Toro 78501 Operator's Manual

Form No. 3329–572

52in TURBO FORCE Mower Finishing Kit

Z500 Twin Soft Bagger

Model No. 78501—Serial No. 230000001 and Up

Operator ’s Manual

Original Instructions (EN)

Contents

Introduction

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

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

Safety and Instruction Decals 4. . . . . . . . . . . . . . .

Setup 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loose Parts 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Before Installation 7. . . . . . . . . . . . . . . . . . . . . . . . . . .

Prepare the Mower 7. . . . . . . . . . . . . . . . . . . . . . . .

Positioning the Flow Baffle 7. . . . . . . . . . . . . . . . .

Installation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing the Existing Belt Cover 8. . . . . . . . . . .

Removing the Existing Anti-Scalp

Roller and Bracket 8. . . . . . . . . . . . . . . . . . . . . .

Installing the New Bracket and Anti-Scalp Roller 9

Installing the Mounting Plate 9. . . . . . . . . . . . . . . .

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

Removing the Drive Wheels and Bumper Guard 10

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

Installing the Hood Assembly and Bags 12. . . . . . .

Installing the Blower Assembly 14. . . . . . . . . . . . . .

Installing the Bagger Belt and Idler Spring 14. . . . .

Installing the Belt Cover 16. . . . . . . . . . . . . . . . . . .

Installing the Bagger Tube 17. . . . . . . . . . . . . . . . . .

Installing the Weights 18. . . . . . . . . . . . . . . . . . . . .

Adjusting the Parking Brake 19. . . . . . . . . . . . . . . .

Operation 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emptying the Grass Bags 20. . . . . . . . . . . . . . . . . . .

Clearing Obstructions From the Bagger System 21.

Operating and Bagging Tips 21. . . . . . . . . . . . . . . .

Maintenance 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Maintenance Schedule 23. . . . . . . .

Cleaning the Hood Screen 23. . . . . . . . . . . . . . . . . .

Cleaning the Bagger 23. . . . . . . . . . . . . . . . . . . . . . .

Checking and Adjusting the Bagger Belt Tension 23

Checking and Adjusting the Blower Latch 24. . . . .

Replacing the Blower Belt 25. . . . . . . . . . . . . . . . . .

Checking the Blower Liner 26. . . . . . . . . . . . . . . . .

Replacing the Blower Liner 26. . . . . . . . . . . . . . . . .

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

Greasing the Blower 27. . . . . . . . . . . . . . . . . . . . . .

Inspecting the Mower Blades and Baffles 27. . . . . .

Installing Mower Blades 27. . . . . . . . . . . . . . . . . . .

Storage 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

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–6231

Figure 1

1. Location o f 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.

 2003 by The Toro Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196

Printed in the USA

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.

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

grass catcher could cause loss of control or overturn the machine.

• Do not use your hands to unclog the chute, blower or

bagger.

• 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.

• 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 or

removed and never altered, unless using a grass catcher or mulching baffles.

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

make adjustments with the engine running.

• 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.

• 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.

• Turn off the engine and wait for all moving parts to

stop before removing the grass catcher or unclogging the chute.

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

79-0360

1-653554

80-8040

88-8950

106-0871

98-4387

1. Warning—wear hearing protection.

68-3650

93-1122

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.

Important This kit and bagger will require significant time to install the first time. A right angle drill is recommended

for installation.

Step Description Qty. Use

1 2 3

4 5

6 7

No parts needed Removing the existing mower cover

No parts needed

Anti-scalp roller bracket Tapping screw, 3/8 x 1 inch

Mounting plate Bolt, 3/8 x 1-1/4 inch Flange nuts, 3/8 inch

Pulley assembly 1 Installing the pulley assembly

No parts needed

Bagger mounting bracket Left side bagger bracket Right side bagger bracket Bolt, 3/8 x 1 inch Flange nut, 3/8 inch Belleville washer, 3/8 inch

1 1

1 2 2

1 1

1 10 10

Removing the anti-scalp roller and bracket

Installing the anti-scalp roller and bracket

Installing the mounting plate

Removing the drive wheels and bumper guard

Installing the bagger brackets

8 9 10

Hood assembly Bag Clevis pin Hairpin cotter

Blower assembly 1 Installing the blower assembly

Blower belt cover Bagger Belt Idler spring Pulley cover

Installing the hood assembly and bags

Installing the bagger belt and idler spring

Step UseQty.Description

11 12

Belt cover 1 Installing the belt cover

Bagger tube Clamp Knob Blower adapter

Caster weight U–bolt Nut, 1/2 inch Lock washer, 1/2 inch Plate Top weight Bolt, 1/2 x 3 inch Plate

No parts needed Adjusting the parking brake

1 1 2 1

2 2 4 4 2 2 2 2

Installing the bagger tube

Installing the weights

Before Installation

Prepare the Mower

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.

