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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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

Installation
9
9. Remove (2) 3/8”–16 x 1-5/8” (41.5 mm) bolts
and 3/8”–16 locknuts from universal joint and
slide the driveshaft off gearbox shaft (Fig. 14).
Note: Save all hardware for use when
installing mower.
1
2
4
m-3198
3
5
Figure 14
1. PTO Driveshaft
2. Universal Joint
3. Gearbox shaft
4. Bolt 3/8”–16 x 1-5/8”
(41.5 MM)
5. Locknut 3/8”–16

10
Operation
Operating the Power Take Off
(PTO)
The power take off (PTO) switch engages and
disengages power to the electric clutch.
Engaging the PTO
1. Release pressure on the traction control levers
and place in neutral (Fig. 15).
2. Release the parking brake (Fig. 15).
m-3939
3
2
1
Figure 15
1. Traction control lever
2. Parking brake 3. PTO-Switch
3. To engage lift cover and move the PTO switch to
the “ON” position (Fig. 16).
Disengaging the PTO
1. Closing the cover moves the PTO switch to the
“OFF”position (Fig. 16).
m-2721
2
1
Figure 16
1. PTO-Off 2. PTO-On

Operation
11
Adjusting Height-of-Cut
The height-of-cut is adjusted from 1” to 4-1/2”
(25 to 115 mm) in 1/2” (13 mm) increments by
relocating four clevis pins in different hole locations.
1. To adjust, remove hairpin cotter and clevis pin
from mower hanger bracket (Fig. 17).
2. 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. 17).
3. Secure clevis pin with hairpin cotter (Fig. 17).
Note: All four clevis pins should be in the
same hole location for a level cut.
1
m-3532
32
Figure 17
1. Mower Hanger Bracket
2. Clevis Pin 3. Hairpin Cotter
Adjusting Rollers
The rollers are preset for heights-of-cut above 2”
(51 mm) If the height-of-cut is set to the 1” or 1–1/2”
(25 or 39 mm) the rollers must be adjusted to the
upper hole location.
1. After adjusting height-of-cut, tilt mower to
adjust rollers, refer to; Tilting Mower.
2. Remove the locknut and bolt to change hole
location (Fig. 18).
3. Select the proper hole position for the
height-of-cut to be used (Fig. 18).
4. Insert bolt through roller and secure with
locknut.
5. Repeat adjustment on remaining rollers.
m–3940
1
2
3
2
1
3
4
5
5
1
32
Figure 18
1. Roller
2. Bolt
3. Locknut
4. Spacer
5. Holes

Operation
12
Tilting the Mower
The mower can be tilted up for ease of service or to
shorten unit length for transport and storage.
To Raise Mower
1. Set the parking brake and check that PTO cover
is down against footrest (Fig. 15).
2. Remove 5/16–18 x 7/8” (11 mm) shoulder bolt
and 5/16” flange nut holding PTO cover down
(Fig. 21).
3. Lift on side of mower to release weight on latch
pin and pull out on latch pin to release (Fig. 19).
Lower rear of mower onto roller. Repeat on the
other side.
m-3374
3
1
4
2
Figure 19
1. Parking brake
2. PTO cover 3. Latch pin 4. Notch–open
4. Standing in front of the mower, lift up and push
rearward on front to raise mower (Fig. 20). Raise
mower until it contacts stops and latch pins snap
into locked position.
m–3375
1
Figure 20
1. Mower up
To Lower Mower
1. Pull out latch pins and rotate into notch to hold
in the open position (Fig. 19). Standing in front
of the mower, pull forward on front and lower
mower (Fig. 20).
2. Rotate latch pins into released position and lift
on side of mower until latch pin engages
(Fig. 19). Repeat on the other side.
3. Secure PTO cover down with 5/16–18 x 7/8”
(11 mm) shoulder bolt and 5/16” flange nut
(Fig. 21).
2
m-3718
3
1
Figure 21
1. PTO cover
2. Shoulder bolt
5/16–18 x 7/8” (11 mm)
3. Flange nut 5/16”

