Form No. 3412-791 Rev B TimeCutter® HD ZX4800, ZX5400, and ZX6000 Riding Mower Model No. 75201—Serial No. 400000000 and Up Model No. 75202—Serial No. 400000000 and Up Model No. 75203—Serial No. 400000000 and Up Register at www.Toro.com.
WARNING CALIFORNIA Proposition 65 Warning This product contains a chemical or chemicals known to the State of California to cause cancer, birth defects, or reproductive harm. The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
Transporting the Machine........................................25 Loading the Machine ..............................................26 Maintenance .................................................................27 Recommended Maintenance Schedule(s) ......................27 Pre-Maintenance Procedures ......................................28 Maintenance and Storage Safety................................28 Engine Maintenance ..................................................28 Engine Safety.................
Safety This machine has been designed in accordance with ANSI B71.1-2012. General Safety This product is capable of amputating hands and feet and of throwing objects. Always follow all safety instructions to avoid serious personal injury. Using this product for purposes other than its intended use could prove dangerous to you and bystanders. • Read and understand the contents of this Operator’s Manual before you start the engine.
Slope Indicator G011841 g011841 Figure 4 This page may be copied for personal use. 1. The maximum slope you can safely operate the machine on is 15 degrees. Use the slope chart to determine the degree of slope of hills before operating. Do not operate this machine on a slope greater than 15 degrees. Fold along the appropriate line to match the recommended slope. 2. Align this edge with a vertical surface, a tree, building, fence pole, etc. 3.
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 missing. decaloemmarkt Manufacturer's Mark 1. Indicates the blade is identified as a part from the original machine manufacturer. decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery. 1. Explosion hazard 6. Keep bystanders a safe distance away from the battery. 2.
decal132-0872 132-0872 1. Thrown object hazard—keep bystanders away from the machine. 3. Severing hazard of hand or foot—keep away from moving parts. 2. Thrown object hazard, raised baffle—do not operate the machine with an open deck; use a bagger or a baffle. 4. Entanglement hazard—keep away from moving parts; keep all guards and shields in place. decal117-1194 117-1194 1. Engine decal130-0731 130-0731 1. Warning—thrown object hazard; keep the deflector shield in place. 2.
decal131-3947 131-3947 1. Trim—slow 2. Tow—medium 3. Mow—fast decal133-9255 133-9255 5. Tipping hazard—do not use on slopes near open water; do not use on slopes greater than 15°. 1. Warning—read the Operator's Manual. 2. Ramp hazard—do not use dual ramps when loading onto a 6. Cutting and pinch hazard—keep away from moving parts; trailer; use 1 ramp wide enough for the machine; use a ramp keep all guards and shields in place.
decal133-9263 133-9263 1. Fast 4. PTO disengage 2. Slow 5. PTO engage 3. Choke decal136-5596 decal136-4243 136-5596 136-4243 1. Fast 2. Slow 4. Reverse 5. Parking brake disengaged 1. Check the tire pressure every 25 operating hours. 4. Check the tire pressure every 25 operating hours. 3. Neutral 6. Parking brake engaged 2. Engine oil 5. Read the Operator's Manual before performing maintenance. 3. Check the tire pressure every 25 operating hours. decal136-4244 136-4244 1. Fast 2. Slow 3.
Controls Product Overview Become familiar with all controls in Figure 6 and Figure 7 before you start the engine and operate the machine. g188738 Figure 6 1. Hour meter 4. Key switch 2. Throttle control 3. Choke control 5. PTO switch 6. 12 V power point g188739 Figure 5 1. Deck-lift pedal 7. Engine 2. Height-of-cut pin 8. Fuel cap 3. Smart Speed™ lever 9. Mower deck 4. Height-of-cut lever/transport lock 10. Anti-scalp roller 5. Motion-control lever 6. Controls 11. Caster wheel 12.
Choke Control Blade-Control Switch (Power Takeoff) Use the choke control to start a cold engine. Pull the choke control to engage it. Push the choke control to disengage it. The blade-control switch (PTO) engages and disengages power to the mower blades (Figure 6). Hour Meter Height-of-Cut Lever The hour meter records the number of hours the engine has operated. It operates when the engine is running. Use these times for scheduling regular maintenance (Figure 6).
Operation • Do not operate the machine without the entire exhaust Note: Determine the left and right sides of the machine from the normal operating position. • Before Operation • • Before Operation Safety • General Safety • Never allow children or untrained people to operate or • • • • • • • service the machine. Local regulations may restrict the age of the operator. The owner is responsible for training all operators and mechanics.
