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Electrical System
Maintenance

Servicing the Battery

Service Interval:

Monthly

DANGER

Battery electrolyte contains sulfuric acid which is a
deadly poison and causes severe burns.

Do not drink electrolyte and avoid contact with
skin, eyes or clothing. Wear safety glasses to shield
your eyes and rubber gloves to protect your hands.

Removing the Battery

WARNING

Battery terminals or metal tools could short against
metal machine components causing sparks. Sparks
can cause the battery gasses to explode, resulting
in personal injury.

•

When removing or installing the battery, do not
allow the battery terminals to touch any metal
parts of the machine.

•

Do not allow metal tools to short between
the battery terminals 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.

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.

3.

Remove the wing nut securing the battery clamp
(Figure 53).

G010240

1

2

3

4

Figure 53

1.

Remove the wing nut and
clamp

3.

Remove the positive
battery cable

2.

Remove the negative
battery cable before the
positive

4.

Remove battery

4.

Remove the clamp (Figure 53).

5.

First disconnect the negative battery cable (black) from
the negative (-)(black) battery terminal (Figure 53).

6.

Slide the red terminal boot off the positive (red) battery
terminal and remove the positive (+)(red) battery cable
(Figure 53).

7.

Remove the battery.

Installing the Battery

1.

Position battery in the tray with the terminal posts
opposite from the fuel tank (Figure 53).

2.

First, install the positive (red) battery cable to positive
(+) battery terminal.

3.

Then install the negative battery cable to the negative
(-) battery terminal.

4.

Secure the cables with 2 bolts, 2 washers, and 2 locknuts
(Figure 53).

5.

Slide the red terminal boot onto the positive (red)
battery post.

6.

Install the clamp and secure it with the wing nut
(Figure 53).

Charging the Battery

WARNING

Charging the battery produces gasses that can
explode.

Never smoke near the battery and keep sparks and
flames away from battery.

39

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Содержание 74920 TITAN ZX4820

Страница 1: ...375 781 Rev A TITAN ZX4820 or ZX5420 Zero Turn Radius Riding Mower Model No 74920 Serial No 313000001 and Up Model No 74924 Serial No 313000001 and Up Register at www Toro com Original Instructions EN 3375 781 A ...

Страница 2: ... number location Model No Serial No This manual identifies potential hazards and has safety messages identified by the safety alert symbol Figure 2 which signals a hazard that may cause serious injury or death if you do not follow the recommended precautions Figure 2 1 Safety alert symbol This manual uses 2 other words to highlight information Important calls attention to special mechanical inform...

Страница 3: ...h Mower to Side Discharge 26 Converting the 54 inch Mower to Side Discharge 27 Using the Side Discharge 29 Operating Tips 30 Maintenance 31 Recommended Maintenance Schedule s 31 Premaintenance Procedures 33 Raising the Seat 33 Lubrication 33 Greasing the Bearings 33 Engine Maintenance 34 Servicing the Air Cleaner 34 Servicing the Engine Oil 34 Servicing the Spark Plug 36 Cleaning the Cooling Syste...

Страница 4: ...ear and long trousers Do not operate the equipment when barefoot or wearing open sandals Thoroughly inspect the area where the equipment is to be used and remove all objects which may be thrown by the machine Warning Fuel is highly flammable Store fuel in containers specifically designed for this purpose Refuel outdoors only and do not smoke while refueling Add fuel before starting the engine Neve...

Страница 5: ...ty If the fuel tank has to be drained this should be done outdoors When machine is to be parked stored or left unattended lower the cutting means Toro Riding Mower Safety The following list contains safety information specific to Toro products or other safety information that you must know that is not included in the CEN standard Engine exhaust contains carbon monoxide which is an odorless deadly ...

Страница 6: ...which includes an Uncertainty Value K of 1 dBA Sound power level was determined according to the procedures outlined in EN 836 Hand Arm Vibration Measured vibration level for left hand 2 4 m s2 Measured vibration level for right hand 2 6 m s2 Uncertainty Value K 1 3 m s2 Measured values were determined according to the procedures outlined in EN 836 Whole Body Vibration Measured vibration level 0 6...

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: ... engaged 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 107 3069 1 Warning there is no rollover protection when the roll bar is down 2 To avoid injury or death from a rollover acci...

Страница 9: ...g parts Battery Symbols Some or all of these symbols are on your battery 1 Explosion hazard 6 Keep bystanders a 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 8 Battery acid can cause blindness or severe burns 4 Wear eye protection 9 Flush eyes immediately with water a...

Страница 10: ...ginal machine manufacturer 114 1606 1 Entanglement hazard belt keep all guards in place 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 117 1194 1 Engine 10 ...

Страница 11: ...f bystanders reversing 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 t...

Страница 12: ...e 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 119 8983 1 Fuel 2 Full 3 Half 4 Empty 12 ...

Страница 13: ...119 8986 1 Fuel 2 Full 3 Half 4 Empty 13 ...

