Toro TimeCutter Z5020 Riding Mower User manual

Brand: Toro

Model: TimeCutter Z5020 Riding Mower

Type: User manual

This manual is also suitable for

5HVLGHQWLDO3URGXFWV

7LPH&XWWHU



=3UHFLVLRQ



=

=HUR5DGLXV7XUQ5LGLQJ0RZHU

6HUYLFH0DQXDO

ABOUT THIS MANUAL

This service manual was written expressly for Toro and Lawn-Boy service technicians. The Toro Company has made

every effort to make the information in this manual complete and correct.

Basic shop safety knowledge and mechanical/electrical skills are assumed. The Table of contents lists the systems

and the related topics covered in this manual.

)RUDGGLWLRQDOLQIRUPDWLRQRQWKHHOHFWULFDOV\VWHPSOHDVHUHIHUWRWKH7RUR(OHFWULFDO'HP\VWL¿FDWLRQ*XLGH

DQGVXEVHTXHQW)RUVHUYLFHLQIRUPDWLRQRQGULYHV\VWHPVSOHDVHUHIHUWRWKH+\GUR*HDU(=7VHUYLFHPDQXDO

)RULQIRUPDWLRQVSHFL¿FWRWKHHQJLQHVXVHGRQWKLVXQLWUHIHUWRWKHDSSURSULDWHHQJLQHPDQXIDFWXUHU¶V

service and repair instructions.

7RUR7LPH&XWWHU=PRGHO\HDU±DQG/DZQ%R\3UHFLVLRQ=PRGHO\HDU±DUHFRYHUHGLQWKLV

PDQXDO7KHPDQXDOPD\DOVREHVSHFL¿HGIRUXVHRQODWHUPRGHOSURGXFWV

The hydrostatic transaxle is a sophisticated piece of machinery. Maintain strict cleanliness control during all stages of

VHUYLFHDQGUHSDLU&RYHURUFDSDOOKRVHHQGVDQG¿WWLQJVZKHQHYHUWKH\DUHH[SRVHG(YHQDVPDOODPRXQWRIGLUWRU

other contamination can severely damage the system.

:HDUHKRSHIXOWKDW\RXZLOO¿QGWKLVPDQXDODYDOXDEOHDGGLWLRQWR\RXUVHUYLFHVKRS,I\RXKDYHDQ\TXHVWLRQVRU

comments regarding this manual, please contact us at the following address:

The Toro Company

Residential and Landscape Contractor Service Training Department

8111 Lyndale Avenue South

Bloomington, MN 55420

7KH7RUR&RPSDQ\UHVHUYHVWKHULJKWWRFKDQJHSURGXFWVSHFL¿FDWLRQVRUWKLVPDQXDOZLWKRXWQRWLFH

7KH7RUR&RPSDQ\

ABOUT THIS MANUAL

   7LPH&XWWHU=3UHFLVLRQ=6HUYLFH0DQXDO

THIS PAGE INTENTIONALLY LEFT BLANK.

TABLE OF CONTENTS

i7LPH&XWWHU=3UHFLVLRQ=6HUYLFH0DQXDO

Safety Information

*HQHUDO,QIRUPDWLRQ......................................................................................................................

7KLQN6DIHW\)LUVW..........................................................................................................................

6SHFL¿FDWLRQV

(QJLQH6SHFL¿FDWLRQV ...................................................................................................................

*HQHUDO6SHFL¿FDWLRQV..................................................................................................................

7UDFWLRQ6\VWHP............................................................................................................................

*URXQG6SHHG6SHFL¿FDWLRQV.......................................................................................................

7LUH6SHFL¿FDWLRQV ........................................................................................................................

0RZHU'HFN6SHFL¿FDWLRQV ..........................................................................................................

Dimensions & Weight...................................................................................................................

Dimensions & Weight cont. ..........................................................................................................

+\GURVWDWLF7UDQVD[OH6SHFL¿FDWLRQV............................................................................................

+\GUR*HDU(=7+\GURVWDWLF7UDQVD[OHV ...............................................................................

7RUTXH6SHFL¿FDWLRQV ...................................................................................................................

6WDQGDUG7RUTXHIRU'U\=LQF3ODWHGDQG6WHHO)DVWHQHUV,QFK6HULHV....................................

6WDQGDUG7RUTXHIRU'U\=LQFDQG6WHHO)DVWHQHUV0HWULF)DVWHQHUV ....................................

2WKHU7RUTXH6SHFL¿FDWLRQV .......................................................................................................

(TXLYDOHQWV&RQYHUVLRQV.........................................................................................................

'HFLPDO0LOOLPHWHU(TXLYDOHQWV.........................................................................................

86WR0HWULF&RQYHUVLRQV.........................................................................................................

Chassis

0RGHO6HULDO1XPEHU,GHQWL¿FDWLRQ .............................................................................................

