Form No. 3417-433 Rev A 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.
high-altitude label for your machine. To locate a dealer convenient to you, access our website at www.Toro.com or contact our Toro Customer Care Department at the number(s) listed in your Emission Control Warranty Statement. Remove the kit from the engine and restore the engine to its original factory configuration when running the engine under 1500 m (5,000 ft). Do not operate an engine that has been converted for high-altitude use at lower altitudes; otherwise, you could overheat and damage the engine.
Contents Safety ....................................................................... 4 General Safety ................................................... 4 Slope Indicator ................................................... 5 Safety and Instructional Decals .......................... 6 Product Overview ................................................... 10 Controls ........................................................... 10 Before Operation .................................................
Safety Leveling the Mower Deck.................................. 40 Removing the Mower Deck............................... 42 Installing the Mower Deck................................. 43 Replacing the Grass Deflector .......................... 43 Mower Belt Maintenance...................................... 44 Inspecting the Belts .......................................... 44 Replacing the Mower Belt ................................. 44 Cleaning .............................................................
Slope Indicator g011841 Figure 4 This page may be copied 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. Indicates 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 a safe distance away from the battery.
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 controls in Figure 6 and Figure 7 before you start the engine and operate the machine. Control Panel g188738 Figure 6 g188739 1. Hour meter 4. Key switch 2. Throttle control 5. Blade-control switch (power takeoff) 3. Choke control 6. 12 V power point Figure 5 1. Deck-lift pedal 7. Engine 2. Height-of-cut pin 8. Fuel cap 3. Height-of-cut lever/transport lock 9. Mower deck 4. Smart Speed™ lever 10. Anti-scalp roller 5.
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 • 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. Become familiar with the safe operation of the equipment, operator controls, and safety signs.
Using Stabilizer/Conditioner Use a fuel stabilizer/conditioner in the machine to provide the following benefits: • Keeps fuel fresh during storage of 90 days or less (drain the fuel tank when storing the machine for more than 90 days) • Cleans the engine 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 fuel stabilizer/conditioner to the fuel.
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 owner/operator can prevent and is responsible • • • • g027252 Figure 10 • • 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.
• Identify hazards at the base of the slope. Do • Before leaving the operating position (including not operate the machine near drop offs, ditches, embankments, water, or other hazards. The machine could suddenly roll over if a wheel goes over the edge or the edge collapses. Keep a safe 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.
Operating the Parking Brake 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. g229111 Figure 12 1. Safe Zone—use the machine here on slopes less than 15 degrees or flat areas. 2. Danger Zone—use a walk-behind mower and/or a hand trimmer on slopes greater than 15 degrees and near drop-offs or water. 3. Water 4. W=width of the machine 5.
Operating the Mower Operating the Throttle Blade-Control Switch (PTO) You can move the throttle control between 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 engaging the PTO. Engaging the Blade-Control Switch (PTO) g187517 Figure 18 g008945 Figure 15 Note: Always engage the blades with the throttle in Operating the Choke the FAST position (Figure 16).
Starting the Engine Shutting Off the Engine Note: A warm or hot engine may not require choking. 1. Disengage the blades by moving the blade-control switch to the OFF position (Figure 17). 2. Engage the parking brake; refer to Engaging the Parking Brake (page 17). 3. Move the throttle control to the FAST position. 4. Turn the key to the OFF position and remove the key. Important: Do not engage the starter for more than 5 seconds at a time.
Driving the Machine 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. 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.
Using the Smart SpeedTM Control System Tow 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. • Bagging This is the medium speed. The suggested uses for this speed are as follows: • Mulching Mow This is the fastest speed.
Adjusting the Height of Cut 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. 3. Select a hole in the height-of-cut system corresponding to the desired height of cut and insert the pin (Figure 26). 4.
Operating Tips 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. Always try to have 1 side of the mower deck free from uncut grass, which allows air to be drawn into the mower deck. g029955 Figure 27 1. Anti-scalp roller 4. Flange nut 2. Spacer 5.
After Operation 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. After Operation Safety Keeping the Underside of the Mower Deck Clean General Safety • Clean grass and debris from the cutting units, Clean clippings and dirt from the underside of the mower deck after each use. If grass and dirt build up inside the mower deck, cutting quality will eventually become unsatisfactory.
Transporting the Machine Use a heavy-duty trailer or truck to transport the machine. Use a full-width ramp. Ensure that the trailer or truck has all the necessary brakes, lighting, and marking as required by law. Please carefully read all the safety instructions. Knowing this information could help you or bystanders avoid injury. Refer to your local ordinances for trailer and tie-down requirements.
1. If using a trailer, connect it to the towing vehicle and connect the safety chains. 2. If applicable, connect the trailer brakes and lights. 3. Lower the ramp, ensuring that the angle between the ramp and the ground does not exceed 15 degrees (Figure 29). 4. Back the machine up the ramp (Figure 30). g027995 Figure 30 1. Back the machine up the ramp. 2. Drive the machine forward down the ramp. 5. Shut off the engine, remove the key, and engage the parking brake. 6.
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 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.
Pre-Maintenance Procedures Engine Maintenance Maintenance Safety • Shut off the engine before checking the oil or • Before repairing the machine do the following: • Keep your hands, feet, face, clothing, and other Engine Safety adding oil to the crankcase. body parts away the muffler and other hot surfaces. – Disengage the drives. – Engage the parking brake. – Shut off the engine and remove the key. Servicing the Air Cleaner – Disconnect the spark-plug wire.
