Form No. 3417-433 Rev B TimeCutter® HD ZX4800 and ZX5400 Riding Mower Model No. 75201—Serial No. 401500000 and Up Model No. 75202—Serial No. 401500000 and Up Register at www.Toro.com.
Gross or Net Torque: The gross or net torque of this engine was laboratory rated by the engine manufacturer in accordance with the Society of Automotive Engineers (SAE) J1940 or J2723. As configured to meet safety, emission, and operating requirements, the actual engine torque on this class of mower will be significantly lower. Please refer to the engine manufacturer’s information included with the machine. injury and product damage. You are responsible for operating the product properly and safely.
Contents Drive System Maintenance .................................. 39 Checking the Tire Pressure............................... 39 Belt Maintenance ................................................ 40 Inspecting the Belts .......................................... 40 Replacing the Mower Belt ................................. 40 Mower Maintenance............................................. 41 Blade Safety ..................................................... 41 Servicing the Cutting Blades ...............
General Safety Safety This machine is capable of amputating hands and feet and of throwing objects. Toro designed and tested this lawn mower to offer reasonably safe service; however, failure to comply with safety instructions may result in injury or death. The following instructions are from ANSI standard B71.1-2017. Safety Alert Symbol • Read, understand, and follow all instructions and warnings in the Operator’s Manual and other training material, on the machine, engine, and attachments.
Slope Indicator g011841 Figure 4 You may copy this page for personal use. 1. The maximum slope you can 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. This mark indicates that the blade is identified as a part from the original machine manufacturer. decal117-1194 117-1194 decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery. 1. Explosion hazard 6. Keep bystanders away from the battery. 2.
decal131-1097 131-1097 1. Oil drain decal130-0654 130-0654 1. Transport—lock 3. Height of cut 2. Transport—unlock decal132-0872 132-0872 decal130-0731 130-0731 1. Warning—thrown object hazard; keep the deflector shield in place. 2. Cutting hazard of hand or foot, mower blade—keep away from moving parts. 1. Thrown object hazard—keep bystanders away from the machine. 3. Severing hazard of hand or foot—keep away from moving parts. 2.
decal136-5596 decal136-4244 136-5596 136-4244 1. Fast 2. Slow 3. Neutral 4. Reverse 1. Check the tire pressure every 25 operating hours. 4. Check the tire pressure every 25 operating hours. 2. Engine oil 5. Read the Operator's Manual before performing maintenance. 3. Check the tire pressure every 25 operating hours. decal136-9186 136-9186 1. Read the Operator's Manual before adding weight to the bucket. decal131-3947 131–3947 1. Trim—slow 2. Tow—medium 3.
decal133-9263 133-9263 1. Fast 4. PTO disengage 2. Slow 5. PTO engage 3. Choke decal133-9255 133-9255 Note: This machine complies with the industry standard stability test in the static lateral and longitudinal tests with the maximum recommended slope indicated on the decal.
Controls Product Overview Become familiar with all the controls before you start the engine and operate the machine. Control Panel g188738 Figure 6 1. Hour meter 4. Key switch 2. Throttle control 5. Blade-control switch (power takeoff) 3. Choke control 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.
Choke Control 12 V Power Point Use the choke control to start a cold engine. Use the power point to power 12 V accessories (Figure 6). Hour Meter Important: When not using the 12 V power point, insert the rubber plug to prevent damage to the power point. 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 Pre-Start Note: Determine the left and right sides of the Fill fuel tank on level ground. See Fuel Recommendations in the Specifications section for additional gasoline information. machine from the normal operating position. Do Not add oil to gasoline. Before Operation Do Not overfill fuel tank. Fill the fuel tank to the bottom of the filler neck. The empty space in the tank allows gasoline to expand. Overfilling may result in fuel leakage or damage to the engine or emission system.
Fuel Safety DANGER In certain conditions during fueling, static electricity can be released causing a spark which can ignite gasoline vapors. A fire or explosion from gasoline can burn you and others and cause property damage. • Always place gasoline containers on the ground away from your vehicle before filling.
Adding Fuel Recommended Fuel • For best results, use only clean, fresh (less than 30 days old), unleaded gasoline with an octane rating of 87 or higher ((R+M)/2 rating method). • Ethanol: Gasoline with up to 10% ethanol (gasohol) or 15% MTBE (methyl tertiary butyl ether) by volume is acceptable. Ethanol and MTBE are not the same. Gasoline with 15% ethanol (E15) by volume is not approved for use.
