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

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. . . . . . . . . . . . . . . . . . . . . . . . .
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
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.
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%'( & 
  !
$
%'( & 
!  $
" ! !
%'( & 
 ! 
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$! ! ! #
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3
Installation
Loose Parts
Note: Use the chart below to identify parts used for assembly.
DESCRIPTION QTY. USE
Castor Wheel
Thrust Washer
Spacer
Retaining Ring
2
8
2
2
Install castor wheels to carrier frame
Push Arms
Flat Washer 1-1/2” O.D. (38 mm)
Retaining Ring
2
2
2Install push arms to carrier frame
Spring Assembly
Shoulder Bolt 3/8”–16 x 7/8” (22 mm)
Locknut 3/8”–16
2
2
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
2
2
2
2
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
1
1Secure power take off (PTO) cover
Operator’s Manual
Parts Catalog
1
1
Read before operating
Ordering parts

Installation
4
Remove Carrier Frame
1. Remove hairpin cotters and clevis pins from
mower hanger brackets and remove mower from
carrier frame (Fig. 1).
1m-3531
32
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
4
2
2
1
3
6
5
Figure 2
1. Retaining ring
2. Thrust Washer (4)
3. Spacer
4. Carrier Frame Mounting
Tube
5. Grease fitting
6. Castor Wheel Fork

Installation
5
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
3
2
1
4
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).
1
m-3209
3
2
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
4
3
1
Figure 5
1. Clevis
2. Push Arm 3. Pivot Pin Assembly–flat 4. Hairpin Cotter

Installation
6
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).
1
m-3193
3
2
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.
1
2
4
m-3376
3
Figure 7
1. PTO Driveshaft
2. Universal Joint 3. Gearbox shaft 4. Roll Pin

Installation
7
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.
1
m-3532
32
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).
2
m-3718
3
1
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.
1
2
4
m-3376
3
Figure 10
1. PTO Driveshaft
2. Universal Joint 3. Gearbox shaft 4. Roll Pin

Installation
8
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).
1
m-3209
3
2
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).
1
m-3532
32
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
4
3
1
Figure 13
1. Clevis
2. Push Arm 3. Pivot Pin Assembly–flat 4. Hairpin Cotter