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Engine Maintenance

WARNING

Contact with hot surfaces may cause personal
injury.

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.

Removing the Element

1. Park the machine on a level surface and disengage

the blade control (PTO).

2. Move the motion control levers to the brake position,

stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.

3. Clean around the air cleaner cover to prevent dirt

from getting into the engine and causing damage.
Lift the cover and remove the hose clamp securing
the air cleaner assembly to the engine (Figure 35).

4. Loosen the hose clamp and remove the paper

element (Figure 35).

G015155

Figure 35

Cover

Hose clamp

Paper element

Cleaning the Element

Service Interval:

Every 100 hours—Service the paper

element. (more often in dusty, dirty
conditions)

Every 200 hours/Yearly (whichever
comes first)—Replace the paper
element. (more often in dusty, dirty
conditions)

1. Lightly tap the element on a flat surface to remove

dust and dirt.

2. Inspect the element for tears, an oily film, and

damage to the seal.

Important:

Never clean the paper element with

pressurized air or liquids, such as solvent, gas,
or kerosene. Replace the paper element if it is
damaged or cannot be cleaned thoroughly.

Servicing the Engine Oil

Oil Type:

Detergent oil (API service SF, SG, SH, SJ,

or SL)

Crankcase Capacity:

61 ounces (1.8 l), [when oil filter

is removed: 70 ounces (2.1 l)]

Viscosity:

See the table below.

g017470

SAE V iscosity Grades

SAE 40

SAE 30

SAE 10W

–

30/ SAE 10W

–

-20 0 20 32 40 60 80 100

-30 -20 -10 0 10 20 30 40

°F

°C

STARTING TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE

SAE 5W

–

Figure 36

Note:

Using multi grade oils (5W-20, 10W-30, and 10W

-40) will increase oil consumption. Check oil level more
frequently when using them.

Checking the Engine Oil Level

Service Interval:

Before each use or daily

Note:

Check the oil when the engine is cold.

Содержание 74841

Страница 1: ...v A TITAN ZX4820 Zero Turn Radius Riding Mower Model No 74841 Serial No 312000001 and Up To register your product or download an Operator s Manual or Parts Catalog at no charge go to www Toro com Original Instructions EN ...

Страница 2: ...ronmental Protection Agency EPA and the California Emission Control Regulation of emission systems maintenance and warranty Replacements may be ordered through the engine manufacturer For models with stated engine horsepower the gross horsepower of the engine was laboratory tested by the engine manufacturer in accordance with SAE J1995 and rated to J2723 Introduction Read this information carefull...

Страница 3: ...afety Interlock System 23 Driving Forward or Backward 24 Stopping the Machine 25 Adjusting the Height of Cut 25 Adjusting the Anti Scalp Rollers 26 Positioning the Seat 27 Adjusting the Motion Control Levers 27 Pushing the Machine by Hand 28 Using the Side Discharge 28 Operating Tips 29 Maintenance 30 Recommended Maintenance Schedule s 30 Premaintenance Procedures 32 Raising the Seat 32 Lubricatio...

Страница 4: ... alert slow down and use caution when making turns Look behind and to the side before changing directions Never leave a running machine unattended Always turn off blades set parking brake stop engine and remove key before dismounting Turn off 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 catche...

Страница 5: ... children Children are often attracted to the machine and the mowing activity Never assume that children will remain where you last saw them Keep children out of the mowing area and under the watchful care of another responsible adult not the operator Be alert and turn the machine off if children enter the area Before and while backing or changing direction look behind down and side to side for sm...

Страница 6: ...ear 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 Mower blades are sharp and can cut Wrap the blade s or wear gloves and use extra caution when servicing them Check for proper brake operation frequently Adjust and service as required Maintain or replace safety and in...

Страница 7: ... 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 7 ...

Страница 8: ... 2 Fast 5 Reverse 3 Slow 115 9625 1 Parking brake disengaged 2 Parking brake engaged 117 1158 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 5 Fast 2 Blade control switch On 6 Continuous variable setting 3 Blade control switch Off 7 Slow 4 Choke 114 1606 1 Entanglement hazard belt k...

Страница 9: ...acturer 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 3 Cutting dismemberment of hand or foot stay away from moving parts 112 9840 1 Read the Operator s Manual 3 Remove the ignition key and read the instructions before servicing or performing main...

Страница 10: ...d 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 Press the pedal to move the deck to the transport position 10 ...

