Toro 78477 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. 3321-443

Z – Master

48” Recycler

for

OUT FRONT Z –TRACTION UNIT

Model No. 78477– 891696 & Up

The Toro Company – 1998

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

Remove Carrier Frame 4. . . . . . . . . . . . . . . .

Install Castor Wheels 4. . . . . . . . . . . . . . . . .

Installing Push Arms 5. . . . . . . . . . . . . . . . .

Installing Lift Springs 5. . . . . . . . . . . . . . . .

Installing Mower 5. . . . . . . . . . . . . . . . . . . .

Removing the Mower 7. . . . . . . . . . . . . . . . .

Operation 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating the Power Take Off (PTO) 10. . . .

Adjusting Height-of-Cut 11. . . . . . . . . . . . . .

Adjusting Rollers 11. . . . . . . . . . . . . . . . . . . .

Tilting the Mower 12. . . . . . . . . . . . . . . . . . .

Page

Maintenance 13. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Interval Chart 13. . . . . . . . . . . . . . . .

Cutting Blades 13. . . . . . . . . . . . . . . . . . . . . .

Correcting Cutting Unit Mismatch 16. . . . . .

Setting the Front-to-Rear Pitch 17. . . . . . . . .

Setting the Side-to-Side Leveling 17. . . . . . .

Greasing and Lubrication 18. . . . . . . . . . . . . .

Replacing the Castor Wheel Fork Bushings 19

Servicing the Castor Wheels and Bearings 20

Replacing Push Arm Bushings 21. . . . . . . . .

Storage 22. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 23. . . . . . . . . . . . . . . . . . . . . . . . .

Safety

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

Castor Wheel

Thrust Washer

Spacer

Retaining Ring

Install castor wheels to carrier frame

Push Arms

Flat Washer 1-1/2” O.D. (38 mm)

Retaining Ring

2Install push arms to carrier frame

Spring Assembly

Shoulder Bolt 3/8”–16 x 7/8” (22 mm)

Locknut 3/8”–16

2Install springs to carrier frame

Shoulder Bolt 3/8”–16 x 7/8” (22 mm)

Locknut 3/8”–16

Bolt 3/8”–16 x 1-5/8” (41.5 mm)

Locknut 3/8”-16

Install mower to traction unit

Save when removing PTO drive shaft

Shoulder bolt 5/16–18 x 7/16” (11 mm)

Flange nut 5/16”–18

1Secure power take off (PTO) cover

Operator’s Manual

Parts Catalog

Read before operating

Ordering parts

Installation

Remove Carrier Frame

1. Remove hairpin cotters and clevis pins from

mower hanger brackets and remove mower from

carrier frame (Fig. 1).

1m-3531

Figure 1

1. Mower Hanger Bracket

2. Clevis Pin 3. Hairpin Cotter

Install Castor Wheels

1. Place spacer and (2) thrust washers on shaft and

slide the castor wheel into the mounting tube

(Fig. 2).

2. Place (2) thrust washers on top of the fork and

secure with retaining ring (Fig. 2).

Note: The location of the thrust washers on

each fork may need adjustment to

maintain a level deck.

3. Grease the fitting on the carrier frame mounting

tube using No. 2 general purpose lithium base or

molybdenum base grease, refer to: Greasing and

Lubrication.

4. Set the castor wheel tire pressure to 50 psi

(345 kPa).

m-3531

Figure 2

1. Retaining ring

2. Thrust Washer (4)

3. Spacer

4. Carrier Frame Mounting

Tube

5. Grease fitting

6. Castor Wheel Fork

Installation

Installing Push Arms

1. Place push arm onto carrier frame pin as shown

(Fig. 3).

2. Secure with 1-1/2” (38 mm) flat washer and

retaining ring (Fig. 3).

m-3936

Figure 3

1. Pin

2. Push arm 3. Flat washer 1-1/2”

(38 mm)

4. Retaining ring

Installing Lift Springs

1. Secure spring end plate assembly to traction unit

with 3/8” x 7/8” (23 mm) shoulder bolt and 3/8”

locknut (Fig. 4).

m-3209

Figure 4

1. Spring Assembly

2. Shoulder Bolt 3/8” x 7/8”

(22 mm)

3. Locknut 3/8”

Installing Mower

1. Position carrier frame in front of traction unit

and place push arms into clevises (Fig. 5).

