FormNo.3435-395RevA
BlowerandDriveKit
60inor72inE-ZVac
™
BaggerforZ500SeriesZMaster
®
Mowers
ModelNo.78538—SerialNo.400000000andUp
ModelNo.78539—SerialNo.400000000andUp
InstallationInstructions
Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescription
Qty.
Use
1
Nopartsrequired
–
Preparethemachine.
2
Nopartsrequired
–
Removetheexistingbeltcoverand
bracket.
Pulleyassembly1
Pulley-platemount—formachineswith
analuminumspindleonly
1
3
Flangenut(3/8inch)—formachines
withanaluminumspindleonly
3
Installthepulleyassemblyandbelt.
4
Nopartsrequired
–
Removetheexistinganti-scalproller
andbracket.
Blowerpivot1
Metaltemplate1
Bolt(3/8x1inch)
3
5
Locknut(3/8inch)
3
Installtheblowerpivot(fora60-inch
bagger).
Blowerpivot1
Metaltemplate1
Bolt(3/8x1inch)
4
6
Locknut(3/8inch)
4
Installtheblowerpivot(fora72-inch
bagger).
Blowerassembly1
Baggerbelt1
Blowerbeltcover1
7
Spring
1
Installtheblower,baggerbelt,spring,
andbeltcover.
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OriginalInstructions(EN)
PrintedintheUSA
AllRightsReserved
*3435-395*A
1
PreparingtheMachine
NoPartsRequired
Procedure
1.Parkthemachineonalevelsurface.
2.Movethemotion-controlleverstotheNEUTRAL-LOCKposition.
3.Engagetheparkingbrake.
4.Shutofftheengineandremovethekey.
g037289
Figure1
2
2
RemovingtheExistingBelt
CoverandBracket
NoPartsRequired
Procedure
Note:Cleantheareaaroundthebeltcoverbefore
removingit.
1.Lowerthemowerdecktothelowestheight-of-cut
position.
2.Unlatchandremovetherightbeltcover(Figure
2).
Retainthehardware.
g003517
Figure2
1.Rightbeltcoverbracket3.Latch
2.Beltcover
3.Removetheoutsiderightbeltcoverbracket
(Figure3).
g003518
Figure3
1.Self-threadingbolt
3.Mowerdeck
2.Rightbeltcoverbracket
4.Storetherightbeltcover,bracket,andhardware
forlateruseifyouremovethebaggerblower
andpulley.
5.For72-inchmowerdecksonly—removethe4
rubberstopsfromthemowerdeck(Figure4).
g003375
Figure4
1.Rubberstop(72-inch
mowerdecksonly)
2.Mowerdeck
3
3
InstallingthePulley
AssemblyandBelt
Partsneededforthisprocedure:
1Pulleyassembly
1
Pulley-platemount—formachineswithanaluminum
spindleonly
3
Flangenut(3/8inch)—formachineswithanaluminum
spindleonly
ForMachineswithanAluminum
Spindle
1.Removethetopnut,washer,andsheavefrom
thespindle(Figure5).
Note:Notetheorientationofthesheavewhen
youremoveitfromthespindletoensurethat
youinstallitproperlylaterintheprocess.
g302393
Figure5
1.Topnut
3.Sheave
2.Washer
4.Spindle
2.Insertthepulley-platemountstudsintotheholes
inthesheave(Figure6).
g302390
Figure6
1.Sheave
2.Pulley-platemountstuds
3.Looselyinstallthe3nutstothestuds(Figure7).
Leaveaclearanceof5mm(3/16inch)between
thenutandsheave.
g302412
Figure7
1.Nut
2.Stud
4
4.Installthesheaveassemblytothespindleusing
thewasherandtopnut(Figure8).
g302413
Figure8
1.Topnut
3.Sheaveassembly
2.Washer
4.Spindle
5.Torquethetopnutto176to217N∙m(130to
160ft-lb).
Note:Ensurethatthesheavespinsfreely.
6.Alignthenewpulleyassemblysothatthe
openingstoverthenuts(Figure9).
g302411
Figure9
1.Pulleyassembly2.Nuts
7.Turnthepulleytolockitintoposition(Figure10).
Note:Ifthepulleydoesnotturn,loosenthe
nutsmoretoraisethenutsandallowthepulley
tolockintoposition.
g302414
Figure10
1.Pulleyassembly
8.Afterthenewpulleyassemblyisinposition,
tightenthenutstosecurenewpulleyassembly.
Torquethe3nutsto28to34N∙m(21to25ft-lb).
9.Installthedeckbelt.
5
ForMachineswithBolts
1.Loosen,butdonotremove,thetappingboltson
theexistingmower-deckpulley(Figure11).
Note:Thereshouldbea5mm(3/16inch)
clearancebetweentheboltheadandpulley.
2.Alignthenewpulleyassemblysothatthe
openingstoverthepulleyboltheads(Figure
11).
3.Turnthepulleytolockitintoposition(Figure11).
Note:Ifthepulleydoesnotturn,loosenthe
boltsmoretoraisetheboltheadsandallowthe
pulleytolockintoposition.
4.Afterthenewpulleyassemblyisinposition,
tightentheexistingboltstosecurenewpulley
assembly.
