Form No. 3356-557 Rev B TimeCutter® Z5020 Riding Mower Model No. 74399—Serial No. 270000001 and Up Register at www.Toro.com.
Introduction Figure 2 1. Safety alert symbol. 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. This manual uses two other words to highlight information. Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention. You may contact Toro directly at www.Toro.
Safety Servicing the Air Cleaner .................................... 24 Servicing the Engine Oil ..................................... 25 Servicing the Spark Plug ..................................... 27 Cleaning the Blower Housing.............................. 28 Fuel System Maintenance ....................................... 28 Replacing the Fuel Filter ..................................... 28 Electrical System Maintenance................................ 29 Charging the Battery..........................
– stay alert for humps and hollows and other hidden hazards; ◊ lack of awareness of the effect of ground conditions, especially slopes; ◊ incorrect hitching and load distribution. • Use care when pulling loads. – Use only approved drawbar hitch points. Preparation – Limit loads to those you can safely control. • While mowing, always wear substantial footwear and long trousers. Do not operate the equipment when barefoot or wearing open sandals.
Maintenance and Storage • Do not mow slopes when grass is wet. Slippery conditions reduce traction and could cause sliding and loss of control. • Keep all nuts, bolts and screws tight to be sure the equipment is in safe working condition. • Never store the equipment with fuel in the tank inside a building where fumes can reach an open flame or spark. • Allow the engine to cool before storing in any enclosure.
Slope Chart 6
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. 114-1606 1. Entanglement hazard, belt—keep all guards in place. 106-8717 1. Read the instructions before servicing or performing maintenance. 2. Check tire pressure every 25 operating hours. 3. Grease every 25 operating hours. 4. Engine 93-7009 1.
112-9751 1. Parking brake 2. Fast 3. Slow 4. Neutral 5. Reverse 110-6824 1. Height-of-cut 112-9840 3. Remove the ignition key and read the instructions before servicing or performing maintenance. 1. Read the Operator’s Manual. 2. Height of cut 110-6654 1. Fast 2. Continuous variable setting 3. Slow 4. Choke 5. Power take-off (PTO), Blade control switch on some models 6. Disengage 7. Engage 110-6680 1. Bypass lever, engaged 2. Bypass lever, disengaged 112-9750 1. Parking brake 2. Fast 3. Slow 4.
Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 6. Keep bystanders a safe distance from the battery. 7. Wear eye protection; explosive gases can cause blindness and other injuries 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. 10. Contains lead; do not discard. 2. No fire, open flame, or smoking. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 5. Read the Operator’s Manual. 1. 1.
Product Overview Figure 3 1. Operator seat 2. Motion control levers 3. Control panel 7. Front caster wheel 8. Rear drive wheel 9. Anti-scalp roller 4. Height of cut lever 5. Footrest 6. Mower deck 10. Washout fitting Figure 4 1. Motion control levers 2. Height of cut lever 3. Gas tank cap 4. Engine 5. Deflector 6. Engine guard 10 7.
Controls or backward turns the wheel on the same side forward or in reverse; wheel speed is proportional to the amount the lever is moved. Moving the control levers outward from the center position engages the parking brake and allows the operator to exit the machine (Figure 13). Always position the motion control levers into the brake position when you stop the machine or leave it unattended.
Operation Recommended Fuel Note: Determine the left and right sides of the machine from the normal operating position. Use Unleaded Regular Gasoline suitable for automotive use (87 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available. Think Safety First Important: Never use methanol, gasoline containing methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged. Do not mix oil with gasoline.
Add the correct amount of gas stabilizer/conditioner to the gas. 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. 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.
3. Pull up on the Choke control before starting a cold engine (Figure 10). 4 Note: A warm or hot engine may not require choking. 2 1 6 3 2 1 G005302 3 Figure 7 3. Fill to here, approximately 4. Gas tank opening 1. Gas tank body 2. Gas tank neck 2 G005183 4 Checking the Engine Oil Level Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking the Oil Level in Engine Maintenance , page 24. 5 Figure 9 Starting and Stopping the Engine 1.
7 2 2 3 1 4 G005185 1 5 6 Figure 11 1. Control panel G005184 2. Blade control switch—On position Figure 10 1. 2. 3. 4. Disengaging the Blades 5. Run Control panel Ignition key—run position 6. Start Ignition key—start position 7. Choke control Off Push the blade control switch to Off to disengage the blades (Figure 12). 5. After the engine starts, push down on the Choke control (Figure 10). If the engine stalls or hesitates, pull up on the Choke control and let the engine run for a few seconds.
Driving Forward or Backward The Safety Interlock System 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. If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. • Do not tamper with the interlock switches.
