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

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.

1
Contents
Page
Safety and Instruction Decals 2.
. . . . . . . . . . . . .
Installation 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts 3 . . . . . . . . . . . . . . . . . . . . . . . . .
Assemble the Grass Deflector
4 . . . . . . . . . .
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 10 . . . . . . . . . . . . . . . . . . . . . .
Correcting Cutting Unit Mismatch 13 . . . . . .
Setting the Side-to-Side Leveling 13 . . . . . . .
Setting the Front-to-Rear Pitch 14 . . . . . . . . .
Greasing the Bearings 15 . . . . . . . . . . . . . . . .
Replacing the Deck Belt 15 . . . . . . . . . . . . . .
Replacing the Drive Belt 16 . . . . . . . . . . . . . .
Replacing the Grass Deflector 17 . . . . . . . . . .
Storage 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 18 . . . . . . . . . . . . . . . . . . . . . . . . .

Safety
2
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.
      
#%& $ 
 
#%& $ 
  
#%& $ 
 
#%& $ 
  
#%& $ 
    !
#%& $ 
  
"    !
#%& $ 

3
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
1
2
2
2
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
2
4
2
6
Install stabilizer bars
Flange nut
W asher 3/8”
Jam nut 3/8–16
2
2
2
Install mower to traction unit
Operator’ s Manual
Parts Catalog
1
1
Read before operating
Ordering parts

Installation
4
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.
2
5
14m–2549
3
Figure 1
1. Bolt 3/8–24 x 3-3/4”
(95 mm)
2. Deflector Mount
3. Spring
4.
Pivot Bracket
5. 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
2
1
34
5
4
3
1
2
5
Figure 2
1. Stabilizer bar
2. Frame mount
3. Clevis pin 3/8”–1-1/4”
(32 mm)
4. Hairpin cotter
5. Front mower bracket

Installation
5
5. Push attachment lift pedal all the way forward,
remove pedal spring and move foot pedal all the
way back (Fig. 3).
12

Figure 3
1. Attachment lift pedal 2. 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
1
2
3
4
Figure 4
1. Lift chain
2. Flange nut 3/8”
3. W asher 3/8”
4. 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
7
5
1
3
4
2
6
Figure 5
1. Pin
2. Spring
3. Eye
bolt 3/8”
4. W asher 3/8”
5. Jam nut 3/8”
6. Clutch pulley
7. 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.

6
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 O)
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
3
2
1
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
7
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
21
Figure 7
1. Lift pedal -UP 2. 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).
1
2
Figure 8
1. Attachment lift 2. Down stop

Operation
8
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).
2
1
3
4
5
m-2553
Figure 9
1. Mounting Bracket
2. Hairpin Cotter
3. Clevis Pin
4. Gauge Wheel Plate
5. Gauge Wheel