Страница 11: ...y acid can cause blindness or severe burns 4 Wear eye protection 9 Flush eyes immediately with water and get medical help fast 5 Read the Operator s Manual 10 Contains lead do not discard 115 9630 1 Read the Operator s Manual before performing any maintenance 4 Check the hydraulic oil every 25 hours 2 Check the engine oil every 8 hours 5 Check the caster wheel tire pressure every 25 hours 3 Check ...

Страница 12: ...ing do not carry passengers look behind and down when reversing 3 Cutting dismemberment hazard mower blade entanglement hazard belt stay away from moving parts keep all guards and shields in place 7 Thrown object hazard keep bystanders a safe distance from the machine pick up debris before operating keep deflector in place 4 Warning do not use split ramps use a full ramps when transporting machine...

Страница 13: ...sher 5 Nut 3 Negative battery cable 2 Completing the Setup Parts needed for this procedure 1 Ignition Key 1 Hose coupling 1 Operator s Manual 1 Engine Operator s Manual 1 Operator Training Material Procedure Setting Up the Motion Control Levers If needed remove the upper bolt washer and nut and raise the motion control levers to the upright position Secure the motion control levers Refer to Adjust...

Страница 14: ...he Oil Level in the Operator s Manual 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 before operating the machine 3 Checking the Mower Adjustment No Parts Required Procedure Adjust the side to side level and the front to rear blade slope Use the relevant procedures in...

Страница 15: ...evers 7 Front caster wheel 10 Deflector 2 Operator seat 5 Parking brake 8 Anti scalp roller 3 Roll over protection system ROPS 6 Footrest 9 Foot pedal deck lift and height of cut G014766 1 2 3 4 Figure 6 1 Mower Deck 3 Engine 2 Drive wheel 4 Roll over protection system ROPS folded down 15 ...

Страница 16: ...hours the blades have operated It operates when the blade control switch PTO is engaged Use these times for scheduling regular maintenance Figure 7 Fuel Gauge The fuel window located below the operator position can be used to verify the level of gasoline in the tank Figure 8 G010077 1 Figure 8 1 Fuel gauge window Motion Control Levers The motion control levers are speed sensitive controls of indep...

Страница 17: ...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 Wheels dropping over edges can cause rollovers which may result in serious injury death or drowning A loss of traction is a loss of steering control To avoid loss of control and possibility of rollover Do not mow ...

Страница 18: ...eck carefully for overhead clearances i e branches doorways electrical wires before driving under any objects and do not contact them Important Lower the roll bar only when absolutely necessary 1 To raise the roll bar remove the hair cotter pin and remove the locking pins 2 Raise the roll bar to the upright position Figure 10 G015034 Figure 10 Important Always use the seat belt with the roll bar i...

Страница 19: ...n 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 Do not fill gasoline containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic tru...

Страница 20: ... result in fuel leakage or damage to the engine or emission system 1 Clean around the fuel tank cap and remove the cap Note You can use the fuel window below the operating position verify the presence of gasoline before filling the tank Figure 12 2 Slowly add regular unleaded gasoline until the fuel reaches the base of the filler neck Figure 13 G010475 1 2 4 3 Figure 13 3 Install the fuel tank cap...

Страница 21: ... the choke to disengage the choke after the engine has started Figure 17 G008959 1 2 Figure 17 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 Important Do not engage starter for more than 5 seconds at a time If the engine fails to start allow a 15 second cool down period between attempts Failure to follow the...

Страница 22: ...fails to start allow a 15 second cool down period between attempts Failure to follow these instructions can burn out the starter motor 7 After the engine starts push down on the Choke control If the engine stalls or hesitates pull up on the Choke control and let the engine run for a few seconds Then push down the Choke control Repeat as required Note Additional starting cycles may be required when...

Страница 23: ...ARNING If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury Do not tamper with the interlock switches Check the operation of the interlock switches daily and replace any damaged switches before operating the machine Understanding the Safety Interlock System The safety interlock system is designed to prevent the engine from starting...

Страница 24: ...le sitting on the seat engage the parking brake move the blade control switch to Off and lock the motion control levers in neutral Start the engine While the engine is running center the motion controls the engine should stop Driving Forward or Backward The throttle control regulates the engine speed as measured in rpm revolutions per minute Place the throttle control in the fast position for best...

Страница 25: ...attended 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 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 The operator can use the height ...

Страница 26: ...of cut position To lock the deck in the transport position 1 Push on the deck lift pedal with your foot and raise the mower deck to the transport position also the 4 5 inch 114 mm cutting height position Figure 28 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 To lock the deck in the lowest height of cut position 1 P...