*UHDVH/XEULFDWLRQ ......................................................................................................................

Front Castor Fork Replacement .....................................................................................................

6W\OH$)URQW$[OH$VVHPEO\&DVWHU)RUN5HPRYDO ...............................................................

6W\OH$)URQW$[OH$VVHPEO\&DVWHU)RUN,QVWDOODWLRQ ............................................................

6W\OH%)URQW$[OH$VVHPEO\&DVWHU)RUN5HPRYDO ...............................................................

6W\OH%)URQW$[OH$VVHPEO\&DVWHU)RUN,QVWDOODWLRQ ............................................................

Caster Wheel Assembly Removal ............................................................................................

&DVWRU:KHHO$VVHPEO\,QVWDOODWLRQ ......................................................................................... 

Front Axle Assembly Removal .................................................................................................

)URQW$[OH$VVHPEO\,QVWDOODWLRQ ............................................................................................

Fuel Tank Replacement ................................................................................................................

Fuel Tank Removal ................................................................................................................

)XHO7DQN,QVWDOODWLRQ .............................................................................................................

6HDW3LYRW&RQWURO$VVHPEO\5HSODFHPHQW ..................................................................................

6HDW3LYRW&RQWURO$VVHPEO\5HPRYDO ..................................................................................

6HDW3LYRW&RQWURO$VVHPEO\,QVWDOODWLRQ ...............................................................................

'HFN/LIW6HDW3RGV%UDFNHW5HSODFHPHQW ...............................................................................

'HFN/LIW6HDW3RGV%UDFNHW5HPRYDO ................................................................................

'HFN/LIW6HDW3RGV%UDFNHW,QVWDOODWLRQ ............................................................................. 

Arm-Lift, Rear, Replacement ........................................................................................................

Arm-Lift, Rear, Removal .........................................................................................................

$UP/LIW5HDU,QVWDOODWLRQ ...................................................................................................... 

Rear Bumper Replacement ..........................................................................................................

Rear Bumper Removal ..........................................................................................................

5HDU%XPSHU,QVWDOODWLRQ .......................................................................................................

TABLE OF CONTENTS

ii   7LPH&XWWHU=3UHFLVLRQ=6HUYLFH0DQXDO

Engine

Engine Replacement....................................................................................................................

Engine Removal.....................................................................................................................

(QJLQH,QVWDOODWLRQ..................................................................................................................

(QJLQH0XIÀHU5HSODFHPHQW ......................................................................................................

(QJLQH0XIÀHU5HPRYDO.......................................................................................................

(QJLQH0XIÀHU,QVWDOODWLRQ....................................................................................................

Hydrostatic Drive System

+\GUR'ULYH%HOW5HSODFHPHQW .....................................................................................................

+\GUR'ULYH%HOW5HPRYDO......................................................................................................

'ULYH%HOW,QVWDOODWLRQ .............................................................................................................

Transaxle Replacement................................................................................................................

Transaxle Removal................................................................................................................

7UDQVD[OH,QVWDOODWLRQ ...........................................................................................................

Actuator Arm Replacement.........................................................................................................

Actuator Arm Removal.........................................................................................................

$FWXDWRU$UP,QVWDOODWLRQ ......................................................................................................

Activator Arm Assembly Replacement........................................................................................

Activator Arm Assembly Removal........................................................................................

$FWLYDWRU$UP$VVHPEO\,QVWDOODWLRQ .....................................................................................

1HXWUDO$GMXVWPHQW .....................................................................................................................

7UDFNLQJ$GMXVWPHQW ...................................................................................................................

3XUJLQJ3URFHGXUHV7UDQVD[OHV ...............................................................................................

(=77URXEOHVKRRWLQJ&KHFNOLVW.................................................................................

Mower Deck

0RZHU6SLQGOH5HSODFHPHQW..........................................................................................................

0RZHU6SLQGOH5HPRYDO ..........................................................................................................

0RZHU6SLQGOH,QVWDOODWLRQ .......................................................................................................

,GOHU$UP5HSODFHPHQW ...................................................................................................................

,GOHU$UP5HPRYDO ...................................................................................................................

,GOHU$UP,QVWDOODWLRQ ..............................................................................................................

)L[HG)ODW,GOHU3XOOH\5HSODFHPHQW .............................................................................................

)L[HG)ODW,GOHU3XOOH\5HPRYDO .............................................................................................

)L[HG)ODW,GOHU3XOOH\,QVWDOODWLRQ ..........................................................................................

Mower Deck Replacement ...........................................................................................................

Mower Deck Removal ............................................................................................................

0RZHU'HFN,QVWDOODWLRQ

.........................................................................................................

Leveling the Mower Deck .............................................................................................................

6LGHWR6LGH/HYHOLQJ .............................................................................................................