Using the Safety-Interlock System and rise slightly from the seat; the engine should shut off. 4. Sit on the seat, engage the parking brake, move the blade-control switch (PTO) to the OFF position, and move the motion-control levers to NEUTRAL-LOCK position. Start the engine. While the engine is running, center either motion-control lever and move it forward or reverse; the engine should shut off. Repeat for other motion-control lever. 5.
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 10). The operator must use their full attention when operating the machine. Do Not engage in any activity that causes distractions; otherwise, injury or property damage may occur. WARNING Operating engine parts, especially the muffler, become extremely hot.
• Be sure all drives are in neutral and parking brake • • • • is engaged before starting engine. Start the engine carefully according to instructions with feet well away from the blades. Never operate the mower with damaged guards, shields, or covers. Always have safety shields, guards, switches and other devices in place and in proper working condition. Keep clear of the discharge opening at all times.
Operating the Parking Brake distance (twice the width of the machine) between the machine and any hazard. Use a walk behind machine or a hand trimmer to mow the grass in these areas. Always engage the parking brake when you stop the machine or leave it unattended. Engaging the Parking Brake Park the machine on a level surface. g188778 g229111 Figure 12 Figure 11 1. Safe Zone-Use the mower here on slopes less than 15 degrees 2.
Engaging the Blade-Control Operating the Throttle You can move the throttle control between FAST and Switch (PTO) SLOW positions (Figure 17). Always use the FAST position when engaging the PTO. g008945 Figure 14 Note: Always engage the blades with the throttle in the FAST position (Figure 15). g187517 Figure 17 Operating the Choke Use the choke to start a cold engine. 1. Pull up the choke knob to engage the choke before using the key switch (Figure 18). Note: Ensure that you fully engage the choke.
Operating the Key Switch 1. Starting the Engine Turn the key to the START position (Figure 19). Note: A warm or hot engine may not require choking. Note: When the engine starts, release the key. Important: Do not engage the starter for more Important: Do not engage the starter motor than 5 seconds at a time. Engaging the starter motor for more than 5 seconds can damage the starter motor. If the engine fails to start, wait 10 seconds before operating the engine starter again.
Driving the Machine CAUTION Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. The drive wheels turn independently, powered by hydraulic motors on each axle. You can turn 1 side in reverse while you turn the other forward, causing the machine to spin rather than turn. This greatly improves the machine maneuverability but may require some time for you to adapt to how it moves.
Using the Smart SpeedTM Control System The Smart Speed TM Control-System lever, located below the operating position (Figure 24), gives the operator a choice to drive the machine at 3 ground speed ranges—trim, tow, and mow. g027625 Figure 24 1. Smart-speed lever g008952 Figure 22 To change speeds, do the following: 1. Move the motion-control levers to neutral and outward to the PARK position. 2. Disengage the blade-control switch. 3. Adjust the lever to the desired position. Driving Backward 1.
Adjusting the Height of Cut • Heavy, wet grass mowing conditions • Training The machine is equipped with a foot pedal deck-lift system. You 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. You can use the height-of-cut lever with the foot pedal to lock the deck in a specific cutting height. • Trimming grass Tow This is the medium speed.
3. Select a hole in the height-of-cut system corresponding to the desired height of cut and insert the pin (Figure 26). 4. Push on the deck-lift pedal with your foot and pull the handle rearward to disengage the transport lock (Figure 25). 5. Lower the deck slowly until the lever makes contact with the pin. g029955 Figure 27 1. Anti-scalp roller 4. Flange nut 2. Spacer 5. Bolt 3. Bushing Using Attachments and Accessories Use only Toro approved attachments and accessories.
Operating Tips drop onto your lawn. To avoid this, move onto a previously cut area with the blades engaged or you can disengage the mower deck while moving forward. Using the Fast Throttle Setting 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 deck in uncut grass.