13
Maintenance
Service Interval Chart
Service Operation Each
Use 8 Hours 25 Hours Storage Service Notes
Cutting Blades – check X X
Push arm bushings – grease X
Castor Wheels – grease X
Gear box – check X
Mower Housing – clean X X X
Chipped Surfaces – paint X
For ease of maintenance and service the mower can
be tilted up, refer to: Tilting the Mower, in the
Operation section for instructions.
Cutting Blades
To ensure a superior quality of cut, keep the blades
sharp. For convenient sharpening and replacement,
you may want to keep extra blades on hand.
POTENTIAL HAZARD
•A blade that is worn or damaged could
break apart and pieces could be thrown at
bystanders or at you as you use the mower.
WHAT CAN HAPPEN
•Pieces of blade that may be thrown could
seriously injure or kill you or bystanders.
HOW TO AVOID THE HAZARD
•Periodically inspect the blade for wear and
damage. Immediately install a new blade if
it is worn or damaged.
Before Inspecting or Servicing the
Blades
Park the machine on a level surface, disengage the
blade control (PTO) and set the parking brake. Turn
the ignition key to “OFF” to stop the engine. Remove
the key and disconnect the spark plug wire(s) from
the spark plug(s).

Maintenance
14
Inspecting the Blades
1. Inspect the cutting edges (Fig 22). If the edges
are not sharp or have nicks, remove and sharpen
the blades. Refer to Sharpening the Blades on
page 16.
2. Inspect the blades, especially the curved area
(Fig. 22). If you notice any damage, wear, or a
slot forming in this area (item 3 in Fig. 22),
immediately install a new blade.
1
2
3
m–151
Figure 22
1. Cutting Edge
2. Curved Area 3. Wear/slot Forming
Checking for Bent Blades
1. Rotate the blades until the ends face forward and
backward (Fig. 23). Measure from a level
surface to the cutting edge of the blades
(Fig. 24). Note this dimension.
2. Rotate the opposite ends of the blades forward.
Measure from a level surface to the cutting edge
of the blades at the same position as in step 1
above. The difference between the dimensions
obtained in steps 1 and 2 must not exceed 1/8”
(3 mm). If this dimension exceeds 1/8” (3 mm),
the blade is bent and must be replaced. Refer to
Removing the Blades, and Installing the Blades
on page 15.
Front
m–3372
Figure 23
 
   
  m–3372
Figure 24

Maintenance
15
POTENTIAL HAZARD
•A blade that is bent or damaged could
break apart and pieces could be thrown at
bystanders or at you as you use the mower.
WHAT CAN HAPPEN
•Pieces of blade that may be thrown could
seriously injure or kill you or bystanders.
HOW TO AVOID THE HAZARD
•Always replace bent or damaged blade with
a new blade.
•Never file or create sharp notches in the
edges or surfaces of blade.
Removing the Blades
Blades must be replaced if a solid object is hit, if the
blade is out of balance or is bent. To ensure optimum
performance and continued safety conformance of the
machine, use genuine TORO replacement blades.
Replacement blades made by other manufacturers
may result in non-conformance with safety standards.
Hold the blade end using a rag or thickly-padded
glove. Remove the retainer bolt with its washer and
spacer, and the blade bolts and locknuts from the
blade retainer (Fig. 26).
Installing the Blades
IMPORTANT: The blades are different for
each side and rotate in opposite directions
forcing clippings to the center rear of the
mower. Align cutting edges properly when
installing (Fig. 25).
Front
m–3372
1
1
1
Figure 25
1. Cutting edge
1. Install the blade onto the blade retainer and
secure with retainer bolt, spacer and washer
(Fig. 26).
IMPORTANT: The curved part of the blade,
the sail, must be pointing upward toward the
top of the mower to ensure proper cutting.
2. Install the blade bolts and locknuts (Fig. 26).
3. Torque blade bolts to 120 in-lb (13.5 Nm).
4. Torque the retainer bolt to 85–110 ft-lb
(115–140 Nm).
2
4
m–3182
1
3
6
8
10
5
7
9
Figure 26
1. Spindle
2. Key
3. Blade retainer
4. Blade
5. Sail Area of Blade
6. Retainer bolt
7. Spacer
8. Washer
9. Blade Bolt
10. Locknut