Страница 27: ... 1 Adjustment lever Adjusting the Motion Control Levers Adjusting the Height The motion control levers can be adjusted higher or lower for maximum operator comfort 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 Secure the lever with the 2 bolts and 2 washers Figure 31 4 1 2 G014970 3 Figure 31 1 Cont...

Страница 28: ...ove the motion control levers outward to neutral lock position stop the engine remove the key and wait for all moving parts to stop before leaving the operating position Make sure the parking brake is disengaged 3 Locate the bypass levers at the rear of the machine on the left and right side of the frame 4 Move the bypass levers rearward and then down to lock them in place as shown in Figure 32 to...

Страница 29: ...s also helps disperse clippings which enhances decomposition and fertilization Mow at Correct Intervals 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 fir...

Страница 30: ... oil more often in dusty dirty conditions Check the spark plug s Replace the fuel filters more often under dusty dirty conditions Every 200 hours Replace the paper element more often in dusty dirty conditions Change the oil filter more often in dusty dirty conditions Every 400 hours Change the hydraulic system filter and oil Monthly Check the battery charge Yearly or before storage Paint chipped s...

Страница 31: ...nual before performing any maintenance 4 Check the hydraulic oil every 25 hours 2 Check the engine oil every 8 hours 5 Check the caster wheel tire pressure every 25 hours 3 Check the drive wheel tire pressure every 25 hours 6 Lubricate the caster wheel every 25 hours 31 ...

Страница 32: ...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 Clean the grease fittings Figure 34 and Figure 34 with a rag Make sure to scrape any paint off of the front of the fitting s G009949 1 Figure 34...

Страница 33: ...very 100 hours Service the paper element more often in dusty dirty conditions Every 200 hours Yearly whichever comes first Replace the paper element more often in dusty dirty conditions 1 Lightly tap the element on a flat surface to remove dust and dirt 2 Inspect the element for tears an oily film and damage to the seal Important Never clean the paper element with pressurized air or liquids such a...

Страница 34: ...keep dirt grass clippings etc out of the engine clean the area around the oil fill cap dipstick before removing it Figure 37 G008792 1 2 5 6 7 3 9 10 4 8 Figure 37 Changing the Engine Oil Service Interval After the first 8 hours Change the engine oil Every 100 hours Change the engine oil more often in dusty dirty conditions Note Dispose of the used oil at a recycling center 1 Park the machine so t...

Страница 35: ...il 2 Change the engine oil filter Figure 40 G008748 3 4 1 2 3 4 5 6 Figure 40 Note Ensure the oil filter gasket touches the engine and then an extra 3 4 turn is completed 3 Fill the crankcase with the proper type of new oil refer to Changing the Oil Servicing the Spark Plug Service Interval Every 100 hours Check the spark plug s Make sure the air gap between the center and side electrodes is corre...

Страница 36: ...m or cracks If you see light brown or gray on the insulator the engine is operating properly A black coating on the insulator usually means the air cleaner is dirty Set the gap to 0 030 inches 0 76 mm G008794 1 2 Figure 42 Installing the Spark Plug Tighten the spark plug s to 16 ft lb 22 N m 16 ft lb 22 N m G010687 Figure 43 Cleaning the Cooling System Clean the air intake screen from grass and de...

Страница 37: ...ove 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 3 Allow the machine to cool down 4 Raise the seat and locate the fuel filters as shown in Figure 44 g017723 1 2 3 4 5 Figure 44 1 Fuel line from tank 4 Fuel line to engine 2 In line Fuel filter 5 Hose clamp...

Страница 38: ...nals and metal parts of the machine 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 Always Disconnect the negative black battery cable before disconnecting the positive red cable Always Reconnect the positive red battery cable before reconnecting the negative black cable 1 Disenga...

Страница 39: ...s below 32 F 0 C 1 Charge battery for 10 to 15 minutes at 25 to 30 amps or 30 minutes at 10 amps 2 When the battery is fully charged unplug the charger from the electrical outlet then disconnect the charger leads from the battery posts Figure 47 3 Install the battery in the machine and connect the battery cables refer to Installing the Battery Note Do not run the machine with the battery disconnec...

Страница 40: ...he 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 Refer to the maximum pressure suggested by the tire manufacturer on the sidewall of the caster wheel tires Inflate the rear drive wheel tires to 13 psi Figure 49 1 Valve stem 40...

Страница 41: ... irreparable damage to the transaxle drive system 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 G010254 1 2 3 4 5 Figure 51 Right side shown 1 Transaxle drive 4 Screws...