Breaking in a New Machine Add the correct amount of fuel stabilizer/conditioner to the fuel. New engines take time to develop full power. Mower decks and drive systems have higher friction when new, placing additional load on the engine. Allow 40 to 50 hours of break-in time for new machines to develop full power and best performance. Note: A fuel stabilizer/conditioner is most effective when mixed with fresh fuel.
1. Sit on the seat, engage the parking brake, and move the blade-control switch (PTO) to the ON position. Try starting the engine; the engine should not crank. CAUTION This machine produces sound levels in excess of 85 dBA at the operator’s ear and can cause hearing loss through extended periods of exposure. 2. Sit on the seat, engage the parking brake, and move the blade-control switch (PTO) to the OFF position. Move either motion-control lever (out of the NEUTRAL-LOCK position).
Adjusting the Motion-Control Levers During Operation During Operation Safety Adjusting the Height General Safety You can adjust the motion-control levers higher or lower for maximum comfort (Figure 12). A • The owner/operator can prevent and is responsible for B • • • • • g027252 g027252 Figure 12 • Adjusting the Tilt • You can adjust the motion-control levers forward or rearward for your comfort. • 1. Loosen the upper bolt holding the control lever to the control-arm shaft. • 2.
Operating the Parking Brake – Wait for all moving parts to stop. • Do not operate the machine when there is the risk of Always engage the parking brake when you stop the machine or leave it unattended. lightning. • Do not use the machine as a towing vehicle. Engaging the Parking Brake • Do not change the governor speed or overspeed the engine. WARNING • Use accessories and attachments approved by Toro only.
Operating the Mower Blade-Control Switch (PTO) Operating the Throttle You can move the throttle control between the FAST and SLOW positions (Figure 18). The blade-control switch (PTO) starts and stops the mower blades and any powered attachments. Always use the FAST position when turning on the mower deck with the blade-control switch (PTO).
Starting and Shutting Off the Engine Operating the Key Switch 1. Turn the key to the START position (Figure 20). Note: When the engines starts, release the key. Starting the Engine 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 these instructions can burn out the starter motor. Note: A warm or hot engine may not require choking.
Driving Forward Using the Motion-Control Levers Note: The engine stops when you move the traction-control with the parking brake engaged. To stop, pull the motion-control levers to the NEUTRAL position. 1. Disengage the parking brake; refer to Disengaging the Parking Brake (page 16). 2. Move the levers to the center, unlocked position. 3. To go forward, slowly push the motion-control levers forward (Figure 23). g004532 Figure 22 1. Motion-control lever—NEUTRAL-LOCK position 4. Backward 2.
Driving Backward Using the Smart SpeedTM Control System 1. Move the levers to the center, unlocked position. 2. To go backward, slowly pull the motion-control levers rearward (Figure 24). The Smart Speed TM Control-System lever, located below the operating position (Figure 25), gives the operator a choice to drive the machine at 3 ground speed ranges—trim, tow, and mow. g027625 Figure 25 1. Smart-speed lever G008953 To change speeds, do the following: g008953 Figure 24 1.
Adjusting the Height of Cut This is the medium speed. The suggested uses for this speed are as follows: • Bagging • Mulching 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-of-cut lever with the foot pedal to lock the deck in a specific cutting height. Mow This is the fastest speed.
Adjusting the Height of Cut Adjusting the Anti-Scalp Rollers You can adjust the height of cut from 38 to 114 mm (1-1/2 to 4-1/2 inches) in 6 mm (1/4 inch) increments by relocating the height-of-cut pin into different hole locations. Whenever you change the height-of-cut, it is recommended to adjust the height of the anti-scalp rollers. 1.
Using Attachments and Accessories Operating Tips Using the Fast Throttle Setting Use only Toro approved attachments and accessories. For best mowing and maximum air circulation, operate the engine at the FAST position. Air is required to thoroughly cut grass clippings, so do not set the height-of-cut so low as to totally surround the mower in uncut grass. Always try to have 1 side of the mower free from uncut grass, which allows air to be drawn into the mower.
Keeping the Underside of the Mower Clean After Operation Clean clippings and dirt from the underside of the mower after each use. If grass and dirt build up inside the mower, cutting quality will eventually become unsatisfactory. After Operation Safety General Safety Maintaining the Blade(s) • Clean grass and debris from the cutting units, mufflers, and engine compartment to help prevent fires. Clean up oil or fuel spills.