Maintenance
16
Sharpening the Blades
1. Use a file to sharpen the cutting edge at both
ends of the blade (Fig. 27). Maintain the original
angle. The blade retains its balance if the same
amount of material is removed from both cutting
edges.
1
m–1854
Figure 27
1. Sharpenatoriginalangle
2. Check the balance of the blade by putting it on a
blade balancer (Fig. 28). If the blade stays in a
horizontal position, the blade is balanced and can
be used. If the blade is not balanced, file some
metal off the end of the sail area only (Fig. 26).
Repeat this procedure until the blade is balanced.
12m–1855
Figure 28
1. Blade 2. Balancer
Correcting Cutting Unit
Mismatch
If one cutter blade cuts lower than the other, correct
as follows:
1. Stop the engine, remove the key and disconnect
the spark plug wire(s) from the spark plug(s).
2. Adjust the tire pressure in all tires to
specifications and check that the blades are not
bent. Refer to Checking for Bent Blades on page
14.
3. Set the height-of-cut to the 2-1/2” position.
Refer to Adjusting the Height-Of-Cut in the
Operation section. Make sure the clevis pins are
resting on the frame cushions.
4. Rotate the blades so the tips line up with one
another. The blade tips must be within 1/8”
(3 mm) of each other. If the blade tips are not
within 1/8” (3 mm) of each other, add shims
(Part No. 3256-24) between the appropriate
spindle housing and the bottom of the cutting
unit to align the blades.

Maintenance
17
Setting the Front-to-Rear Pitch
1. Check the tire pressure.
2. Position the blades front-to-rear (Fig. 29).
Measure at “C” and “D” locations (Fig. 29) from
a level surface to the cutting edge of the blades
(Fig. 30).
3. The mower should be 1/8”–5/8” (3–16 mm)
lower in front “C” than in the rear “D”.
D
Front
C
D
m–3372
C
Figure 29
 
   
  m–3372
Figure 30
4. To change the front-to-rear pitch, remove the
retaining ring and move an equal number of
thrust washers on both castor wheel forks. Move
the thrust washers from the top of the carrier
frame mounting tube to the bottom to raise the
front of the mower. Move the thrust washers
from the bottom of the mounting tube to the top
to lower the front of the mower (Fig. 36).
5. Check the side-to-side leveling of the cutting
unit.
Setting the Side-to-Side Leveling
1. Check the tire pressure.
2. Position the blades side-to-side (Fig.31 ).
Measure at “A” and “B” locations (Fig. 31) from
a level surface to the cutting edge of blades
(Fig.32).
3. The difference between measurements “A” and
“B” should be no more than 1/4” (6 mm).
Front
m–3372
AB
Figure 31
 
   
  m–3372
Figure 32
4. To change the side-to-side leveling, remove the
retaining ring and move the thrust washers on
one castor wheel fork only. Move the thrust
washers from the top of the carrier frame
mounting tube to the bottom to raise the
corresponding side of the mower. Move the
thrust washers from the bottom of the mounting
tube to the top to lower the corresponding side of
the mower. (Fig. 36).
5. Recheck the front-to-rear pitch of the cutting
unit.

Maintenance
18
Greasing and Lubrication
The cutting unit must be lubricated regularly. Refer to
the Service Interval Chart on page 13. Grease with
No. 2 general purpose lithium base or molybdenum
base grease.
1. Stop the engine, remove the key and disconnect
the spark plug wire(s) from the spark plug(s).
2. Grease the fittings on push arms (Fig. 33).
1
m-3936
Figure 33
1. Push arm bearing
3. Grease the fittings on the carrier frame mounting
tubes and castor wheels (Fig. 34).
m-3281
1
2
Figure 34
1. Carrier Frame Mounting
Tube Grease Fitting 2. Castor Wheel Grease Fitting
4. Remove plug on the side of the gearbox and
check the level of lubrication in the gearbox. If
level is low, add SAE EP-80\90 wt. gear oil until
level is up to side plug in gearbox. (Fig. 35).
5. Repeat for remaining gearboxes.
m-3378
1
2
Figure 35
1. Gearbox 2. Side plug