2. Retain push arms with pivot pin assemblies,

aligned with flat against frame, and secure with

hairpin cotters (Fig. 5).

Note: Pivot pin assemblies and hairpin

cotters are part of traction unit.

2m-3937

Figure 5

1. Clevis

2. Push Arm 3. Pivot Pin Assembly–flat

4. Hairpin Cotter

Installation

3. Lift carrier frame into vertical position, refer to:

Tilting the Mower.

4. Secure spring end plate assembly to carrier

frame with 3/8” x 7/8” (23 mm) shoulder bolt

and 3/8” locknut (Fig. 6).

m-3193

Figure 6

1. Spring Assembly

2. Shoulder Bolt 3/8” x 7/8”

(22 mm)

3. Locknut 3/8”

5. Roll mower in front of traction unit.

6. Rotate PTO drive shaft so holes in universal

joint align with hole in gearbox shaft and slide

together (Fig. 7).

7. Drive roll pin through hole in universal joint to

secure PTO drive shaft to gearbox shaft (Fig. 7).

Note: Drive shaft and roll pin are part of

traction unit.

m-3376

Figure 7

1. PTO Driveshaft

2. Universal Joint 3. Gearbox shaft

4. Roll Pin

Installation

8. Release the latch levers and push carrier frame

down. Latch pins should lock.

9. Select hole in mower hanger bracket

corresponding to the height-of-cut desired. Lift

on side and front handles to align holes and

insert clevis pin (Fig. 8).

10. Secure clevis pin with hairpin cotter (Fig. 8).

Note: All four clevis pins should be in the

same hole location for a level cut.

m-3532

Figure 8

1. Mower Hanger Bracket

2. Clevis Pin 3. Hairpin Cotter

11. Secure PTO cover down with 5/16–18 x 7/8”

(11 mm) shoulder bolt and 5/16” flange nut

(Fig. 9).

m-3718

Figure 9

1. PTO cover

2. Shoulder bolt

5/16–18 x 7/8” (11 mm)

3. Flange nut 5/16”

Removing the Mower

1. Remove 5/16–18 x 7/8” (11 mm) shoulder bolt

and 5/16” flange nut holding PTO cover down

(Fig. 9).

2. Drive roll pin through hole in universal joint to

remove PTO drive shaft from gearbox shaft

(Fig. 7).

Note: Roll pin and drive shaft remain with

traction unit.

m-3376

Figure 10

1. PTO Driveshaft

2. Universal Joint 3. Gearbox shaft

4. Roll Pin

Installation

3. Tilt mower into raised position, refer to: Tilting

the Mower.

4. Remove 3/8” x 7/8” (23 mm) shoulder bolt and

3/8” locknut securing spring end plate assembly

to carrier frame (Fig. 11).

m-3209

Figure 11

1. Spring Assembly

2. Shoulder Bolt 3/8” x 7/8”

(22 mm)

3. Locknut 3/8”

5. Carefully lower mower from vertical position

using front lift handles, refer to: Tilting the

Mower.

6. Remove hairpin cotters and clevis pins from

mower hanger brackets and remove mower from

carrier frame (Fig. 12).

m-3532

Figure 12

1. Mower Hanger Bracket

2. Clevis Pin 3. Hairpin Cotter

7. Raise the carrier frame and roll the mower away

from traction unit.

8. Lower carrier frame and remove hairpin cotters

and pivot pin assemblies securing push arms to

traction unit clevises (Fig. 13).

Note: Save all hardware for use when

installing mower. Items 3 and 4 are

part of traction unit.

2m-3937

Figure 13

1. Clevis

2. Push Arm 3. Pivot Pin Assembly–flat

4. Hairpin Cotter

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