Note:Torquetheboltsto28to34N∙m(21to
25ft-lb).
g003396
Figure11
1.Pulley
assembly
3.Lockingslots
5.Clearance—5
mm(3/16inch)
2.Mower-deck
pulley
4.Boltheads
5.Installthedeckbelt.
4
RemovingtheExisting
Anti-ScalpRollerand
Bracket
NoPartsRequired
Procedure
Note:Donotperformthisprocedureifapivotis
installed.
1.Cleantheareaaroundtheright,rearanti-scalp
roller.
2.Removetheanti-scalprollerfromthebracket
bylooseningandremovingtheangenut(3/8
inch)andaxlebolt(3/8x4-1/2inches)asshown
inFigure12.
Saveallhardwareforlateruse.
3.Removethe3carriagebolts(3/8x3/4inch)and
3angenuts(3/8inch)securingthebracketto
themower(Figure12).
Saveallhardwareforlateruse.
g003313
Figure12
1.Anti-scalproller
4.Carriagebolt(3/8x3/4
inch)
2.Anti-scalpbracket
5.Flangenut(3/8inch)
3.Bolt(3/8x4-1/2inches)
6.Mowerdeck
6
5
InstallingtheBlowerPivot
Fora60-inchBagger
Partsneededforthisprocedure:
1Blowerpivot
1Metaltemplate
3
Bolt(3/8x1inch)
3
Locknut(3/8inch)
Procedure
Note:Donotperformthisprocedureifapivotis
installed.
1.Installthemetaltemplatewiththenumber60in
ittothemowerdeckwiththepreviouslyremoved
carriageboltsandnutsusingtheexistingholes
inthemowerdeck(Figure13).
Ensurethatthecarriageboltsandnutsaretight
andthetemplateistightagainstthemowerdeck.
2.Center-punchthenewmowerdeckhole
locationsusingthe3holesinthetemplate
(Figure13).
3.Removethemetaltemplateanddrill3pilot
holes(1/8-inchdiameter)withasharpdrillbit
(Figure13).
4.Drill3holes(13/32-inchdiameter)intothepilot
holeswithasharpdrillbit(Figure13).
g003395
Figure13
1.Mowerdeck4.Templatelocationonthe
mowerdeck
2.Drilltheholeshere.5.Nuts
3.Templatewiththenumber
60init
6.Carriagebolts
5.Installthenewblowerpivotusing3bolts(3/8x
1inch)and3locknuts(3/8inch)usingthedrilled
holes(Figure14).
6.Installtheanti-scalprollertotheblowerpivot
usingthepreviouslyremovedaxlebolt(3/8x
4-1/2inches),spacer,bushing,andangenut
(3/8inch)asshowninFigure14.
7
g003382
Figure14
1.Mowerdeck
6.Carriagebolts
2.Bolt(3/8x1inch)
7.Bushing
3.Locknut(3/8inch)
8.Blowerpivotassembly
4.Bolt(3/8x4-1/2inches)
9.Holes
5.Spacer
6
InstallingtheBlowerPivot
Fora72-inchBagger
Partsneededforthisprocedure:
1Blowerpivot
1Metaltemplate
4
Bolt(3/8x1inch)
4
Locknut(3/8inch)
Procedure
Note:Donotperformthisprocedureifapivotis
installed.
1.Installthemetaltemplatewiththenumber72in
ittothemowerdeckwiththepreviouslyremoved
carriageboltsandnutsusingtheexistingholes
inthemowerdeck(Figure15).
Ensurethatthecarriageboltsandnutsaretight
andthetemplateistightagainstthemowerdeck.
2.Center-punchthenewmowerdeckhole
locationsusingthe4holesinthetemplate
(Figure15).
3.Removethemetaltemplateanddrill4pilot
holes(1/8-inchdiameter)withasharpdrillbit
(Figure15).
4.Drill4pilotholes(13/32-inchdiameter)intothe
pilotholeswithasharpdrillbit(Figure15).
g003383
Figure15
1.Mowerdeck4.Templatelocationon
mowerdeck
2.Drilltheholeshere.5.Nuts
3.Templatewiththenumber
72init
6.Carriagebolts
5.Installthenewblowerpivotusing4bolts(3/8x
1inch)and4locknuts(3/8inch)usingthedrilled
holes(Figure16).
6.Installtheanti-scalprollerbracketusingthe
previouslyremovedcarriageboltsandnutsto
themowerdeck(Figure16).
7.Installtheanti-scalprollertothebracketusing
thepreviouslyremovedaxlebolt(3/8x4-1/2
inches),bushings,andangenut(3/8inch)as
showninFigure16.
8
g003376
Figure16
1.Mowerdeck6.Anti-scalproller
2.Bolt(3/8x1inch)
7.Bushing
3.Flangenut(3/8inch)
8.Anti-scalpbracket
4.Bolt(3/8x4-1/2inches)9.Carriagebolt(3/8x3/4
inch)
5.Blowerpivotassembly
10.Spacer
7
InstallingtheBlower
Assembly,BaggerBelt,
SpringandBlower-Belt
Cover
Partsneededforthisprocedure:
1Blowerassembly
1Baggerbelt
1Blowerbeltcover
1
Spring
Procedure
RefertothebaggerOperator'sManualforthecorrect
proceduretoinstalltheblower,baggerbelt,spring,
andblower-beltcover.
9
Notes:
Notes:
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