Form No. 3375-768 Rev A TITAN ZX4820, ZX5420, and ZX6020 Zero-Turn-Radius Riding Mower Model No. 74841—Serial No. 313000001 and Up Model No. 74842—Serial No. 313000001 and Up Model No. 74843—Serial No. 313000001 and Up Model No. 74845—Serial No. 313000001 and Up Register at www.Toro.com.
Introduction WARNING CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage. You are responsible for operating the product properly and safely. You may contact Toro directly at www.Toro.
Contents Changing the Hydraulic System Filter and Oil ....................................................................40 Mower Deck Maintenance...........................................43 Servicing the Cutting Blades.....................................43 Mower Deck Leveling .............................................45 Inspecting the Belts ................................................47 Replacing the Mower Belt ........................................47 Removing the Mower........................
Safety • Disengage blades when not mowing. Stop the engine, wait for all parts to come to a complete stop and remove the key before cleaning the machine, removing the grass catcher or unclogging the discharge chute. This machine meets or exceeds the B71.1-2012 specifications of the American National Standards Institute, in effect at the time of production. However, improper use or maintenance by the operator or owner can result in injury.
Towing • Be aware that loss of traction may occur going downhill. Weight transfer to the front wheels may cause drive wheels to slip and cause loss of braking and steering. A hitch kit is available for this machine and can be obtained by contacting an Authorized Toro Dealer. Do not tow without first installing this manufacturer approved hitch. The following guidelines apply when towing with the approved hitch kit installed. • Tow only with a machine that has a hitch designed for towing.
• Never interfere with the intended function of a safety device or reduce the protection provided by a safety device. Check their proper operation regularly. • Keep machine free of grass, leaves, or other debris build up. Clean up oil or fuel spillage and remove any fuel soaked debris. Allow machine to cool before storing. • If you strike a foreign object, stop and inspect the machine. Repair, if necessary, before restarting. • Never make any adjustments or repairs with the engine running.
Slope Indicator G011841 Figure 3 This page may be copied for personal use. 1. The maximum slope you can safely operate the machine on is 15 degrees. Use the slope chart to determine the degree of slope of hills before operating. Do not operate this machine on a slope greater than 15 degrees. Fold along the appropriate line to match the recommended slope. 2. Align this edge with a vertical surface, a tree, building, fence pole, etc. 3. Example of how to compare slope with folded edge.
Safety and Instructional 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. 99-8936 1. Machine speed 4. Neutral 2. Fast 3. Slow 5. Reverse 107-3069 1. Warning-there is no rollover protection when the roll bar is down. 2. To avoid injury or death from a rollover accident, keep the roll bar in the fully raised and locked position and wear the seat belt.
110-6691 1. Thrown object hazard—keep bystanders a safe distance from the machine. 2. Thrown object hazard, mower—do not operate without the deflector, discharge cover, or grass collection system in place. 117–1158 3. Cutting/dismemberment of hand or foot—stay away from moving parts. 1. Bypass lever position for operating the machine. 2. Bypass lever position for pushing the machine. 115-9632 1. Power take-off (PTO), Blade control switch on some models 2. Blade control switch—On 3.
115-9630 1. Read the Operator's Manual before performing any maintenance. 2. Check the engine oil every 8 hours 4. Check the hydraulic oil every 25 hours 3. Check the drive wheel tire pressure every 25 hours 6. Lubricate the caster wheel every 25 hours 5. Check the caster wheel tire pressure every 25 hours Battery Symbols Some or all of these symbols are on your battery 112-9840 3. Remove the ignition key and read the instructions before servicing or performing maintenance. 1.
7–2718 Model 74845 only 114-1606 1. Entanglement hazard, belt—keep all guards in place. 117-1194 1. Engine 120-5466 1. Warning—read the Operator's Manual. 5. Loss of traction/control hazard, slopes—loss of traction/control on a slope, disengage the blade control switch (PTO), proceed off the slope slowly. 2. Warning—read the instructions before servicing or performing maintenance; move the motion control levers to the park (brake) position, remove the ignition key and disconnect the spark plug wire.
119-8983 1. Fuel 2. Full 3. Half 4. Empty 119-8986 1. Fuel 2. Full 3. Half 4. Empty 119-8987 1. Fuel 2. Full 3. Half 12 4.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description 1 2 3 Use Qty. No parts required – Connect the battery. No parts required – Check the mower adjustment. Ignition Key Hose coupling Operator's Manual Engine Operator's Manual Operator Training Material 1 1 1 1 1 Complete the Setup. 1 2 Connecting the Battery Checking the Mower Adjustment No Parts Required No Parts Required Procedure Procedure 1.
Review the Remaining Parts 3 Keep all the following items with the machine: • Ignition Key Completing the Setup • Hose coupling • Operator's Manual Parts needed for this procedure: 1 Ignition Key 1 Hose coupling 1 Operator's Manual 1 Engine Operator's Manual 1 Operator Training Material • Engine Operator's Manual • View the Operator training material before operating the machine.
Product Overview 2 3 4 1 5 6 10 G015763 9 7 8 Figure 5 1. Drive wheel 2. Operator seat 4. Motion control levers 5. Parking brake 7. Front caster wheel 8. Anti-scalp roller 3. Roll over protection system (ROPS) 6. Footrest 9. Foot pedal deck lift and height-of-cut 10. Deflector 3 G014766 1 4 2 Figure 6 1. Mower Deck 3. Engine 2. Drive wheel 4.
Controls Fuel Gauge Become familiar with all the controls before you start the engine and operate the machine (Figure 7). The fuel window located below the operator position can be used to verify the level of gasoline in the tank (Figure 8). 1 2 1 3 1 5 4 g017722 G020318 Figure 7 1. Throttle control 4. Ignition switch 2. Choke 5. Blade control switch (PTO) Figure 8 1. Fuel gauge window 3.
Operation Distributor or go to www.Toro.com for a list of all approved attachments and accessories. Note: Determine the left and right sides of the machine from the normal operating position. Think Safety First Please carefully read all of the safety instructions and decals in the safety section. Knowing this information could help you, your family, pets, or bystanders avoid injury. DANGER Mowing on wet grass or steep slopes can cause sliding and loss of control.
Using the Rollover Protection System (ROPS) G015035 2 1 2 WARNING To avoid injury or death from rollover: keep the roll bar in the raised locked position and use the seat belt. 3 Figure 11 1. Hole in ROPS WARNING 3. Hair pin cotter 2. Locking pin There is no rollover protection when the roll bar is in the down position. 4. To lower the roll bar, remove the hair cotter pin and remove the locking pin (Figure 11). • Lower the roll bar only when absolutely necessary. 5.
Adding Fuel DANGER • For best results, use only clean, fresh, unleaded gasoline In certain conditions during fueling, static electricity can be released causing a spark which can ignite the gasoline vapors. A fire or explosion from gasoline can burn you and others and can damage property. • Always place gasoline containers on the ground away from your vehicle before filling.
Fuel Gauge 1 2 Use the fuel window below the operator to verify the level of gasoline before filling the tank (Figure 12). 1 1 3 4 G020318 Figure 12 1. Fuel gauge window G020304 Figure 13 Filling the Fuel Tank Make sure the engine is shut off and the motion controls are in the park position. 3. Install the fuel tank cap securely and tighten until it “clicks.” Wipe up any gasoline that may have spilled. Important: Do not overfill fuel tank. Fill the fuel tank to the bottom of the filler neck.
Operating the Parking Brake 1. Pull up on the choke knob to engage the choke before using the ignition switch (Figure 17). Always set the parking brake when you stop the machine or leave it unattended. 2. Push down on the choke to disengage the choke after the engine has started (Figure 17). Setting the Parking Brake 1 2 1 G020305 Figure 14 Releasing the Parking Brake 1 2 2 G008959 Figure 17 1. On 2. Off Operating the Ignition Switch G020306 Figure 15 1.
Starting and Stopping the Engine Note: If the fuel system was depleted of fuel—add fuel to the machine and use additional starting cycles when starting the engine. Starting the Engine 1. Sit down on the seat (Figure 19). 2. Move the motion controls outward to the neutral lock position (Figure 19). 3. Set the parking brake (Figure 15); refer to Setting the Parking Brake. 4. Move the blade control switch (PTO) to the Off position (Figure 19). 5. Pull up on the Choke control before starting a cold engine.
Operating the Mower Blade Control Switch (PTO) The Safety Interlock System WARNING The blade control switch (PTO) starts and stops the mower blades and any powered attachments. If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. Engaging the Blade Control Switch (PTO) • Do not tamper with the interlock switches. • Check the operation of the interlock switches daily and replace any damaged switches before operating the machine.
Driving Forward or Backward 3. To go forward, slowly push the motion control levers forward (Figure 25). The throttle control regulates the engine speed as measured in rpm (revolutions per minute). Place the throttle control in the fast position for best performance. Always operate in the full throttle position when mowing. CAUTION Machine can spin very rapidly. Operator may lose control of machine and cause personal injury or damage to machine. • Use caution when making turns.
Stopping the Machine Adjusting the Height of Cut To stop the machine, move the traction control levers to neutral and move to locked position, disengage the blade control switch (PTO), and turn the ignition key to off. The machine is equipped with a foot pedal deck lift system. The operator can use the foot pedal to lift the deck briefly to avoid obstacles or lock the deck in the highest height-of-cut or transport position.
4. Push on the deck lift pedal with your foot and raise the height-of-cut lever slightly to disengage the transport lock (Figure 27). Adjusting the Anti-Scalp Rollers 5. Lower the deck slowly until the pin makes contact with the lever. Whenever you change the height-of-cut, it is recommended to adjust the height of the anti-scalp rollers. 1 1. Disengage the blade control switch (PTO), move the motion control levers to the neutral lock position and set the parking brake. 5 2.
Positioning the Seat Adjusting the Tilt The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable. The motion control levers can be tilted forward or backward for maximum operator comfort. 1. Loosen the upper bolt holding the control lever to the control arm shaft. While sitting in the operator's position, raise the seat adjustment lever slightly and move the seat forward or backward to the desired position (Figure 30). 2.
Pushing the Machine by Hand Using the Side Discharge Important: Towing the machine will damage the drivetrain of the machine. Always push the machine by hand. The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. DANGER To Push the Machine Without a grass deflector, discharge cover, or complete grass catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris.
Operating Tips cutting height higher than usual and cut the grass at this setting. Then cut the grass again using the lower, normal setting. Fast Throttle Setting When Stopping For best mowing and maximum air circulation, operate the engine at the fast throttle position. Air is required to thoroughly cut grass clippings, so do not set the height-of-cut so low as to totally surround the mower by uncut grass.
Maintenance Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 8 hours • Change the engine oil. After the first 50 hours • Change the hydraulic system filter and oil. Before each use or daily • • • • • Check the safety interlock system. Check the engine oil level. Clean the air intake screen. Check the mower blades. Inspect the grass deflector for damage After each use • Clean the mower housing. Every 25 hours • Grease all lubrication points.
Figure 33 Located on the seat pan underside 1. Read the Operator's Manual before performing any maintenance. 2. Check the engine oil every 8 hours 4. Check the hydraulic oil every 25 hours 3. Check the drive wheel tire pressure every 25 hours 6. Lubricate the caster wheel every 25 hours 5. Check the caster wheel tire pressure every 25 hours Premaintenance Procedures Lubrication Raising the Seat Service Interval: Every 25 hours—Grease all lubrication points.
Engine Maintenance WARNING Contact with hot surfaces may cause personal injury. 1 Keep hands, feet, face, clothing and other body parts away the muffler and other hot surfaces. Servicing the Air Cleaner Note: Service the air cleaner more frequently (every few hours) if operating conditions are extremely dusty or sandy. G009949 Removing the Element Figure 34 1. Park the machine on a level surface and disengage the blade control (PTO). 1. Front caster tire 4.
Cleaning the Element Important: Do not overfill the crankcase with oil because damage to the engine may result. Do not run engine with oil below the low mark because the engine may be damaged. Service Interval: Every 100 hours—Service the paper element. (more often in dusty, dirty conditions) 1. Park the machine on a level surface, disengage the blade control switch, stop the engine, engage parking brake, and remove the key. Every 200 hours/Yearly (whichever comes first)—Replace the paper element.
Changing the Engine Oil 4. Slowly pour approximately 80% of the specified oil into the filler tube and slowly add the additional oil to bring it to the Full mark (Figure 39). Service Interval: After the first 8 hours—Change the engine oil. Every 100 hours—Change the engine oil. (more often in dusty, dirty conditions) 1 2 3 4 5 6 Note: Dispose of the used oil at a recycling center. 1.
Changing the Engine Oil Filter Servicing the Spark Plug Service Interval: Every 200 hours—Change the oil filter. (more often in dusty, dirty conditions) Service Interval: Every 100 hours—Check the spark plug(s). 1. Drain the oil from the engine; refer to Changing the Engine Oil (page 34). Make sure the air gap between the center and side electrodes is correct before installing the spark plug.
Installing the Spark Plug Fuel System Maintenance Tighten the spark plug(s) to 22 N-m (16 ft-lb). 1 2 DANGER In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property. 3 • Perform any fuel related maintenance when the engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills.
1 2 3 G008963 Figure 45 1. Fuel filter 2. Hose clamp 3. Fuel line 1 2 g020178 Figure 46 6. Remove the filter from the fuel lines. 1. Emissions filter 7. Install a new filter with the flow direction arrow coming from the fuel tank and pointing to the engine. Move the hose clamps close to the filter (Figure 44) to secure it in place.
Electrical System Maintenance 1. Disengage the blade control switch (PTO), move the motion control levers to the neutral lock position, and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Servicing the Battery 3. Remove the wing nut securing the battery clamp (Figure 47).
Charging the Battery 1. Grasp the fuse and pull it straight and away from the fuse block. WARNING 1 3 2 4 25 30 Charging the battery produces gasses that can explode. Never smoke near the battery, and keep sparks and flames away from battery. Important: Always keep the battery fully charged. This is especially important to prevent battery damage when the temperature is below 32°F (0°C). 1. Charge the battery for 10 to 15 minutes at 25 to 30 amps or 30 minutes at 10 amps. 2.
Drive System Maintenance Hydraulic System Maintenance Hydraulic System Oil Specification Checking the Tire Pressure Oil Type: 20w-50 engine oil. Service Interval: Every 25 hours—Check tire pressure. System Capacity: approximately 4.495 liter (152 oz) with a filter change. Maintain the air pressure in the front and rear tires as specified. Uneven tire pressure can cause uneven cut. Check the pressure at the valve stem (Figure 50).
Removing Hydraulic System Filters 1 2 3 4 5 6 1. Stop engine, wait for all moving parts to stop, and allow engine to cool. 2. Remove the key and engage the parking brake. 3. Locate the filter and guards on each transaxle drive system (Figure 52). 5 G010254 1 2 3 4 Figure 52 Right side shown 3/4 G0201 18 1. Transaxle drive 2. Oil filter 4. Screws 5. Vent plug Figure 53 3. Filter guard 7. Locate and remove the vent plug on each transmission 8.
Installing the Hydraulic System Filters Service Interval: After the first 50 hours Every 400 hours 1. Apply a thin coat of oil on the surface of the rubber seal of each filter (Figure 53). 2. Turn the filter clockwise until rubber seal contacts the filter adapter then tighten the filter an additional 3/4 to 1 full turn (Figure 53). 3. Repeat step 2 for the other filter. 1 4. Align the filter guards over each filter; refer to step 4 of Removing Hydraulic System Filters (page 41). G010333 Figure 54 1.
Mower Deck Maintenance Servicing the Cutting Blades Maintain sharp blades throughout the cutting season because sharp blades cut cleanly without tearing or shredding the grass blades. Tearing and shredding turns grass brown at the edges, which slows growth and increases the chance of disease. Figure 55 Check the cutter blades daily for sharpness, and for any wear or damage. File down any nicks and sharpen the blades as necessary.
3. Measure from the tip of the blade to the level surface. 1 1 G014973 3 G014973 2 3 Figure 59 2 1. Opposing blade edge, in position for measuring Figure 57 2. Level surface 3. Second measured distance between blade and surface (B) 1. Blade, in position for measuring 2. Level surface 3. Measured distance between blade and surface (A) WARNING 4. Rotate the same blade 180 degrees so that the opposing cutting edge is now in the same position.
B. Repeat this procedure until the blade is balanced. Figure 62 1. Blade 1 2. Balancer Installing the Blades 2 3 1. Install the blade onto the spindle shaft (Figure 60). 4 Important: The curved part of the blade must point upward toward the inside of the mower to ensure proper cutting. G010341 Figure 60 1. Sail Area of Blade 2. Blade 2. Install the spring disk and blade bolt (Figure 60). 3. Curved washer 4. Blade Bolt Note: The spring disk cone must be installed toward the bolt head 3.
Note: If both measurements are not within 5 mm (3/16 inch), an adjustment is required; continue to the Leveling procedure. Figure 64 1. Blades front to rear 3. Measure from the tip of the blade to the flat surface here Figure 63 2. Outside cutting edges 1. Blades side to side 3. Measure from the tip of the blade to the flat surface here 2. Outside cutting edges Leveling the Mower Deck 1.
5. Loosen the leveling adjust locking nuts (item 3) on all four corners so that the deck is sitting securely on all four blocks (Figure 66 and Figure 67). 8. Check that blocks fit just snugly under the deck skirt. Make sure all attachment bolts are tight 6 1 1 7. Tighten the four leveling adjust locking nuts (Figure 66 and Figure 67). 2 3 9. Verify that the deck is level by checking the side-to-side level and front-to-rear blade slope; repeat the deck leveling procedure if necessary.
1 Installing the Belt 2 1. Install the new belt around the mower pulleys and the clutch pulley under the engine (Figure 69). 2. Using a spring removal tool (Toro part no. 92-5771), install the idler spring over the deck post and place tension on the idler pulley and mower belt (Figure 69). 3. Ensure that the belt is properly seated in all pulleys. 4. Install the belt covers (Figure 70). 3 A 1 B 2 G02031 1 Figure 68 1. Loosen the screws 2. Pivot the belt cover up 3. Remove belt cover C 3 5.
48 and 54 Inch Mower Decks 60 Inch Mower Decks 1. Move the spring loaded J-hooks out of the slot in the rear hanger brackets on both sides of the deck (Figure 71). 1 1. Remove the hair pin cotter and washer securing the long, link bar to the frame and deck; remove the link bar (Figure 73). 2 2 3 1 3 G010309 Figure 73 G020314 1. Hair pin cotter Figure 71 3. Washer 2. Link bar 2. Remove the hardware from the front deck hangers on both sides of the deck (Figure 72). 3.
Installing the Mower Replacing the Grass Deflector Installing 54 inch Mower Decks Service Interval: Before each use or daily—Inspect the grass deflector for damage 1. Park the machine on a level surface and disengage the blade control switch. WARNING 2. Move the motion control levers outward to the neutral lock position, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
Cleaning the shorter spring end is coming from under the rod before the bend and going over the rod as it returns from the bend. Washing the Underside of the Mower 5. Lift the loop end of the spring and place it into the notch on the deflector assembly bracket (Figure 76). 2 Service Interval: After each use—Clean the mower housing. Wash the underside of the mower after each use to prevent grass buildup for improved mulch action and clipping dispersal. 1.
5. Sit on the seat and start the engine. Engage the blade control switch and let the mower run for 1 to 3 minutes. Storage 6. Disengage the blade control switch, stop the engine, and remove the ignition key. Wait for all moving parts to stop. Cleaning and Storage 1. Disengage the blade control switch (PTO), set the parking brake, and turn the ignition key to Off. Remove the key. 7. Turn the water off and remove the coupling from the washout fitting. 2.
C. Stop the engine, allow it to cool, and drain the fuel tank. D. Restart the engine and run it until it stops. E. Dispose of fuel properly. Recycle the fuel according to local codes. Important: Do not store stabilizer/conditioned fuel over 90 days. 13. Check and tighten all bolts, nuts, and screws. Repair or replace any part that is damaged. 14. Paint all scratched or bare metal surfaces. Paint is available from your Authorized Service Dealer. 15.
Troubleshooting Problem The starter does not crank. The engine will not start, starts hard, or fails to keep running. Possible Cause 1. Blade control switch (PTO) is engaged. 1. Move blade control switch (PTO) to disengaged. 2. Parking brake is not on. 3. Drive levers are not in neutral lock position. 4. Operator is not seated. 5. Battery is dead. 6. Electrical connections are corroded or loose. 7. Fuse is blown. 8. Relay or switch is defective. 2. Set the parking brake. 3.
Problem The machine does not drive. The machines vibrates abnormally. The machine cuts grass at an uneven cutting height. Possible Cause 1. By pass valves is not closed tight. 1. Tighten the by pass valves. 2. 3. 4. 5. 2. 3. 4. 5. Pump belt is worn, loose or broken. Pump belt is off a pulley. Broken or missing idler spring. Hydraulic oil level is low or too hot. Change the belt. Change the belt. Replace the spring. Add hydraulic oil to reservoirs or let it cool down. 1.
Schematics G014723 Wire Diagram (Rev.
Notes: 57
Notes: 58
Notes: 59
The Toro Total Coverage Warranty TimeCutter and TITAN Mowers Limited Warranty (see warranty periods below) Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to the original purchaser to repair the Toro Products listed below if defective in materials or workmanship.