Страница 14: ...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 5 1 Mower Deck 3 Engine 2 Drive wheel 4 Roll over protection system ROPS folded down 14 ...

Страница 15: ... level of gasoline in the tank Figure 7 g020264 1 Figure 7 1 Fuel gauge window Motion Control Levers The motion control levers are speed sensitive controls of independent wheel motors Moving a lever forward or backward turns the wheel on the same side forward or in reverse wheel speed is proportional to the amount the lever is moved Move the control levers outward from the center to the neutral lo...

Страница 16: ...ristics of the machine Use extra caution when using attachments with the machine G015033 1 2 3 Figure 8 1 Safe Zone use the machine here 2 Use walk behind mower and or hand trimmer near drop offs and water 3 Water Using the Rollover Protection System ROPS WARNING To avoid injury or death from rollover keep the roll bar in the raised locked position and use the seat belt WARNING There is no rollove...

Страница 17: ...d 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 truck bed liners may insulate the container and slow the loss of...

Страница 18: ...ne while it runs Eliminates gum like varnish buildup in the fuel system which causes hard starting Important Do not use fuel additives containing methanol or ethanol Add the correct amount of gas stabilizer conditioner to the gas 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 a...

Страница 19: ... Use the choke to start a cold engine 1 If the engine is cold use the choke to start the engine 2 Pull up on the choke knob to engage the choke before using the ignition switch Figure 16 3 Push down on the choke to disengage the choke after the engine has started Figure 16 G008959 1 2 Figure 16 1 On 2 Off Operating the Ignition Switch 1 Turn the ignition key to the Start position Figure 17 When th...

Страница 20: ...erating the Choke Note A warm or hot engine may not require choking In this case first try starting the engine without using the choke G010080 2 3 4 5 1 Figure 18 7 Turn the ignition key to the Start position Figure 17 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 att...

Страница 21: ...he throttle position at half or less will cause excessive wear to the drive belts G008945 Figure 21 Disengaging the Blade Control Switch PTO G009174 Figure 22 The Safety Interlock System WARNING 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 switch...

Страница 22: ...eat the engine should stop 4 While 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 contr...

Страница 23: ...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 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 p...

Страница 24: ...n lowest height of cut use only for deck removal 2 Cut height pin 5 Lock position transport position 3 Height of cut positions Using the Lock Positions The deck can be locked in the highest height of cut or transport position or the lowest height 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 positio...

Страница 25: ...ve the 2 bolts and 2 washers holding the control lever to the control arm shaft Figure 30 2 Move the control lever to the next set of holes Secure the lever with the 2 bolts and 2 washers Figure 30 4 1 2 G015764 3 5 Figure 30 1 Control arm shaft 4 Washer 2 Control lever 5 Bolt 3 Slotted upper hole 3 Repeat the adjustment for the opposite control lever Adjusting the Tilt The motion control levers c...

Страница 26: ... Baffle 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 set the parking brake stop the engine remove the key and wait for all moving parts to stop before leaving the operating position 3 Remove the mower as described in the Removing the Mower procedure in the Maintenance section for more information ...

Страница 27: ...e fasteners removed to secure the cut off baffle to the deck 13 Install the blades to the deck Refer to the Installing the Blades procedure in the Maintenance section for more information 14 Install the mower as described in the Installing the Mower procedure in the Maintenance section for more information Converting the 54 inch Mower to Side Discharge The mower deck and mower blades shipped with ...

Страница 28: ...e bolt up through the underside of the deck and use an existing locknut to secure from the topside WARNING Open holes in the mower expose you and others to thrown debris which can cause severe injury Never operate the mower without hardware mounted in all holes in the mower housing Install the hardware in the mounting holes when you remove the mulching baffle 9 Remove the carriage bolt 5 16 x 3 4 ...

Страница 29: ... mower as described in the Installing the Mower procedure in the Maintenance section for more information Using the Side Discharge The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf DANGER 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 Conta...

Страница 30: ...w for an extended period first mow at a high cutting height then mow again two days later at a lower height setting Cutting Speed To improve cut quality use a slower ground speed in certain conditions Avoid Cutting Too Low If the cutting width of the mower is wider than the mower you previously used raise the cutting height to ensure that uneven turf is not cut too short Long Grass If the grass is...

Страница 31: ...e engine 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 c...

Страница 32: ...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 32 ...

Страница 33: ...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 41 and Figure 40 with a rag Make sure to scrape any paint off of the front of the fitting s G009949 1 Figure 41...

Страница 34: ...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 ...

Страница 35: ... 9 10 4 8 Figure 44 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 that the drain side is slightly lower than the opposite side to ensure the oil drains completely 2 Disengage the PTO move the motion control leve...

Страница 36: ...th 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 correct before installing the spark plug Use a spark plug wrench for removing and installing the spark plug s and a gapping tool feeler gauge to check and adjust the air gap Install a new spark plug ...