Pushing the Machine by Hand lighting, and marking as required by law. Please carefully read all the safety instructions. Knowing this information could help you, your family, pets, or bystanders avoid injury. Important: Always push the machine by hand. Do not tow the machine, because damage may occur.
Loading the Machine 1 Use extreme caution when loading or unloading machines onto a trailer or a truck. Use a full-width ramp that is wider than the machine for this procedure. Back up the ramp and drive forward down the ramp (Figure 31). g027995 Figure 31 1. Back the machine up the ramp. 2 2. Drive the machine forward down the ramp. Important: Do not use narrow individual ramps for each side of the machine.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 5 hours • Change the engine oil. Before each use or daily • • • • • • Check the safety-interlock system. Check the air cleaner for dirty, loose, or damaged parts. Check the engine-oil level. Clean the air intake screen. Inspect the blades. Inspect the grass deflector for damage.
Pre-Maintenance Procedures Engine Maintenance Maintenance and Storage Safety Contact with hot surfaces may cause personal injury. WARNING Keep your hands, feet, face, clothing, and other body parts away the muffler and other hot surfaces. • Before repairing the machine do the following: – Disengage the drives. Engine Safety – Engage the parking brake. – Shut off the engine and remove the key. Shut off the engine before checking the oil or adding oil to the crankcase.
Servicing the Paper Element Service Interval: Every 100 hours/Yearly (whichever comes first)—Service the air-cleaner paper element (more often in dusty, dirty conditions). Every 200 hours/Every 2 years (whichever comes first)—Replace the air-cleaner paper element (more often in dusty, dirty conditions). 1. Lightly tap the element on a flat surface to remove dust and dirt. g027800 g027800 2. Inspect the element for tears, an oily film, and damage to the seal.
Changing the Engine Oil and Oil Filter 1. Park the machine on a level surface, disengage the blade-control switch, shut off the engine, engage parking brake, and remove the key. Service Interval: After the first 5 hours/After the first month (whichever comes first)—Change the engine oil. 2. Make sure that the engine is shut off, level, and is cool, so that the oil has had time to drain into the sump.
5. Change the engine-oil filter (Figure 38). Note: Ensure that the oil-filter gasket touches the engine and then turn the filter an extra 3/4 turn. A B C D E F g027799 g027799 A B C D E 3/4 g027477 g027477 Figure 38 6. Slowly pour approximately 80% of the specified oil into the filler tube and slowly add the additional oil to bring it to the Full mark (Figure 39).
Removing the Spark Plug 1. Disengage the PTO and ensure that the parking brake is engaged. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. A B g027478 g027478 Figure 40 Note: Due to the deep recess around the spark plug, blowing out the cavity with compressed air is the most effective method for cleaning. The spark plug is most accessible when the blower housing is removed for cleaning.
Installing the Spark Plug Fuel System Maintenance Tighten the spark plug(s) to 25 to 30 N∙m (18.5 to 22.1 ft-lb). B A DANGER In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you, others, and can damage property. C 25-30 N-m 18.5-22.1 ft-lb • Perform any fuel-related maintenance when the engine is cold. Do this outdoors in an open area. Wipe up any fuel that spills.
Electrical System Maintenance Electrical System Safety g027939 • Disconnect the battery before repairing the machine. g027939 Disconnect the negative terminal first and the positive last. Connect the positive terminal first and the negative last. • Charge the battery in an open, well-ventilated area, away from sparks and flames. Unplug the charger before connecting or disconnecting the battery. Wear protective clothing and use insulated tools.
g190587 Figure 44 1. Battery cover 2. Fasteners g188903 Figure 45 4. Disconnect the negative (black) ground cable from the battery post (Figure 45). 1. Battery 5. Positive (+) battery post Note: Retain all fasteners. 2. Negative (–) battery post 6. Terminal boot 3. Bolt, washer, and nut for the negative (–) battery post 7. Battery hold-down WARNING Incorrect battery-cable routing could damage the machine and cables causing sparks.
Installing the Battery Servicing the Fuses 1. Position the battery in the tray (Figure 45). 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. 2. Using the fasteners previously removed, install the positive (red) battery cable to the positive (+) battery terminal. Fuse type: 3. Using the fasteners previously removed, install the negative battery cable to the negative (-) battery terminal.
