 inch • 2 Clevis pins • 4 Nuts, 1/4 inch • 2 Hairpin cotter pins • 4 Flat washers, 1/4 inch Installing the Hood Assembly and Bags Installing the Bagger Tube Support and Elbow Warning 1. Position the elbow inside the bagger hood (Fig. 24). 2.
1 3 4 2 2 5 1 2 m–6718 Figure 27 1. Hood assembly 2. Bag 3. Bag tab m–6740 4. Notch 5. Bagger frame Figure 25 1. Hood assembly 2. Bagger mounting bracket (gasoline machine frame shown) 4. Lower the bagger hood over the bags. 5. Position the bagger latch under the latch hook (Figures 28 and 29). 2. Install the 2 clevis pins into the hood assembly and bagger mounting bracket. Secure it with 2 hairpin cotter pins (Fig. 26). 1 3 3 4 2 4 m–6719 Figure 28 1. Hood 2. Bags 1 2 4 5 6.
Step Step 13 14 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. 30).
6 3 4 2 7 1 5 m–7614 Figure 32 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. 32). 5. Install the bagger belt on the top mower pulley (Fig. 32). 6. Route the bagger belt around the top pulley of the mower pulley assembly (Fig. 32). 7.
12. Adjust the bagger belt tension. Refer to Checking and Adjusting the Bagger Belt Tension on page 28. 1 2 13. Install the belt cover over the pulley assembly and secure the 3 cover latches into the blower (Fig. 34). 3 2 3 1 m–7722 Figure 35 1. Bolt 2. Existing belt cover bracket 3. Mower deck 2. Install the new belt cover bracket to the mower deck with the previously removed bolts (Fig. 36). 1 2 m–6236 Figure 34 1. Blower assembly 2. Blower belt cover 3. Latch Step 15 3 Figure 36 1.
Step Step 16 17 Parts needed for this step: Parts needed for this step: • 1 Belt cover • 1 Bagger tube • 1 Clamp Installing the Belt Cover • 2 Knobs 1. Install the new belt cover over the pulley assembly and secure the latches (Fig. 37). • 1 Blower adapter Installing the Bagger Tube 3 Note: To ease assembly of the bagger tube to the blower adapter, apply soapy water to both the bagger tube and the adapter. 2 1.
Step 4 18 1 4 3 5 Parts needed for this step: 2 • 2 Caster weights • 2 Top weights • 2 U–bolts m–7612 • 4 Nuts, 1/2 inch Figure 39 1. Tube 2. Blower assembly 3. Top blower stud • 2 Plates 4. Knob 5. Side blower stud • 4 Lock washers, 1/2 inch • 2 Bolts, 1/2 x 3 inch Note: There are nubs on the inside of the bagger elbow that hold the upper end of the bagger tube (Fig. 40). Installing the Weights 4. Place the upper tube into the bagger elbow (Fig. 40). To comply with ANSI/OPEI B71.
2 1 1 3 1 6 4 m–1872 5 Figure 43 1. Valve stem m–5882 Figure 41 1. Front caster weight 2. U–bolt 3. Plate Check the Level of the Mower 4. Nut 5. Front caster 6. Lock washer Refer to the mower Operator’s Manual for the correct procedure. Step 19 Installing the Extra Top Weight (For Liquid Cooled and Diesel Machines Only) 1. Install the top weight on top of the caster weight with a bolt (1/2 x 3 inch) (Fig. 42). 2 No parts needed for this step.
Operation 7. Measure the distance between the trunnion roller and the collar on brake rod. The measurement needs be 5/16 inch (8 mm) (Fig. 44). 4 Note: Determine the left and right sides of the machine from the normal operating position. 5 7 Important Set the parking brake when leaving the machine unattended, even for just a few minutes.
Clearing Obstructions From the Bagger System Caution Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. Danger Always remove the ignition key and set the parking brake when leaving the machine unattended, even for just a few minutes. When the bagger is in operation, the blower can be rotating and cut off or injure hands.
Operating and Bagging Tips Bagging Long Grass Machine Size Excessively long grass is heavy and may not be propelled completely into the bagger. If this happens, the tube and blower assembly may plug. Remember that the machine is longer and wider with this attachment installed. By turning too sharply in confined places you may damage the attachment or other property. Bagging Wet Grass If possible, always try to cut grass when it is dry. Wet grass can cause plugging.
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 46 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. 47). 7. Adjust the fixed idler towards the front to shorten the spring and decrease belt tension (Fig. 47). 8. Tighten the two bolts that hold the fixed idler to the blower assembly (Fig. 47). 5 9. Close the blower assembly and measure the spring length again.
2. The blower latch must engage over the front peg (Fig. 49). 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. 50). 5. To shorten the latch turn the hex nut clockwise to tighten the nut. (Fig. 50). 6. When the desired latch length is correct, tighten both nuts. (Fig. 50). 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. 52). 3 2 4 3 4 6 5 7 2 1 m–7007 1 m–6244 5 Figure 53 Figure 52 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 19. 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. 55). This will provide clearance between the impeller and the liner. Grease the bagger belt idler arm every 25 hours (Fig. 56). Grease the blower pivot after installing the blower into the mounting hole (Fig. 56). 11. Rotate the blower pulley to verify that the blower fan does not hit the liner (Fig. 55). Adjust the liner if necessary. 12.
Storage 1. Clean the bagger attachment. Refer to Cleaning the Bagger on page 28. 2. Inspect the bagger attachment for damage. Refer to Inspecting the Bagger on page 32. 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.