$GMXVWLQJWKH)URQWWR5HDU%ODGH6ORSH ...............................................................................

Mower Belt Maintenance ..............................................................................................................

Mower Belt Routing ................................................................................................................

,QVSHFWLQJWKH%HOWV ................................................................................................................

Mower Belt Replacement .......................................................................................................

Checking for Bent Blades .............................................................................................................

&KHFNLQJWKH7LUH3UHVVXUH ..........................................................................................................

TABLE OF CONTENTS

iii7LPH&XWWHU=3UHFLVLRQ=6HUYLFH0DQXDO

Electrical

(OHFWULFDO6\VWHP ............................................................................................................................

5HOD\.LOO5HOD\ ............................................................................................................................

3XUSRVH ....................................................................................................................................

Location ...................................................................................................................................

+RZ,W:RUNV ............................................................................................................................

Testing ......................................................................................................................................

6ROHQRLG..........................................................................................................................................

3XUSRVH ....................................................................................................................................

Location ...................................................................................................................................

+RZ,W:RUNV ............................................................................................................................

Testing ......................................................................................................................................

,JQLWLRQ6ZLWFK ................................................................................................................................

3XUSRVH ....................................................................................................................................

Location ...................................................................................................................................

+RZ,W:RUNV ............................................................................................................................

Testing ......................................................................................................................................

3726ZLWFK .....................................................................................................................................

3XUSRVH ....................................................................................................................................

Location ...................................................................................................................................

+RZ,W:RUNV ............................................................................................................................

Testing ......................................................................................................................................

(OHFWULF372&OXWFK ......................................................................................................................

3XUSRVH ....................................................................................................................................

Location ...................................................................................................................................

+RZ,W:RUNV ............................................................................................................................

Testing ......................................................................................................................................

Coil Resistance Measurement .................................................................................................

Measuring Clutch Current Draw ...............................................................................................

3DUN%UDNH6ZLWFK ..........................................................................................................................

3XUSRVH ....................................................................................................................................

Location ...................................................................................................................................

+RZ,W:RUNV ............................................................................................................................

Testing ......................................................................................................................................

6ZLWFK6HDW..................................................................................................................................

3XUSRVH ..................................................................................................................................

Location .................................................................................................................................

+RZ,W:RUNV ..........................................................................................................................

Testing ....................................................................................................................................

FlyBack Diode ..............................................................................................................................

3XUSRVH ..................................................................................................................................

Location .................................................................................................................................

+RZ,W:RUNV .......................................................................................................................... 

Testing ....................................................................................................................................

7RUR7LPH&XWWHU=0RGHOV6FKHPDWLF ........................................................................

7RUR7LPH&XWWHU=0RGHOV6FKHPDWLF .................................................................................

/DZQ%R\3UHFLVLRQ=6LQJOH&\OLQGHU(QJLQHV0RGHOV6FKHPDWLF..................................

/DZQ%R\3UHFLVLRQ=7ZLQ&\OLQGHU(QJLQHV0RGHOV6FKHPDWLF ....................................

TABLE OF CONTENTS

iv   7LPH&XWWHU=3UHFLVLRQ=6HUYLFH0DQXDO

THIS PAGE INTENTIONALLY LEFT BLANK.

SAFETY INFORMATION

1-1TimeCutter® Z/Precision® Z Service Manual

This symbol means WARNING or

PER SONAL SAFETY INSTRUCTION

– read the instruction because it has to

do with your safety. Failure to comply

with the instruction may result in

personal injury or even death.

This manual is intended as a service and repair manual

only. The safety instructions provided herein are for

troubleshooting, service, and repair of the TimeCutter® Z

and the Precision® Z zero radius turn mowers.

General Information

Think Safety First

Avoid unexpected starting of engine…

Always turn off the engine and disconnect the spark plug

wire(s) before cleaning, adjusting, or repair.

Avoid lacerations and amputations…

Stay clear of all moving parts whenever the engine is

running. Treat all normally moving parts as if they were

moving whenever the engine is running or has the

potential to start.

Avoid burns…

'RQRWWRXFKWKHHQJLQHPXIÀHURURWKHUFRPSRQHQWV

which may increase in temperature during operation,

while the unit is running or shortly after it has been

running.

$YRLG¿UHVDQGH[SORVLRQV«

Avoid spilling fuel and never smoke while working with

any type of fuel or lubricant. Wipe up any spilled fuel

or oil immediately. Never remove the fuel cap or add

fuel when the engine is running. Always use approved,

labeled containers for storing or transporting fuel and

lubricants.

Avoid asphyxiation…

1HYHURSHUDWHDQHQJLQHLQDFRQ¿QHGDUHDZLWKRXW

proper ventilation.