Adjusting the Height of Cut To turn, release pressure on the motion control lever toward the direction you want to turn (Figure 13). 1. Enter the operator’s position. Place a foot on the foot assist pedal and apply pressure. The farther you move the motion control levers in either direction, the faster the machine will move in that direction. 2. While maintaining pressure on the pedal, pull inward and up on the height-of-cut lever and move it to the desired position.
Adjusting the Motion Control Levers 1 4-1/2inin(1(11515 mm) 4-1/2 mm) Adjusting the Height 44 in mm) in.(102 (102 mm) The motion control levers can be adjusted higher or lower for maximum operator comfort. 1. Remove the 2 bolts holding the control lever to the control arm shaft (Figure 17). 2. Move the control lever to the next set of holes. Secure the lever with the 2 bolts (Figure 17).
To Push the Machine 1. Park the machine on a level surface and disengage the blade control switch. 2. Move the motion control levers outward to park position, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 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 18 to disengage the wheel motors.
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. Figure 19 1. Knob 7. Install the right mower blade. Refer to the Mower Maintenance, page 32 section. 8. Lower the grass deflector over the discharge opening. 3. Baffle stud coming through the mower 2.
Cutting a Lawn for the First Time lawn. To avoid this, move onto a previously cut area with the blades engaged. Cut grass slightly longer than normal to ensure that the cutting height of the mower does not scalp any uneven ground. However, the cutting height used in the past is generally the best one to use. When cutting grass longer than six inches tall, you may want to cut the lawn twice to ensure an acceptable quality of cut.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval Before each use or daily Maintenance Procedure • • • • • • Check the safety interlock system. Check the air cleaner for dirty, loose or damaged parts. Check the engine oil level. Check air intake and cooling areas (clean as necessary). Check the cutting blades. Clean the mower housing. Every 25 hours • Grease all lubrication points.
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 park position. Lift the seat forward and lower it to the floor board. 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. • Serial plate 2.
Engine Maintenance 4. Connect a grease gun to each fitting (Figure 22 and Figure 23). Pump grease into the fittings until grease begins to ooze out of the bearings. Servicing the Air Cleaner 5. Wipe up any excess grease. Service Interval: Before each use or daily—Check the air cleaner for dirty, loose or damaged parts. This engine is equipped with a replaceable, high density paper air cleaner element. Check the air cleaner daily or before starting the engine.
3. Gently tap the paper element to dislodge dirt. Do not wash the paper element or use pressurized air, as this will damage the element. Replace a dirty, bent, or damaged element. Handle the new element carefully; do not use if the sealing surfaces are bent or damaged. 1 4. Clean the air cleaner base as required and check condition. 5. Install the paper element onto the air cleaner base. Secure with the latch. 6. Close the air cleaner cover door.
3 F ULL rest the cap on the tube. Do not screw the cap onto the tube. Change the oil and oil filter as follows: 1. Start the engine and let it run until warm. This warms the oil so it drains better. 2. Park the machine so that the drain side is slightly lower than the opposite side to assure the oil drains completely. 1 2 ADD 3. Disengage the blade control switch and move the motion controls outward to the park position. 4.
Removing the Spark Plug 1. Disengage the blade control switch, move the motion controls outward to the park position, stop the engine, and remove the key. 2. Before removing the spark plug(s), clean the area around the base of the plug to keep dirt and debris out of the engine. 1 Pull the wire off of the spark plug(s) (Figure 29). 3. Clean around the spark plug(s) to prevent dirt from falling into the engine and potentially causing damage. Remove the spark plug(s) and metal washer.
Fuel System Maintenance 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. Figure 30 1. Center electrode insulator 2. Side electrode 3. Air gap (not to scale) • Perform any fuel related maintenance when the engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills.
Electrical System Maintenance 6 Charging the Battery 1 Removing the Battery 3 5 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. G005071 2 4 • When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine. Figure 31 1. Fuel line from tank 2. Hose clamp 3. Filter 4. Fuel line to engine 5. Flow direction arrow 6.
5. Slide the rubber cover up the positive (red) cable. Disconnect the positive (red) cable from the battery post (Figure 32). Retain all fasteners. 6. Remove the battery hold-down (Figure 32) and lift the battery from the battery tray. 3 2 6 5 1 Figure 33 7 1. Positive battery post 2. Negative battery post 3. Red (+) charger lead 4. Black (-) charger lead Note: Do not run the machine with the battery disconnected, electrical damage may occur. 4 Installing the Battery 1.