Position B

Use this position when bagging.

Middle Position

3. Clean the mower of any debris on the deck or rear of

mower to ease installation.

Positioning the Flow Baffle

The following figures are only recommendations for use. Adjustments will vary by grass type, moisture content, and height of grass. The middle position or Position B is recommended for bagging.

Note: If the engine power draws down and the mower ground speed is the same, open up the baffle.

Position A

This is the full rear position. The suggested use for this position is a follows.

• Use for short, light grass mowing conditions.

• Use in dry conditions.

• For smaller grass clippings.

• Propels grass clippings farther away from the mower.

Full Rearward Position

m–6880

Figure 3

Position C

This is the full open position. The suggested use for this position is as follows.

• Use in tall, dense grass mowing conditions.

• Use in wet conditions.

• Lowers the engine power consumption.

• Allows increased ground speed in heavy conditions.

• This position is similar to the benefits of the Toro SFS

mower.

Full Forward Position

Figure 2

m–6879

Figure 4

m–6881

Installation

Step

No Parts needed for this step.

Removing the Existing Belt Cover

Note: Clean the area around the belt cover before removing.

1. Unlatch and remove the right belt cover (Fig. 5).

2. Store the right belt cover for later use. If the bagger

blower and pulley is removed it can be reused.

Step

No Parts needed for this step.

Removing the Existing Anti-Scalp Roller and Bracket

Note: Clean the area around the right, rear anti-scalp wheel

1. Remove the anti-scalp roller from the bracket by

loosening and removing the flange nut (3/8 inch) and axle bolt (3/8 x 4-1/2 inch) as shown in figure 6.

2. Remove the three carriage bolts (3/8 x 3/4 inch) and

flange nuts (3/8 inch) securing the bracket to the mower (Fig. 6). Save the fasteners for later use.

3. Remove the bracket and discard.

Figure 5

1. Belt cover 2. Latch

m–6824

1. Anti-scalp roller

2. Anti-scalp bracket

3. Bolt, 3/8 x 4-1/2 inch

m–6981

Figure 6

4. Carriage bolt, 3/8 x 3/4 inch

5. Flange nut, 3/8 inch

6. Mower deck

Step

Parts needed for this step:

• 1 Anti-scalp roller bracket

• 1 Tapping screw

Installing the New Bracket and Anti-Scalp Roller

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).

2. Install a tapping screw (3/8 x 1 inch) into the deck and

roller bracket (Fig. 7).

Note: The screw requires effort to turn. By installing the screw, threads will be cut into the new bracket.

3. Install the anti-scalp roller with the axle bolt

(3/8 x 4-1/2 inches), flange nut (3/8 inch) (Fig. 7).

Parts needed for this step:

• 1 Mounting plate

• 2 Bolts, 3/8 x 1-1/4 inch

• 2 Flange nuts, 3/8 inch

Installing the Mounting Plate

1. Move the grass deflector into the upright position. Note: When the mower is switched to bagging leave the

grass deflector on the machine. The grass deflector will rest against the blower belt cover.

2. Install the mounting plate to the inside of the deck

mounting bracket with 2 bolts (3/8 x 1-1/4 inch) and 2 flange nuts (3/8 inch) as shown in figure 8.

1. Anti-scalp bracket, new

2. Carriage bolt, 3/8 x 3/4 inch

3. Flange nut, 3/8 inch

Figure 7

m–6980

4. Screw, tapping, 3/8 x 1inch

5. Bolt, 3/8 x 4-1/2 inch

6. Anti-scalp roller

m–7005

1. Mounting plate

2. Bolt, 3/8 x 1–1/4 inch

Figure 8

3. Flange nut, 3/8 inch

Step

Note: If the pulley does not turn, loosen the bolts to raise the bolt heads and allow the pulley to lock into position.

4. After the new pulley assembly is in position, tighten

the existing bolts to secure new pulley.

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 (0.64 cm) clearance between the bolt head and pulley.

1/4 inch

(0.64 cm)

Important Torque the nuts to 23 ft-lb ± 2 ft-lb

(31 N⋅m ± 3 N⋅m).

Step

No parts needed for this step.

Removing the Drive Wheels and Bumper Guard

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.

m–7004

Figure 9

1. Pulley assembly, bagger belt

2. Pulley assembly, drive belt

2. Align the new pulley assembly so that the openings fit over the pulley bolt heads loosened in step 1 and install (Fig. 9).

3. Turn the pulley to lock it into position (Fig. 9).

3. Locking slots

4. Bolts heads

m–6794

Figure 10

1. Rear bumper guard

2. Bolt

1. Remove the existing rear bumper guard (Fig.10.

2. Loosen the drive wheel lugs or nuts.

3. Raise the rear of the machine and support with jack

stands.

4. Remove the drive wheels.

3. Nut

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