Avoid injury from batteries…

Battery acid is poisonous and can cause burns. Avoid

contact with skin, eyes and clothing. Battery gases can

H[SORGH.HHSFLJDUHWWHVVSDUNVDQGÀDPHVDZD\IURP

the battery.

Avoid injury due to inferior parts…

Use only original equipment parts to ensure that

important safety criteria are met.

Avoid injury to bystanders…

Always clear the area of bystanders before starting or

testing powered equipment.

Avoid injury due to projectiles…

Always clear the area of sticks, rocks or any other debris

that could be picked up and thrown by the powered

equipment.

$YRLGPRGL¿FDWLRQV«

Never alter or modify any part unless it is a factory

approved procedure.

Avoid unsafe operation…

Always test the safety interlock system after making

adjustments or repairs on the machine. Refer to the

Electrical section in this manual for more information.

The TimeCutter Z and the Precision Z operator’s

manuals contain safety information and operating tips

for safe operating practices. Operator’s manuals are

available online through your Toro parts source or:

The Toro Company

Publications Department

8111 Lyndale Avenue South

Bloomington, MN 55420

SAFETY INFORMATION

1-2 TimeCutter® Z/Precision® Z Service Manual

THIS PAGE INTENTIONALLY LEFT BLANK.

SPECIFICATIONS

2-1TimeCutter® Z/Precision® Z Service Manual

Z4200 Kohler, Overhead Valve, Twin Cam, 19.0 hp (14.2kW) @ 3600 RPM

High Idle: 3300 + 100 RPM

Z4200 (CE)

Kohler, Overhead Valve, Twin Cam, 19.0 hp (14.2kW) @ 3600 RPM

High Idle: 2650 + 100 RPM

Z4220

Kohler, Overhead Valve, Twin Cam, 21.0 hp (15.7kW) @ 3600 RPM

High Idle: 3300 + 100 RPM

Z4202 (CE) Kohler, Overhead Valve, Twin Cam, 20.0 hp (14.9kW) @ 3600 RPM

High Idle: 2400 +100/-0 RPM

Z5000

Kohler, Overhead Valve, Twin Cam, 21.0 hp (15.7kW) @ 3600 RPM

High Idle: 3300 + 100 RPM

Z5000 (CE)

Kohler, Overhead Valve, Twin Cam, 21.0 hp (15.7kW) @ 3600 RPM

High Idle: 2900 + 100 RPM

Z5020

Kohler, Overhead Valve, Twin Cam, 23.0 hp (17.2kW) @ 3600 RPM

High Idle: 3300 + 100 RPM

Z5020 (CE) Kohler, Overhead Valve, Twin Cam, 23.0 hp (17.2kW) @ 3600 RPM

High Idle: 2900 +0/-200 RPM

Z5030

Kohler, Overhead Valve, Twin Cam, 23.0 hp (17.2kW) @ 3600 RPM

High Idle: 3300 + 100 RPM

Z5040

Kawasaki, Overhead Valve, 21.0 hp (15.7kW) @ 3600 RPM

High Idle: 3450 + 100 RPM

Z5060

Kohler, Overhead Valve, Twin Cam, 25.0 hp (18.6kW) @ 3600 RPM

High Idle: 3300 + 100 RPM

(QJLQH6SHFL¿FDWLRQV

SPECIFICATIONS

2-2 TimeCutter® Z/Precision® Z Service Manual

*HQHUDO6SHFL¿FDWLRQV

7UDFWLRQ6\VWHP

&RQVWUXFWLRQ Frame: drawn 11 gauge steel

)XHO6\VWHP 6LQJOHIXHOWDQNJDOORQ/FDSDFLW\IXHO¿OWHUUHSODFHDEOHLQOLQHW\SHYHQWHGIXHOFDS

$WWDFKPHQW'ULYH Electric Clutch

6WHHULQJ Levers: Dual wrap-around levers control hydraulic pump

Dampening: Dual hydraulic dampeners

Turning Radius: Zero Radius Turn (ZRT)

,QWHUORFNV Seat: Operator presence switch

Control Lever/Brake: Dual position switch

Power Take Off: Position switch

(OHFWULFDO6\VWHP Battery Voltage: 12 volt negative ground

%DWWHU\7\SH%&,*URXS8ZHWFKDUJHEDWWHU\

)XVHVDPSEODGHW\SHPDLQDPSEODGHW\SHFKDUJHV\VWHP

7UDQVD[OH Twin Hydro-Gear EZT Hydrostatic Transaxles

7UDQVD[OH'ULYH Belt drive with self-tensioning system

SPECIFICATIONS

2-3TimeCutter® Z/Precision® Z Service Manual

*URXQG6SHHG6SHFL¿FDWLRQV

7LUH6SHFL¿FDWLRQV

0RGHO *URXQG6SHHG

Z4200 ,Q¿QLWH WRPSKNPKUIRUZDUG