Toro 78476 User manual

Operator’s Manual

IMPORTANT: Read this manual carefully. It contains information about your

safety and the safety of others. Also become familiar with the controls and

their proper use before you operate the product.

FORM NO. 3318–954 Rev. A

Z–MASTER

60” Mower

for

Zero Radius T

ractors

Model No. 78476 – 790001 & Up

The Toro Co. – 1997

Printed in USA

Introduction

We want you to be completely satisfied with your

new product, so feel free to contact your local

Authorized Service Dealer for help with service,

genuine replacement parts, or other information you

may require.

Whenever you contact your Authorized Service

Dealer or the factory, always know the model and

serial numbers of your product. These numbers will

help the Service Dealer or Service Representative

provide exact information about your specific

product. You will find the model and serial number

plate located in a unique place on the product as

shown below



1. Model

and Serial Number Plate

For your convenience, write the product model and

serial numbers in the space below.

Model No:

Serial No.

The warning system in this manual identifies

potential hazards and has special safety messages that

help you and others avoid personal injury, 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 the recommended

precautions are not followed.

WARNING signals a hazard that may cause serious

injury or death if the recommended precautions are

not followed.

CAUTION signals a hazard that may cause minor or

moderate injury if the recommended precautions are

not followed.

Two other words are also used to highlight

information. “Important” calls attention to special

mechanical information and “Note” emphasizes

general information worthy of special attention.

The left and right side of the machine is determined

by sitting on the seat in the normal operator’s

position.

Contents

Page

Safety and Instruction Decals 2.

. . . . . . . . . . . . .

Installation 3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loose Parts 3

. . . . . . . . . . . . . . . . . . . . . . . . .

Assemble the Grass Deflector

. . . . . . . . . .

Installing the Mower 4

. . . . . . . . . . . . . . . . .

Operation 6

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Side Discharge or Mulch Grass 6

. . . . . . . . .

Operating the Power Take Off (PTO) 6

. . . .

Attachment Lift 7

. . . . . . . . . . . . . . . . . . . . .

Adjusting the Height-of-Cut 7

. . . . . . . . . . .

Adjusting the Gauge Wheel 8

. . . . . . . . . . . .

Tips for Mowing Grass 9

. . . . . . . . . . . . . . .

Page

Maintenance 10

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Interval Chart 10

. . . . . . . . . . . . . . . .

Cutting Blades

. . . . . . . . . . . . . . . . . . . . . .

Correcting Cutting Unit Mismatch 13

. . . . . .

Setting the Side-to-Side Leveling 13

. . . . . . .

Setting the Front-to-Rear Pitch 14

. . . . . . . . .

Greasing the Bearings

. . . . . . . . . . . . . . . .

Replacing the Deck Belt

. . . . . . . . . . . . . .

Replacing the Drive Belt 16

. . . . . . . . . . . . . .

Replacing the Grass Deflector 17

. . . . . . . . . .

Storage 17

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 18

. . . . . . . . . . . . . . . . . . . . . . . . .

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.

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Installation

Loose

Parts

Note: Use the chart below to identify parts used for assembly.

DESCRIPTION QTY. USE

Deflector

Bolt 3/8–24 x 3-3/4” (95 mm)

Spring

Locknut 3/8–24

Install deflector to mower

Stabilizer bars

Clevis pin 3/8–1-1/4” (32 mm)

Clevis pin 3/8–2-1/4” (57 mm)

Hairpin cotter

Install stabilizer bars

Flange nut

asher 3/8”

Jam nut 3/8–16

Install mower to traction unit

Operator’

s Manual

Parts Catalog

Read before operating

Ordering parts

Installation

Assemble

the Grass Deflector

1. Locate the deflector mounts over the pivot

brackets and secure with the (2) 3/8–3-3/4” (95

mm) bolts, (2) springs and (2) 3/8” locknuts.

Make sure the straight ends of the springs are

positioned between the deflector mounts and the

grass deflector (Fig. 1).

2. Tighten the locknuts until they contact the pivot

brackets (Fig. 1).

IMPORTANT: The grass deflector must be

spring-loaded in the down position. Lift the

deflector up to test that it snaps to the full

down position.

14m–2549

Figure 1

1. Bolt

3/8–24 x 3-3/4”

(95 mm)

Deflector Mount

3. Spring

Pivot Bracket

Locknut 3/8”

Installing

the Mower

1. Remove (2) wing nuts and washers on footrest

panel and remove panel from frame.

2. Slide mower under traction unit.

3. Secure stabilizer bars to traction unit frame

mounts with (2) 3/8”–1-1/4” (32 mm) clevis pins

and (2) hairpin cotters (Fig. 2).

4. Select proper hole for height-of-cut. Secure

stabilizer bars to mower front brackets with (2)

3/8”–1-1/4” (32 mm) clevis pins and (2) hairpin

cotters (Fig. 2).

m–2779

Figure 2

1. Stabilizer

bar

Frame mount

Clevis pin 3/8”–1-1/4”

(32 mm)

Hairpin cotter

Front mower bracket

Installation

5. Push attachment lift pedal all the way forward,

remove pedal spring and move foot pedal all the

way back (Fig. 3).