Страница 37: ...lator usually means the air cleaner is dirty Set the gap to 0 030 inches 0 76 mm G008794 1 2 Figure 49 Installing the Spark Plug Tighten the spark plug s to 16 ft lb 22 N m 16 ft lb 22 N m G010687 Figure 50 Cleaning the Cooling System Clean the air intake screen from grass and debris before each use 1 Disengage the blade control switch and move the control levers to the neutral locked position and...

Страница 38: ...he machine to cool down 4 Raise the seat and locate the fuel filters as shown in Figure 51 g017723 1 2 3 4 5 Figure 51 1 Fuel line from tank 4 Fuel line to engine 2 In line Fuel filter 5 Hose clamp 3 Flow direction arrow 5 Squeeze the ends of the hose clamps together and slide them away from the filter Figure 52 G008963 1 2 3 Figure 52 1 Fuel filter 3 Fuel line 2 Hose clamp 6 Remove the filter fro...

Страница 39: ...tch 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 3 Remove the wing nut securing the battery clamp Figure 53 G010240 1 2 3 4 Figure 53 1 Remove the wing nut and clamp 3 Remove the positive battery cable 2 Remove the negative battery cable before t...

Страница 40: ...o not run the machine with the battery disconnected electrical damage may occur Figure 54 1 Positive Battery Post 3 Red Charger Lead 2 Negative Battery Post 4 Black Charger Lead 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 typ...

Страница 41: ... OIL 500 or 20w 50 motor oil System Capacity approximately 4 495 liter 152 oz with a filter change Important Use oil specified or equivalent Other fluids could cause system damage Checking the Hydraulic Oil Level Service Interval Every 25 hours Check expansion reservoir and if necessary add oil to the FULL COLD line G010253 1 2 3 Figure 57 1 Expansion reservoir 3 Engine 2 Full Cold line Changing t...

Страница 42: ...l After the first 50 hours Every 400 hours G008748 3 4 1 2 3 4 5 6 Figure 59 1 Apply a thin coat of oil on the surface of the rubber seal of each filter 2 Turn the filter clockwise until rubber seal contacts the filter adapter then tighten the filter an additional 3 4 to 1 full turn Repeat for the other filter 3 Install the filter guards over each filter as previously removed Use the three screws ...

Страница 43: ...eaches the FULL COLD line on the expansion reservoir if necessary 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 Check the cutter blades daily for sharpness...

Страница 44: ...1 Deck 3 Blade 2 Spindle housing 3 Measure from the tip of the blade to the flat surface here G014973 1 2 3 Figure 63 1 Blade in position for measuring 2 Level surface 3 Measured distance between blade and surface A 4 Rotate the same blade 180 degrees so that the opposing cutting edge is now in the same position G014974 1 2 3 Figure 64 1 Blade side previously measured 2 Measurement position used p...

Страница 45: ...love Remove the blade bolt curved washer and blade from the spindle shaft Figure 66 1 2 3 4 G010341 Figure 66 1 Sail Area of Blade 3 Curved washer 2 Blade 4 Blade Bolt Sharpening the Blades WARNING When sharpening blade pieces of blade could be thrown and cause serious injury Wear proper eye protection when sharpening blade 1 Use a file to sharpen the cutting edge at both ends of the blade Figure ...

Страница 46: ...to side 3 Measure from the tip of the blade to the flat surface here 2 Outside cutting edges Checking the Front to Rear Blade Slope Check the front to rear blade level any time you install the mower If the front of the mower is more than 5 16 inch 7 9 mm lower than the rear of the mower adjust the blade level using the following instructions 1 Park the machine on a level surface and disengage the ...

Страница 47: ...ayed belt edges burn marks and cracks are signs of a worn mower belt Replace the mower belt if any of these conditions are evident Replacing the Mower Belt Squealing when the 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...

Страница 48: ...oving the Mower Park the machine on a level surface and disengage the blade control switch Move the motion control levers outward to the neutral position 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 R...

Страница 49: ...rge 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 the...

Страница 50: ...sing Wash the underside 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 co...

Страница 51: ...mild detergent and 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...

Страница 52: ... 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 users Cover the machine to protect it and ...

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: ...Notes 56 ...

Страница 57: ...Notes 57 ...

Страница 58: ...Notes 58 ...

Страница 59: ...rmation Toro Collects Toro Warranty Company Toro respects your privacy In order to process your warranty claim and contact you in the event of a product recall we ask you to share certain personal information with us either directly or through your local Toro company or dealer The Toro warranty system is hosted on servers located within the United States where privacy law may not provide the same ...

Страница 60: ...turer 5Whichever occurs first 6Lifetime Frame Warranty If the main frame consisting of the parts welded together to form the tractor structure that other components such as the engine are secured to cracks or breaks in normal use it will be repaired or replaced at Toro s option under warranty at no cost for parts and labor Frame failure due to misuse or abuse and failure or repair required due to ...

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