After Operation After Operation Safety General Safety • Park machine on level ground, disengage drives, set parking brake, stop engine, remove key or disconnect spark plug wire. Wait for all movement to stop and allow the machine to cool before adjusting, cleaning, repairing, or storing. Never allow untrained personnel to service machine. g027708 Figure 28 1. Tie-down location • Secure a trailer to the towing vehicle with safety • Clean the machine as stated in the Maintenance chains. section.
on the down side of the slope and the ramp extends up the slope. This will minimize the ramp angle. WARNING Loading a machine onto a trailer or truck increases the possibility of tip-over and could cause serious injury or death. • Use extreme caution when operating a machine on a ramp. • Use only a full-width ramp; do not use individual ramps for each side of the machine. • Do not exceed a 15-degree angle between the ramp and the ground or between the ramp and the trailer or truck.
and loss of control. Reduce the towed weight and slow down. • Stopping distance increases with the weight of the towed load. Travel slowly and allow extra distance to stop. • Make wide turns to keep the attachment clear of the machine. Pushing the Machine by Hand Important: Always push the machine by hand. Do not tow the machine, because towing may damage it. This machine has an electric-brake mechanism, and to push the machine, the key must be in the RUN position.
Maintenance WARNING Removal or modification of original equipment, parts and/or accessories may alter the warranty, controllability, and safety of the machine. Unauthorized modifications to the original equipment or failure to use original Toro parts could lead to serious injury or death. Unauthorized changes to the machine, engine, fuel or venting system, may violate applicable safety standards such as: ANSI, OSHA and NFPA and/or government regulations such as EPA and CARB.
Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 5 hours • Change the engine oil and filter. 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. After each use • Clean the mower-deck housing.
Engine Maintenance Engine Safety • Shut off the engine before checking the oil or adding oil to the crankcase. • Keep your hands, feet, face, clothing, and other body parts away the muffler and other hot surfaces. g027800 Servicing the Air Cleaner Service Interval: Before each use or daily Note: Service the air cleaner more frequently (every few hours) if operating conditions are extremely dusty or sandy. Removing the Foam and Paper Elements 1.
Servicing the Foam Air-Cleaner Element Installing the Air Cleaner 1. Note: Ensure that you do not damage the elements. Service Interval: Every 25 hours/Monthly (whichever comes first)—Clean the air-cleaner foam element (more often in dusty, dirty conditions). Every 100 hours/Yearly (whichever comes first)—Replace the air-cleaner foam element (more often in dusty, dirty conditions). 1. Wash the foam element in liquid soap and warm water. When the element is clean, rinse it thoroughly. 2.
Checking the Engine-Oil Level Changing the Engine Oil and Oil Filter Service Interval: Before each use or daily Service Interval: After the first 5 hours/After the first month (whichever comes first)—Change the engine oil and filter. Note: Check the oil when the engine is cold. Important: If you overfill or underfill the engine crankcase with oil and run the engine, you may damage the engine. 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake.
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. g027799 g027477 Figure 38 6. g029570 Figure 37 34 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).
g027478 Figure 40 Checking the Spark Plug Important: Do not clean the spark plug(s). Always replace the spark plug(s) when it has a black coating, worn electrodes, an oily film, 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. g235264 Figure 39 7. Set the gap to 0.75 mm (0.03 inch). Dispose of the used oil at a recycling center.
Cleaning the Cooling System 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the air filter from the engine. 4. Remove the engine shroud. 5. To prevent debris entering the air intake, install the air filter to the filter base. 6. Clean debris and grass from the parts. 7.
Electrical System Maintenance Electrical System Safety • Disconnect the battery before repairing the g027939 machine. 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.
Charging the Battery Service Interval: Before storage—Charge the battery and disconnect the battery cables. 1. Remove the battery from the chassis; refer to Removing the Battery (page 37). 2. Charge the battery for a minimum of 1 hour at 6 to 10 A. Note: Do not overcharge the battery. 3. g190587 Figure 44 1. Battery cover 4. 2. Fasteners When the battery is fully charged, unplug the charger from the electrical outlet, then disconnect the charger leads from the battery posts (Figure 46).
Servicing the Fuses Drive System Maintenance 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. Checking the Tire Pressure Fuse type: • Main—F1 (15 A, blade-type) Service Interval: Every 25 hours—Check tire pressure. • Charge Circuit—F2 (25 A, blade-type) Maintain the air pressure in the front and rear tires as specified. Uneven tire pressure can cause uneven cut.