Страница 42: ...ransaxle drive system Bleeding the Hydraulic System 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 G010333 1 Figure 53 1 Jacking points 2 Enter the operator s position Start engine and move throttle control ahead to 1 2 throttle position Disengage parking brake A Move the bypass levers into the pushing the mac...

Страница 43: ... Blades Park the machine on a level surface disengage the blade control switch PTO and set the parking brake Turn the ignition key to Off Remove the key Inspecting the Blades Service Interval Before each use or daily 1 Inspect the cutting edges Figure 54 If the edges are not sharp or have nicks remove and sharpen the blades Refer to Sharpening the Blades 2 Inspect the blades especially the curved ...

Страница 44: ...amaged blade with a new blade Never file or create sharp notches in the edges or surfaces of blade A If the difference between A and B is greater than 1 8 inch 3mm replace the blade with a new blade Refer to Removing the Blades and Installing the Blades Note If a bent blade is replaced with a new one and the dimension obtained continues to exceed 1 8 inch 3mm the blade spindle could be bent Contac...

Страница 45: ...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 Mower Deck Leveling Check to ensure the mower deck is level any time you install the mower or when you see an uneven cut on your lawn The mower deck must be checked for bent blades prior to leveling any bent blades must be removed and replaced Refer to the Checking for Bent Blad...

Страница 46: ... rear blade to the flat surface Figure 63 If the front blade tip is not 1 16 5 16 inch 1 6 7 9 mm lower than the rear blade tip continue to the Leveling the Mower Deck procedure Figure 63 1 Blades front to rear 3 Measure from the tip of the blade to the flat surface here 2 Outside cutting edges Leveling the Mower Deck 1 Set anti scalp rollers to top holes or remove completely for this procedure 2 ...

Страница 47: ... belt is rotating blades slipping when cutting grass frayed belt edges burn marks and cracks are signs of a worn mower belt Replace the mower belt if any of these conditions are evident 1 Disengage the blade control switch 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...

Страница 48: ...n engage parking brake stop the engine remove the key and wait for all moving parts to stop before leaving the operating position Lower the mower to the 3 inch 76 mm height of cut position Remove the mower belt from the engine pulley refer to the Replacing the Mower Belt procedure Lower the mower to the lowest height of cut Select one of the following procedures depending on the mower deck size in...

Страница 49: ...arge 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 Never operate the lawn mower unless you install a mulch plate discharge deflector or grass collection system Inspect the grass deflector for damage before each use Replace any damaged parts before use 1 Disengage the spring from th...

Страница 50: ...e of the mower after each use to prevent grass buildup for improved mulch action and clipping dispersal 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 Attach the hose coupling to the end of t...

Страница 51: ... water Do not pressure wash the machine Avoid excessive use of water especially near the control panel engine hydraulic pumps and motors 3 Check the brake refer to Servicing the Brake in the Maintenance Section 4 Service the air cleaner refer to Servicing the Air Cleaner in the Maintenance Section 5 Grease the machine refer to Greasing and Lubrication in the Maintenance Section 6 Change the crankc...

Страница 52: ...ot 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 Store the machine in a clean dry garage or storage area Remove the key from the ignition switch and keep it out of reach of children or other unauthorized u...

Страница 53: ...Replace seat if needed 9 Electrical connections are corroded loose or faulty 9 Check the electrical connections for good contact Clean connector terminals thoroughly with electrical contact cleaner apply dielectric grease and reconnect 10 Relay or switch is defective 10 Contact an Authorized Service Dealer 11 Faulty spark plug 11 Clean adjust or replace spark plug Engine will not start starts hard...

Страница 54: ...rvice Dealer 6 Blade spindle is bent 6 Contact an Authorized Service Dealer Abnormal vibration 7 Motor mount is loose or worn 7 Contact an Authorized Service Dealer 1 Blade s not sharp 1 Sharpen the blade s 2 Cutting blade s is are bent 2 Install new cutting blade s 3 Mower deck is not level 3 Level mower deck from side to side and front to rear 4 Underside of mower is dirty 4 Clean the underside ...

Страница 55: ...Schematics G014723 Wire Diagram Rev B 55 ...

Страница 56: ...tor system 2 Bring the product and your proof of purchase sales receipt to the Service Dealer The dealer will diagnose the problem and determine if it is covered under warranty 3 If for any reason you are dissatisfied with the Service Dealer s analysis or with the assistance provided contact us at Customer Care Department RLC Division Toro Warranty Company 8111 Lyndale Avenue South Bloomington MN ...

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