Figure 3

1. Attachment

lift pedal

Pedal spring

6. Attach front lift chain bolts to mower with (2)

3/8” flange nuts, (2) 3/8” washers and (2) 3/8”

locknuts (Fig. 4).

m–2750

Figure 4

1. Lift

chain

Flange nut 3/8”

3. W

asher 3/8”

Locknut 3/8”

7. Lift up on rear of mower and install (2)

3/8”–2-1/4” (57 mm) clevis pins in top holes of

rear mower brackets. Secure with (2) hairpin

cotters.

8. Push attachment lift pedal all the way forward

and install pedal spring (Fig. 3).

9. Route drive belt around top pulley of mower,

idler pulleys on pivot plate (Fig. 2) and the

clutch drive pulley.

10. Hook spring over pin on idler plate and loosely

mount to mower with eye bolt, 3/8” washer and

(2) 3/8” jam nuts (Fig. 5).

11. Tension the drive belt by tightening the front jam

nut on eyebolt until the spring is 16-1/2”

(41.9 cm). Measure the spring length between

the pin and the eyebolt (Fig. 5).

12. Tighten the jam nuts (Fig. 5).

m–2778

Figure 5

1. Pin

2. Spring

3. Eye

bolt 3/8”

4. W

asher 3/8”

Jam nut 3/8”

Clutch pulley

Spring 16-1/2” (41.9 cm)

13. Adjust mower side-to-side leveling and

front-to-rear pitch; refer to pages 13 and 14.

14. Install footrest panel and secure with (2) washers

and wing nuts.

Operation

Side

Discharge

or Mulch Grass

The mower has a hinged grass deflector that disperses

clippings to the side and down toward the turf.

POTENTIAL HAZARD

•Without the grass deflector or complete

grass catcher assembly mounted in place,

you and others are exposed to blade contact

and thrown debris.

WHAT CAN HAPPEN

•Contact with rotating mower blade(s) and

thrown debris will cause injury or death.

HOW TO AV

OID THE HAZARD

•

NEVER r

emove the grass deflector from

the mower because the grass deflector

routes material down toward the turf. If the

grass deflector is ever damaged, replace it

immediately.

•Never put your hands or feet under the

mower.

•Never try to clear discharge area or mower

blades unless you move the power take-off

(PTO) to “OFF” and rotate the ignition key

to “OFF.” Also remove the key and pull the

wire(s) off the spark plug(s).

The power take off (PT

O) engages and disengages

power to the attachment clutch.

Operating

the

Power T

ake Off (PT

The power take off (PT

O) engages and disengages

power to the attachment clutch.

Engaging the Power Take Off (PTO)

1. Release pressure on the motion control levers to

stop the machine.

2. Raise the cover and move the power take off

(PTO) switch to the “ON” position to engage

(Fig. 6).

m–2721

Figure 6

1. Cover

2. ON-Engaged 3. OFF-Disengaged

Disengaging the Power Take Off (PTO)

1. Release pressure on the motion control levers to

stop the machine.

2. Lower the cover of the power take off (PTO)

switch. This moves the switch to the “OFF”

position to disengage (Fig. 6).

Operation

Attachment

Lift

The attachment lift (Fig. 7) is used to raise and lower

attachments.

Raising Attachments

1. Place your foot on the lift pedal (Fig. 7).

2. Push down with your foot, release the lock by

rocking the pedal with your heel, then press with

your toe to raise the attachment lift (Fig. 7).

Remove your foot to hold the attachment in the

up, or raised position.

Lowering Attachments

1. Place your foot on the lift pedal (Fig. 7).

2. Push down with your foot, release the lock by

rocking the pedal with your heel, then release

foot pressure to lower the attachment lift

(Fig. 7). Remove your foot to hold the

attachment in the down, or desired position.

m–2716

Figure 7

1. Lift

pedal -UP

Lift pedal-DOWN

Adjusting

the Height-of-Cut

The pins and stabilizer bars are used to adjust the

height-of-cut range; refer to; Setting the Front-to-Rear

Pitch page 14.

1. Set the stabilizer bars for the desired cut height

range, refer to; Setting the Front–to–Rear Pitch

page 14.

2. Loosen down stop on attachment lift (Fig. 8).

3. Set attachment lift to the correct position for

selected cut height (Fig. 8).

4. Slide down stop against attachment lift and

tighten bolt (Fig. 8).

2

Figure 8

1. Attachment

lift

Down stop

Operation

Adjusting

the Gauge Wheel

Whenever you change the height-of-cut you must also

adjust the height of the gauge wheels.

Stop the engine before adjusting the gauge wheel

height.

1. Pull the hairpin cotter out of the clevis pin and

remove the clevis pin from the gauge wheel plate

and mounting bracket (Fig. 9).

2. Reposition the gauge wheel so it’s approximately

1/4” to 3/8” (6 to 10 mm) above the ground, then

insert the clevis pin through the gauge wheel

plate and mounting bracket (Fig. 9).

3. Reinstall the hairpin cotter into the clevis pin

(Fig. 9).

m-2553

Figure 9

1. Mounting

Bracket

Hairpin Cotter

Clevis Pin

Gauge Wheel Plate

Gauge Wheel

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