Belt Maintenance Inspecting the Belts Service Interval: Every 25 hours—Check the belts for wear or cracks. Replace the belt if it is worn. The signs of a worn belt include squealing while the belt is rotating; the blades slipping while cutting grass; and frayed edges, burn marks, and cracks on the belt. Replacing the Mower Belt The signs of a worn belt include squealing while the belt is rotating, blades slipping while cutting grass, and frayed edges, burn marks, and cracks on the belt.
Mower Maintenance Blade Safety A worn or damaged blade can break, and a piece of the blade could be thrown toward you or bystanders, resulting in serious personal injury or death. Trying to repair a damaged blade may result in discontinued safety certification of the product. g006530 Figure 51 • Inspect the blades periodically for wear or damage. • Use care when checking the blades. Wrap the blades or wear gloves, and use caution when servicing the blades.
g014973 g014973 Figure 53 Figure 55 1. Blade (in position for measuring) 1. Opposite blade edge (in position for measuring) 2. Level surface 3. Measured distance between blade and the surface (A) 2. Level surface 3. Second measured distance between blade and surface (B) 4. Rotate the same blade 180 degrees so that the opposing cutting edge is now in the same position (Figure 54). A.
Removing the Blades Replace the blades if they hit a solid object, or if the blade is out of balance or bent. 1. Hold the blade end using a rag or thickly padded glove. 2. Remove the blade bolt, curved washer, and blade from the spindle shaft (Figure 56). g000553 Figure 58 1. Blade 3. 2. Balancer Repeat this procedure until the blade is balanced. Installing the Blades 1. Install the blade onto the spindle shaft (Figure 56).
Leveling the Mower Deck Checking the Front-to-Rear Blade Slope Check to ensure that the mower deck is level any time you install the mower 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 7.9 mm (5/16 inch) lower than the rear of the mower, adjust the blade level.
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 24). 2. Set the height-of-cut lever to the 76 mm (3 inch) position; refer to Adjusting the Height of Cut (page 23). 3. Place 2 blocks, each having a thickness of 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 62). 4. Place 2 blocks, each having a thickness of 7.
Removing the Mower Deck 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and disconnect the spark-plug wires from the spark plugs. 3. Lower the mower to the 76 mm (3 inches) height-of-cut position. 4. Remove the mower belt from the engine pulley; refer to Replacing the Mower Belt (page 40). 5.
Replacing the Grass Deflector Service Interval: Before each use or daily—Inspect the grass deflector for damage. 5. Position the spring on the rod as shown in Figure 67 so that the shorter spring end comes from under the rod before the bend and going over the rod as it returns from the bend. 6. Lift the loop end of the spring and place it into the notch on the deflector bracket (Figure 67).
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 (PTO), shut off the engine, remove the key from the key switch, and wait for all moving parts to stop. 8. Turn the water off and remove the coupling from the washout fitting. Service Interval: After each use—Clean the mower-deck housing.
Storage an alcohol-based stabilizer (ethanol or methanol). Storage Safety Note: A fuel stabilizer/conditioner is most effective when mixed with fresh fuel and used at all times. • Let the engine cool before storing the machine. • Do not store the machine or fuel near flames or B. Run the engine to distribute conditioned fuel through the fuel system (5 minutes). C. Shut off the engine, allow it to cool, and drain the fuel tank. D. Start the engine and run it until it stops. E.
Storing the Battery 1. Fully charge the battery. 2. Let the battery rest for 24 hours, then check the battery voltage. Note: If the battery voltage is below 12.6 V, repeat steps 1 and 2. 3. Disconnect the cables from the battery. 4. Check the voltage periodically to ensure that the voltage is 12.4 V or higher. Note: If the battery voltage is below 12.4 V, repeat steps 1 and 2. Battery Storage Tips • Store the battery in a cool, dry area in an upright position.
Troubleshooting Problem Possible Cause The fuel tank is showing signs of collapsing or the machine is frequently showing signs of running out of fuel. 1. The air-cleaner paper element clogged. The engine overheats. 1. The engine load is excessive. 1. Reduce the 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. The machine vibrates abnormally. The cutting height is uneven. The blades do not rotate. Possible Cause Corrective Action 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 the pulleys. 4. The transmission has failed. 2. Contact an Authorized Service Dealer. 1. The cutting blade(s) is/are bent or unbalanced. 1. Install new cutting blade(s). 2. The blade mounting bolt is loose.
Schematics g289095 Electrical Diagram (Rev.
Notes:
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