Servicing the Foam Air-Cleaner Element 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). g027800 1. Wash the foam element in liquid soap and warm water. When the element is clean, rinse it thoroughly. 2. Dry the element by squeezing it in a clean cloth.
Installing the Air Cleaner 1. Checking the Engine-Oil Level Install the foam element over the paper element. Service Interval: Before each use or daily Note: Ensure that you do not damage the Note: Check the oil when the engine is cold. elements. 2. Align the holes of the filter into the manifold ports. 3. Rotate the filter down into the chamber and fully seat it against the manifold (Figure 34).
Changing the Engine Oil and Oil Filter Service Interval: After the first 5 hours/After the first month (whichever comes first)—Change the engine oil and filter. Every 100 hours/Yearly (whichever comes first)—Change the engine oil and oil filter (more often in dirty or dusty conditions). g027799 1. Park the machine on a level surface to ensure that the oil drains completely. 2. Disengage the blade-control switch (PTO) and engage the parking brake. 3.
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. g235264 Figure 39 7. Dispose of the used oil at a recycling center. Servicing the Spark Plug Service Interval: Every 100 hours/Yearly (whichever comes first)—Check the spark plug(s). g027477 Figure 38 Every 200 hours/Every 2 years (whichever comes first)—Replace the spark plug(s). 6.
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.
Fuel System Maintenance 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. g027939 • Perform any fuel-related maintenance when the engine is cold. Do this outdoors in an open area. Wipe up any fuel that spills. • Never smoke when draining fuel, and stay away from an open flame or where a spark may ignite the fuel fumes.
Electrical System Maintenance Electrical System Safety • Disconnect the battery before repairing the 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. • g190587 Figure 44 1. Battery cover WARNING 4.
Charging the Battery Servicing the Fuses Service Interval: Before storage—Charge the battery and disconnect the battery cables. 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. 1. 2. Remove the battery from the chassis; refer to Removing the Battery (page 35). Fuse type: Charge the battery for a minimum of 1 hour at 6 to 10 A.
Mower Maintenance Drive System Maintenance Servicing the Cutting Blades Checking the Tire Pressure Service Interval: Every 25 hours—Check tire pressure. To ensure a superior quality of cut, keep the blades sharp. For convenient sharpening and replacement, keep extra blades on hand. 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).
g006530 Figure 50 1. Cutting edge 3. Wear/slot forming 2. Curved area 4. Crack g014973 Figure 52 1. Blade (in position for measuring) Checking for Bent Blades 2. Level surface 3. Measured distance between blade and the surface (A) Note: The machine must be on a level surface for the following procedure. 4. 1. Raise the mower deck to the highest height-of-cut position. 2.
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 55). g014973 Figure 54 1. Opposite blade edge (in position for measuring) 2. Level surface 3. Second measured distance between blade and surface (B) A.
Leveling the Mower Deck 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. g000553 Figure 57 1. Blade 3. Check the mower deck for bent blades prior to leveling, and remove and replace any bent blades; refer to Servicing the Cutting Blades (page 37) before continuing. 2. Balancer Repeat this procedure until the blade is balanced. Level the mower deck side-to-side first; then you can adjust the front-to-rear slope.
Leveling the Mower Deck 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 7.9 mm (5/16 inch) lower than the rear of the mower, adjust the blade level. 1. 2. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3.
g028276 Figure 63 1. Link pin 3. Hairpin cotter 2. Washer g024313 Figure 62 1. Deck-lift arm 2. Chain 6. Lift up the mower deck to relieve tension from the mower deck. 7. Remove the chains from the hooks on the deck-lift arms (Figure 64). 3. Hook 4. Adjustment bolt 6. Ensure that there is tension on all 4 chains (Figure 62). 7. Tighten the 4 adjustment bolts (Figure 62). 8. Ensure that the blocks fit snugly under the deck skirt and that all bolts are tight. 9.
Installing the Mower Deck 1. 2. Replacing the Grass Deflector Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. Service Interval: Before each use or daily—Inspect the grass deflector for damage. Shut off the engine, remove the key, and disconnect the spark-plug wires from the spark plugs. 3. Slide the mower under the machine. 4. Lower the height-of-cut lever to the lowest position. 5.
4. Install the spring onto the straight end of the rod. 5. Position the spring on the rod as shown in Figure 66 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. Mower Belt Maintenance Inspecting the Belts Service Interval: Every 25 hours—Check the belts for wear or cracks. Lift the loop end of the spring and place it into the notch on the deflector bracket (Figure 66). Replace the belt if it is worn.
Cleaning Washing the Underside of the Mower Service Interval: After each use—Clean the mower-deck housing. Important: You can wash the machine with a mild detergent and water. Do not pressure wash the machine. Avoid excessive use of water, especially near the control panel, under the seat, around the engine, hydraulic pumps, and motors. Wash the underside of the mower deck after each use to prevent grass buildup for improved mulch action and clipping dispersal. 1.
5. Sit on the seat and start the engine. 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. Storage Storage Safety • Let the engine cool before storing the machine. • Do not store the machine or fuel near flames or drain the fuel indoors.
Storing the Battery Note: A fuel stabilizer/conditioner is most effective when mixed with fresh fuel and used at all times. 12. 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. 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. D. Start the engine and run it until it stops. 3.
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 g203461 Electrical Diagram (Rev.
Notes:
