Form No. 3369-581 Rev A TITAN ZX4820, ZX5420 and ZX6020 Zero-Turn-Radius Riding Mowers Model No. 74841—Serial No. 311000001 and Up Model No. 74842—Serial No. 311000001 and Up Model No. 74843—Serial No. 311000001 and Up Model No. 74845—Serial No. 311000001 and Up To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com.
You may contact Toro directly at www.Toro.com for product and accessory information, help finding a dealer, or to register your product. WARNING CALIFORNIA Proposition 65 Warning This engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
Contents Drive System Maintenance ..................................... 42 Checking the Tire Pressure ................................. 42 Hydraulic System Maintenance ............................... 42 Checking the Hydraulic Oil Level........................ 42 Changing the Hydraulic System Filter and Oil.................................................................. 42 Mower Deck Maintenance ...................................... 44 Servicing the Cutting Blades ...............................
Safety back toward the operator. Stop the blade(s) when crossing gravel surfaces. This machine meets or exceeds the B71.1-2003 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. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means CAUTION, WARNING, or DANGER-"personal safety instruction.
• Lower the rollbar only when absolutely necessary. Do not wear the seat belt with the roll bar folded down. • Choose a low ground speed so you will not have to stop while operating on a slope. • Do not mow slopes when grass is wet. Slippery conditions reduce traction and could cause sliding and loss of control. • Check carefully for overhead clearances (i.e. branches, doorways, electrical wires) before driving under any objects and do not contact them.
Service • Grass catcher components are subject to wear, damage and deterioration, which could expose moving parts or allow objects to be thrown. Frequently check components and replace with manufacturers' recommended parts, when necessary. Safe Handling of Gasoline: To avoid personal injury or property damage, use extra care when handling gasoline and other fuels. They are flammable and the vapors are explosive. • Extinguish all cigarettes, cigars, pipes and other sources of ignition.
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. 117-1158 99-8936 1. Machine speed 4. Neutral 2. Fast 3. Slow 5. Reverse 1. Bypass lever position for operating the machine 115-9632 115-9625 1. Parking brake—disengaged 2. Bypass lever position for pushing the machine 1. Power take-off (PTO), Blade control switch on some models 2. Blade control switch—On 2.
3-7009 1. Warning—don't operate the mower with the deflector up or removed; keep the deflector in place. 2. Cutting/dismemberment hazard of hand or foot, mower blade—stay away from moving parts. 117-5344 1. Lock 2. Read the Operator's Manual Manufacturer's Mark 1. Indicates the blade is identified as a part from the original machine manufacturer. 110-6691 1. Thrown object hazard—keep bystanders a safe distance from the machine. 2.
7-3069 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 raised and locked position and wear the seat belt. Lower the roll bar only when absolutely necessary; do not wear the the seat belt when the roll bar is down. 3. Read the Operator's Manual; drive slowly and carefully. 115-9644 1. Press the pedal and lift the height of cut lever to unlock the deck position. 2. Height of cut 3.
Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 6. Keep bystandersa safe distance from the battery. 2. No fire, open flame, or smoking. 7. Wear eye protection; explosive gases can cause blindness and other injuries 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. 5. Read the Operator's Manual. 10. Contains lead; do not discard.
0-5466 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. 6.
119-8986 1. Fuel 2. Full 3. Half 4. Empty 119-8987 1. Fuel 2. Full 3. Half 13 4.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description Use Qty. 1 No parts required – Connect the battery. 2 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 Completing the Setup No Parts Required Parts needed for this procedure: Procedure 1. Locate the battery and negative battery cable in the center of the machine. 2.
The mower deck was leveled at the factory. If the mower is not cutting level, adjust the side-to-side level and the front-to-rear blade slope. See the Operator's Manual for the proper procedure. Review the Remaining Parts Keep all the following items with the machine: • Ignition Key • Hose coupling • Operator's Manual • Engine Operator's Manual • View the Operator training material.
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 switch (PTO) is engaged. Use these times for scheduling regular maintenance (Figure 7). Become familiar with all the controls before you start the engine and operate the machine (Figure 7). 1 2 Fuel Gauge The fuel window located below the operator position can be used to verify the level of gasoline in the tank (Figure 8). 3 1 5 4 G009917 Figure 7 1. Throttle control 4. Ignition switch 2. Choke 5. Blade control switch (PTO) 3. Hour meter G010077 Figure 8 1.
Height-of-Cut Lever Operation The height-of-cut lever works with the foot pedal to lock the deck in a specific cutting height. Only adjust the height of cut while machine is not moving (Figure 5). Note: Determine the left and right sides of the machine from the normal operating position. Attachments/Accessories Think Safety First A selection of Toro approved attachments and accessories are available for use with the machine to enhance and expand its capabilities.
1 2 3 G015033 Figure 9 1. Safe Zone-use the machine here 2. Use walk behind mower and/or hand trimmer near drop-offs and water. 3. Water G015034 Figure 10 Important: Always use the seat belt with the roll bar in the raised position. 3. Install the locking pins. Secure the pins by installing the hair cotter pin (Figure 11). Using the Rollover Protection System (ROPS) G015035 WARNING 2 1 To avoid injury or death from rollover: keep the roll bar in the raised locked position and use the seat belt.
these blends can damage the fuel system or cause performance problems. If any undesirable operating symptoms occur, use gasoline with a lower percentage of alcohol or ether. DANGER 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.
Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline. To minimize the chance of varnish deposits in the fuel system, use fuel stabilizer at all times. 1 2 Fuel Gauge Use the fuel window below the operator to verify the level of gasoline before filling the tank (Figure 12). 3 1 4 G010475 Figure 13 G010077 Figure 12 1. Fuel gauge window 3. Install the fuel tank cap securely and tighten until it “clicks”. Wipe up any gasoline that may have spilled.
Releasing the Parking Brake 1 2 1 G010079 Figure 15 Operating the Throttle 2 The throttle control can be moved between Fast and Slow positions (Figure 16). G008959 Figure 17 Always use the fast position when turning on the mower deck with the blade control switch (PTO). 1. On 2. Off Operating the Ignition Switch 1. Turn the ignition key to the Start position (Figure 18). When the engines starts, release the key. G008946 Important: Do not engage starter for more than 5 seconds at a time.
Starting and Stopping the Engine Note: Additional starting cycles may be required when starting the engine for the first time after the fuel system has been without fuel completely. Starting the Engine 1. Sit down on the seat (Figure 19). 2. Move the motion controls outward to the neutral lock position (Figure 19). ST 3. Set the parking brake (Figure 15); refer to Setting the Parking Brake. RT N RU 4. Move the blade control switch (PTO) to the Off position (Figure 19). P ST O G008947 Figure 20 1.
1 2 G008945 Figure 22 3 4 R Disengaging the Blade Control Switch (PTO) T A ST N R U O ST P 5 G009174 Figure 23 G010081 The Safety Interlock System Figure 21 WARNING Operating the Mower Blade Control Switch (PTO) If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. The blade control switch (PTO) starts and stops the mower blades and any powered attachments. • Do not tamper with the interlock switches.
Testing the Safety Interlock System Using the Motion Control Levers Test the safety interlock system before you use the machine each time. If the safety system does not operate as described below, have an Authorized Service Dealer repair the safety system immediately. 1. While sitting on the seat, engage the parking brake and move the blade control switch to On. Try starting the engine; the engine should not crank. 2.
blade control switch (PTO), and turn the ignition key to off. Set the parking brake when you leave the machine; refer to Setting the Parking Brake. Remember to remove the key from the ignition switch. CAUTION Children or bystanders may be injured if they move or attempt to operate the tractor while it is unattended. Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes.
Adjusting the Height-of-Cut 2. Remove the pin from the height-of-cut bracket (Figure 28). 3. Select the lower hole on the lock decal and insert the pin (Figure 28). The height-of-cut can be adjusted from 1-1/2 to 4-1/2 inch (38 to 114 mm) in 1/4 inch (6 mm) increments by relocating the height-of-cut pin into different hole locations. To lock the deck in the lowest height-of-cut position: 1. Push on the deck lift pedal with your foot and raise the mower deck to the transport position (also the 4.
Adjusting the Motion Control Levers 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). Adjusting the Height The motion control levers can be adjusted higher or lower for maximum operator comfort. 1 1. Remove the 2 bolts and 2 washers holding the control lever to the control arm shaft (Figure 31). 2. Move the control lever to the next set of holes.
Pushing the Machine by Hand 1. Loosen the upper bolt holding the control lever to the control arm shaft. Important: Always push the machine by hand. Never tow the machine because damage may occur. 2. Loosen the lower bolt just enough to pivot the control lever fore or aft. Tighten both bolts to secure the control in the new position. 3. Repeat the adjustment for the opposite control lever. To Push the Machine 1. Park the machine on a level surface and disengage the blade control switch. 2.
Mow at Correct Intervals DANGER Normally, mow every four days. But remember, grass grows at different rates at different times. So to maintain the same cutting height, which is a good practice, mow more often in early spring. As the grass growth rate slows in mid summer, mow less frequently. If you cannot mow for an extended period, first mow at a high cutting height; then mow again two days later at a lower height setting.
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 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.
Premaintenance Procedures Lubrication Raising the Seat Service Interval: Every 25 hours—Grease all lubrication points. Greasing the Bearings Make sure the motion control levers are locked in the neutral lock position. Lift the seat forward. Grease Type: No. 2 General Purpose Lithium Base Grease The following components can be accessed by raising the seat: 1. Park the machine on a level surface and disengage the blade control switch. • Service decal 2.
Engine Maintenance Cleaning the Element Service Interval: Every 100 hours—Service the paper element. (more often in dusty, dirty conditions) WARNING Contact with hot surfaces may cause personal injury. Every 200 hours/Yearly (whichever comes first)—Replace the paper element. (more often in dusty, dirty conditions) Keep hands, feet, face, clothing and other body parts away the muffler and other hot surfaces. 1. Lightly tap the element on a flat surface to remove dust and dirt.
Changing the Engine Oil WARNING Service Interval: After the first 8 hours—Change the engine oil. Contact with hot surfaces may cause personal injury. Every 100 hours—Change the engine oil. (more often in dusty, dirty conditions) Keep hands, feet, face, clothing and other body parts away the muffler and other hot surfaces. 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.
5. 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). 1 3 1 2 3 4 2 4 5 5 6 6 3/4 G008796 Figure 39 G008748 Figure 40 Changing the Engine Oil Filter Note: Ensure the oil filter gasket touches the engine and then an extra 3/4 turn is completed. Service Interval: Every 200 hours—Change the oil filter. (more often in dusty, dirty conditions) 3.
Removing the Spark Plug 1. Disengage the PTO, move the motion control levers to the neutral locked 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. 16 ft-lb 22 N-m G010687 Figure 43 Figure 41 Note: Due to the deep recess around the spark plug, blowing out the cavity with compressed air is usually the most effective method for cleaning.
Fuel System Maintenance 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. 1 4 • Perform any fuel related maintenance when the engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills. 5 6 • Never smoke when draining gasoline, and stay away from an open flame or where a spark may ignite the gasoline fumes.
Servicing the Emissions Filter Electrical System Maintenance Service Interval: Every 100 hours/Yearly (whichever comes first) The machine is equipped with a emissions filter (Figure 44) connected to a tee fitting on the vent line coming from the gas tank. The filter has an open port by design. The filter should be inspected regularly. Replace the filter if the filter is dirty or clogged.
Installing the Battery WARNING Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. 1. Position battery in the tray with the terminal posts opposite from the fuel tank (Figure 46). • Always Disconnect the negative (black) battery cable before disconnecting the positive (red) cable. 3. Then install the negative battery cable to the negative (-) battery terminal. 2.
1 3 2 25 30 4 Figure 47 1. Positive Battery Post 3. Red (+) Charger Lead 2. Negative Battery Post 4. Black (-) Charger Lead G015037 Figure 48 Servicing the Fuses The electrical system is protected by fuses. It requires no maintenance, however, if a fuse blows check the component/circuit for a malfunction or short. Fuses: • Main, 30 amp, blade-type • Engine, 20 amp, blade-type 1. The fuses are located on right hand console next to the seat (Figure 48). 2.
Drive System Maintenance Hydraulic System Maintenance Oil Type: 20w-50 engine oil. Checking the Tire Pressure Important: Use oil specified or equivalent. Other fluids could cause system damage. Service Interval: Every 25 hours—Check tire pressure. 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 49). Check the tires when they are cold to get the most accurate pressure reading.
Removing Hydraulic System Filters 1. Stop engine, wait for all moving parts to stop, and allow engine to cool. Remove the key and engage the parking brake. 2. Locate the filter and guards on each transaxle drive system (Figure 51). Remove three screws securing the filter guard and guard. 5 1 2 3 4 G010254 1 2 5 6 3 4 3/4 Figure 51 Right side shown G008748 Figure 52 1. Transaxle drive 2. Oil filter 4. Screws 5. Vent plug 3. Filter guard 1.
Mower Deck Maintenance hydraulic filters and oil can result in irreparable damage to the transaxle drive system. Bleeding the Hydraulic System Servicing the Cutting Blades 1. Raise the rear of machine up and support with jack stands (or equivalent support) just high enough to allow drive wheels to turn freely. Maintain sharp blades throughout the cutting season because sharp blades cut cleanly without tearing or shredding the grass blades.
3. Measure from the tip of the blade to the flat surface here. 1 Figure 54 1. Cutting Edge 2. Curved Area 3. Wear/slot Forming G014973 3 4. Crack 2 Figure 56 Checking for Bent Blades 1. Blade, in position for measuring 2. Level surface 3. Measured distance between blade and surface (A) Note: The machine must be on a level surface for the following procedure. 1. Raise the mower deck to the highest height-of-cut position; also considered the 'transport' position. 4.
1 G014973 3 2 1 Figure 58 2 3 1. Opposing blade edge, in position for measuring 4 2. Level surface 3. Second measured distance between blade and surface (B) G010341 Figure 59 WARNING 1. Sail Area of Blade 2. Blade A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders. 3. Curved washer 4. Blade Bolt Sharpening the Blades • Always replace bent or damaged blade with a new blade.
are not within 3/16 inch (5 mm), an adjustment is required; continue to the Leveling procedure. Figure 61 1. Blade 2. Balancer Installing the Blades 1. Install the blade onto the spindle shaft (Figure 59). Important: The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting. 2. Install the spring disk and blade bolt. The spring disk cone must be installed toward the bolt head (Figure 59). Torque the blade bolt to 100-110 ft-lb (135-150 N-m).
deck lift foot lever is pushed back against the stop, then tighten the four leveling adjust locking nuts (Figure 65). 6 1 1 2 3 3 5 4 Figure 63 1. Blades front to rear 3. Measure from the tip of the blade to the flat surface here 2. Outside cutting edges G010342 Leveling the Mower Deck 1. Set anti-scalp rollers to top holes or remove completely for this procedure. Figure 65 48 and 54 inch Mower Decks 2. Set the height-of-cut lever to the 3 inch (76 mm) position. 3. Place two 2-5/8 inch (6.
5. Recheck that blocks fit just snugly under the deck skirt. Make sure all attachment bolts are tight 6. Verify the deck is level by checking the side-to-side level and front-to-rear blade slope; repeat deck leveling procedure if necessary. 5. Using a spring removal tool, (Toro part no. 92-5771), remove the idler spring from the deck post to remove tension on the idler pulley (Figure 68).
1 2 1 2 3 3 G01031 1 Figure 70 G015790 Figure 69 1. Position the belt cover, ensure the tabs seat 2. Pivot the belt cover down 3. Tighten the screws 2. Remove the hardware from the front deck hangers on both sides of the deck (Figure 71). 3. Carefully lift the deck off the rear hanger bolts and lower the front of the mower deck to the ground (Figure 71). Removing the Mower Park the machine on a level surface and disengage the blade control switch.
60 Inch Mower Decks Installing the Mower 1. Remove the hair pin cotter and washer securing the long, link bar to the frame and deck; remove the link bar (Figure 72). Installing 54 inch Mower Decks 1. Park the machine on a level surface and disengage the blade control switch. 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. 3. Slide the mower under the machine. 4.
4. Lift the long end of the spring and place it into the notch on the deflector assembly bracket (Figure 75). WARNING An uncovered discharge opening could allow the lawn mower to throw objects in the operator’s or bystander’s direction and result in serious injury. Also, contact with the blade could occur. 2 Never operate the lawn mower unless you install a mulch plate, discharge deflector, or grass collection system. 1 3 Inspect the grass deflector for damage before each use.
Cleaning 1 Washing the Underside of the Mower Service Interval: Before each use or daily—Clean the mower housing. 3 4 Wash the underside of the mower after each use to prevent grass buildup for improved mulch action and clipping dispersal. 6 1. Park the machine on a level surface and disengage the blade control switch. 5 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.
Storage WARNING A broken or missing washout fitting could expose you and others to thrown objects or blade contact. Contact with blade or thrown debris can cause injury or death. Cleaning and Storage 1. Disengage the blade control switch (PTO), set the parking brake, and turn the ignition key to Off. Remove the key. 2. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine and hydraulic system.
B. Run the engine to distribute conditioned fuel through the fuel system (5 minutes). 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 as per 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.
Troubleshooting Problem Starter does not crank 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 Machine does not drive. Abnormal vibration. 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. Cutting blade(s) is/are bent or unbalanced. 1.
Schematics G014723 Wire Diagram (Rev.
Notes: 59
TimeCutter and TITAN Mowers The Toro Total Coverage Warranty 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. 2. Bring the product and your proof of purchase (sales receipt) to the Service Dealer.