Drive System Maintenance Checking the Tire Pressure 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 35). Check the tires when they are cold to get the most accurate pressure reading. G005073 Rear Tires: 13 psi (90 kPa) 1 2 Front Tires (caster wheels): 20 psi (138 kPa) Figure 34 1. Main-30 amp 2. Charge circuit-25 amp Figure 35 1.
Mower 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 36 1. Cutting edge 2. Curved area Check the cutter blades daily for sharpness, and for any wear or damage. File down any nicks and sharpen the blades as necessary.
Removing the Blades The blades must be replaced if a solid object is hit, if the blade is out of balance, or the blade is bent. To ensure optimum performance and continued safety conformance of the machine, use genuine Toro replacement blades. Replacement blades made by other manufacturers may result in non-conformance with safety standards. Figure 40 1. Blade 2. Balancer Installing the Blades Hold the blade end using a rag or thickly-padded glove.
G005278 2 3 3 1 2 4 4 1 3 4 6 Figure 41 1. Blades side to side 2. Sail area of blade 3. Outside cutting edges 4. Measure here 2 5 6. Measure between the outside cutting edges and the flat surface (Figure 41). If both measurements are not within 3/16 inch (5 mm), an adjustment is required; continue with this procedure. G005074 7. At the left side of the machine. Loosen, but do not remove, the rear locking nut on the hanger bracket (Figure 42). Figure 42 1. Hanger bracket 2.
is 1/16-5/16 inch (1.6-7.9 mm) lower than the rear blade tip (Figure 43). 6. Measure from the tip of the front blade to the flat surface and the tip of the rear blade to the flat surface (Figure 43). If the front blade tip is not 1/16-5/16 inch (1.6-7.9 mm) lower than the rear blade tip, adjust the front locknut. 10. When the front-to-rear blade slope is correct check the side-to-side level of the mower again; refer to Leveling the Mower from Side-to-Side. 3 Removing the Mower 2 1.
The spring is under tension when installed and can cause personal injury. Be careful when removing the belt. 2 2 3 3 5 2 1 3 1 G005077 Figure 46 1. Mower deck 2. Hanger bracket 3. Rear lift rod 4 6. Slide the mower rearward to remove the mower belt from the engine pulley. G005191 Figure 47 1. Idler pulley 2. Mower belt 3. Outside pulley 7. Slide the mower out from underneath the machine. 4. Spring 5. Engine pulley Note: Retain all parts for future installation. Mower Belt Maintenance 6.
Replacing the Grass Deflector Cleaning Washing the Underside of the Mower 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. Service Interval: Before each use or daily—Clean the mower housing. Note: Washing the underside of the mower after each use prevents grass buildup and improves mulching and clipping dispersal. 1.
Storage Note: If the mower is not clean after one washing, soak it and let it stand for 30 minutes. Then repeat the process. Cleaning and Storage 8. Run the mower again for one to three minutes to remove excess water. 1. Disengage the blade control switch, move the motion controls outward to the park position, stop the engine, and remove the key. 2. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine.
Important: Do not store stabilizer/conditioned gasoline over 30 days. 11. Remove the spark plug(s) and check its condition; refer to Servicing the Spark Plug in Engine Maintenance , page 24. With the spark plug(s) removed from the engine, pour two tablespoons of engine oil into the spark plug hole. Use the starter to crank the engine and distribute the oil inside the cylinder. Install the spark plug(s). Do not install the wire on the spark plug(s). 12. Clean any dirt and chaff from the top of the mower. 13.
Troubleshooting Problem The engine overheats. Possible Cause 1. The engine load is excessive. 1. Reduce ground speed. 2. The oil level in the crankcase is low. 3. The cooling fins and air passages under the engine blower housing are plugged. 4. The air cleaner is dirty. 2. Add oil to the crankcase. 3. Remove the obstruction from the cooling fins and air passages. 5. Dirt, water, or stale fuel is in fuel system.
Problem There is abnormal vibration. Uneven cutting height. Possible Cause 1. The engine mounting bolts are loose. 1. Tighten the engine mounting bolts. 2. The engine pulley, idler pulley, or blade pulley is loose. 3. The engine pulley is damaged. 4. The cutting blade(s) is/are bent or unbalanced. 5. A blade mounting bolt is loose. 6. A blade spindle is bent. 2. Tighten the appropriate pulley. 1. The blade(s) is not sharp. 1. Sharpen the blade(s). 2. A cutting blade(s) is/are bent. 3.
Schematics Electrical Diagram (Rev.
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The Toro Warranty Conditions and Products Covered Instructions for Obtaining Warranty Service The Toro® Company and its afliate, Toro Warranty Company, pursuant to an agreement between them, jointly promises to the original purchaser* to repair any Toro Product used for normal residential purposes* if defective in materials or workmanship.