Drive System Maintenance Mower Maintenance Checking the Tire Pressure To ensure a superior quality of cut, keep the blades sharp. For convenient sharpening and replacement, keep extra blades on hand. Servicing the Cutting Blades Service Interval: Every 25 hours—Check tire pressure. Blade Safety Maintain the air pressure in the front and rear tires as specified. Uneven tire pressure can cause uneven cut. Check the pressure at the valve stem (Figure 49).
Checking for Bent Blades Note: The machine must be on a level surface for the following procedure. 3 1. Raise the mower deck to the highest height-of-cut position. 2. While wearing thickly padded gloves, or other adequate hand protection, slowly rotate the blade to be measure into a position that allows effective measurement of the distance between the cutting edge and the level surface the machine is on (Figure 51). 2 1 G014974 g014974 Figure 53 1. Blade (side previously measured) 2.
Removing the Blades Note: If the blade is not balanced, file some metal off the end of the sail area only (Figure 56). The blades must be replaced if a solid object is hit, if the blade is out of balance, or if the blade is bent. For best 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. g000553 Figure 57 1.
Leveling the Mower Deck Checking the Front-to-Rear Blade Slope Ensure that the mower deck is level any time you install the mower deck or when you see an uneven cut on your lawn. Check the front-to-rear blade level any time you install the mower. If the front of the mower is more than 7.
Leveling the Mower Deck 1. Set the anti-scalp rollers to the top holes or remove them completely for this procedure; refer to Adjusting the Anti-Scalp Rollers (page 22). 2. Set the height-of-cut lever to the 76 mm (3 inches) position; refer to Adjusting the Height of Cut (page 22). 3. Place 2 blocks–6.6 cm (2-5/8 inches) under each side of the front edge of the deck, but not under the anti-scalp roller brackets (Figure 61). 4. Place 2 blocks–7.
Installing the Mower Deck Removing the Mower Deck 1. Remove the hairpin cotter and washer securing the link pin to the frame and deck, and remove the link bar (Figure 63). 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, shut off the engine, remove the key from the key switch, engage the parking brake, and wait for all moving parts to stop before leaving the operating position. 3.
Replacing the Grass Deflector the bend and going over the rod as it returns from the bend. Service Interval: Before each use or daily—Inspect the grass deflector for damage. 6. Lift the loop end of the spring and place it into the notch on the deflector bracket (Figure 66). WARNING 2 An uncovered discharge opening could allow the lawn mower to throw objects at you or bystanders and result in serious injury. Also, contact with the blade could occur.
Mower Belt Maintenance Inspecting the Belts Service Interval: Every 25 hours—Check the belts for wear or cracks. Check the belts for cracks, frayed edges, burn marks, or any other damage. Replace damaged belts. 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. g028279 Figure 67 1.
Cleaning 4. Lower the mower to the lowest height of cut. 5. Sit on the seat and start the engine. Washing the Underside of the Mower 6. Engage the blade-control switch and let the mower run for 1 to 3 minutes. 7. Disengage the blade-control switch, shut off the engine, remove the key from the key switch, and wait for all moving parts to stop. Service Interval: After each use—Clean the mower-deck housing. Important: You can wash the machine with a mild detergent and water.
Storage E. Dispose of fuel properly. Recycle the fuel according to local codes. Important: Do not store stabilizer/conditioned fuel over 90 days. Cleaning and Storage 1. Disengage the blade-control switch (PTO), engage the parking brake, turn the ignition key to the OFF position, and remove the key from the key switch. 11. Check and tighten all bolts, nuts, and screws. Repair or replace any part that is damaged. 12. Paint all scratched or bare metal surfaces.
Troubleshooting Problem Possible Cause The fuel tank is showing signs of collapsing or the machine is showing signs of frequently running out of fuel. 1. The air-cleaner paper element clogged. 1. Clean the paper element. The engine overheats. 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.
Problem The machine does not drive. There is an abnormal vibration. The cutting height is uneven. Possible Cause 1. The bypass valves are open. 1. Close the tow valves. 2. The traction belts are worn, loose, or broken. 3. The traction belts are off of the pulleys. 4. The transmission has failed. 2. Contact an Authorized Service Dealer. 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.
Schematics g203461 Electrical Diagram (Rev.
Notes:
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TimeCutter The Toro Warranty Limited Warranty (see warranty periods below) Conditions and Products Covered 3. If for any reason you are dissatisfied with the Service Dealer’s analysis or with the assistance provided, contact us at: The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair the Toro Products listed below if defective in materials or workmanship.
