Toro TimeCutter HD ZX4800 Operator'S Manual Download Page 1

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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

*3417-433* B

Summary of Contents for TimeCutter HD ZX4800

Page 1: ...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 Original Instructions EN 3417 433 B ...

Page 2: ...titudes otherwise you could overheat and damage the engine If you are unsure whether or not your machine has been converted for high altitude use look for the following label decal127 9363 Introduction This rotary blade riding lawn mower is intended to be used by homeowners in residential applications It is designed primarily for cutting grass on well maintained lawns Read this information careful...

Page 3: ...e Anti Scalp Rollers 24 Using Attachments and Accessories 24 Operating Tips 25 After Operation 26 After Operation Safety 26 Pushing the Machine by Hand 28 Maintenance 29 Maintenance Safety 29 Recommended Maintenance Schedule s 30 Engine Maintenance 31 Engine Safety 31 Servicing the Air Cleaner 31 Servicing the Engine Oil 32 Servicing the Spark Plug 35 Cleaning the Cooling System 36 Fuel System Mai...

Page 4: ...hrowing 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 Read understand and follow all instructions and warnings in the Operator s Manual and other training material on the machine engine and attachments All operators and mechanics should be trained If the operator s or mechanic s can...

Page 5: ...rees 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 Example of how to compare slope with folded edge 5 ...

Page 6: ...symbols are on your battery 1 Explosion hazard 6 Keep bystanders away from the battery 2 No fire open flame or smoking 7 Wear eye protection explosive gases can cause blindness and other injuries 3 Caustic liquid chemical burn hazard 8 Battery acid can cause blindness or severe burns 4 Wear eye protection 9 Flush eyes immediately with water and get medical help fast 5 Read the Operator s Manual 10...

Page 7: ...s Manual before performing maintenance 2 Height of cut selection decal131 1097 131 1097 1 Oil drain 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 par...

Page 8: ...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 3 Mow fast 2 Tow medium 8 ...

Page 9: ... operating on slopes can cause the machine to become unstable 1 Warning read the Operator s Manual 5 Tipping hazard do not use on slopes near open water do not use on slopes greater than 15 2 Ramp hazard do not use dual ramps when loading onto a trailer use 1 ramp wide enough for the machine use a ramp with a slope less than 15 back up the ramp when loading the machine and drive forward off the ra...

Page 10: ...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 Fuel Gauge The fuel gauge displays the amount of fuel in the tank Figure 7 g238298 Figure 7 1 Fuel gauge 2 Fuel tank cap Throttle Control The throttle controls the engine speed a...

Page 11: ...rating position gives you a choice to drive the machine at 3 speed ranges trim tow and mow Figure 24 12 V Power Point Use the power point to power 12 V accessories Figure 6 Important When not using the 12 V power point insert the rubber plug to prevent damage to the power point Key Switch The key switch used to start and shut off the engine has 3 positions OFF RUN and START Refer to Starting the E...

Page 12: ...y switches and shields are attached and functioning properly Do Not operate unless they are functioning properly Do Not operate the mower when people especially children or pets are in the area Stop the machine and attachment s if anyone enters the area Do Not operate the machine without the entire grass collection system discharge deflector or other safety devices in place and in proper working c...

Page 13: ...ors 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 Do Not fill gasoline containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge When practical remove gas powe...

Page 14: ...lizer conditioner in the machine at all times to keep the fuel fresh longer when used as directed by the fuel stabilizer manufacturer Important Do not use fuel additives containing methanol or ethanol Add the amount of fuel stabilizer conditioner to fresh fuel as directed by the fuel stabilizer manufacturer Filling the Fuel Tank 1 Park the machine on a level surface 2 Engage the parking brake 3 Sh...

Page 15: ...ngine the engine should not crank 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 Try starting the engine the engine should not crank Repeat for other control lever 3 Sit on the seat engage the parking brake move the blade control switch PTO to the OFF position and move the motion...

Page 16: ...d engine area WARNING Engine exhaust contains carbon monoxide which is an odorless deadly poison that can kill you Do Not run engine indoors or in a small confined area where dangerous carbon monoxide fumes can collect The owner user can prevent and is responsible for accidents or injuries occurring to himself or herself other people or property This mower was designed for one operator only Do not...

Page 17: ...ting the mower Before clearing blockages Whenever you leave the mower Do Not leave a running machine unattended Stop engine wait for all moving parts to stop Before refueling Before dumping the grass catcher Before making height adjustments Tragic accidents can occur if the operator is not alert to the presence of children Children are often attracted to the machine and the mowing activity Never a...

Page 18: ...oss of braking and steering The machine can slide even if the drive wheels are stopped Remove or mark obstacles such as ditches holes ruts bumps rocks or other hidden hazards Tall grass can hide obstacles Uneven terrain could overturn the machine Use extra care while operating with accessories or attachments such as grass collection systems These can change the stability of the machine and cause a...

Page 19: ...AST and SLOW positions Figure 17 Always use the FAST position when engaging the PTO 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 You may need to hold the knob up when you use the key switch 2 Push down the choke to disengage the choke after th...

Page 20: ...completely g008947 Figure 19 2 Turn the key to the STOP position to shut off the engine Starting the Engine Note A warm or hot engine may not require choking Important Do not engage the starter for more 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 g1893...

Page 21: ...ime 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 Always operate in the full throttle position when mowing WARNING The machine can spin very rapidly You may lose control of the machine and cause personal injury or damage to the machine Use caution when m...

Page 22: ...625 Figure 24 1 Smart speed lever 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 The following are only recommendations for use Adjustments vary by grass type moisture content and the height of the grass Suggested uses Trim Tow Mow Parking X Heavy wet gras...

Page 23: ...ch to the OFF position and remove the key from the key switch Make sure that the grass deflector is in the down position 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 ped...

Page 24: ...ngage the parking brake refer to Engaging the Parking Brake page 18 2 Shut off the engine remove the key and wait for all moving parts to stop before leaving the operating position 3 Adjust the anti scalp rollers as shown in Figure 27 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 If ...

Page 25: ... the same cutting height mow more often in early spring As the grass growth rate slows in mid summer mow less frequently If you cannot mow for an extended period first mow at a high cutting height then mow again 2 days later at a lower height setting Using a Slower Cutting Speed To improve cut quality use a slower ground speed in certain conditions Avoiding Cutting Too Low When mowing uneven turf ...

Page 26: ...gnated tie down locations on the mower two on the left side and two on the right Figure 28 Use these locations even when transporting the mower with an attached accessory Using non designated locations may cause damage to the mower and or attachment g027708 Figure 28 1 Tie down location Secure a trailer to the towing vehicle with safety chains WARNING Driving on the street or roadway without turn ...

Page 27: ...hile driving the machine on a ramp as this could cause a loss of control or a tip over situation g027996 Figure 30 1 Full width ramp in stowed position 4 Ramp is at least four times 4X as long as the height of the trailer or truck bed to the ground 2 Side view of full width ramp in loading position 5 H height of the trailer or truck bed to the ground 3 Not greater than 15 degrees 6 Trailer Towing ...

Page 28: ...itch 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 Locate the bypass levers on the frame on both sides of the engine 4 Move the bypass levers forward through the key hole and down to lock them in place Figure 31 Note Do this for each lever 5 Turn the ignition key on and disengage the parking brake Not...

Page 29: ...ING 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 NFP...

Page 30: ...aner foam element more often in dusty dirty conditions Clean the paper air cleaner element more often in dirty or dusty conditions Change the engine oil and oil filter more often in dirty or dusty conditions Check the spark plug s Check the in line fuel filter Every 200 hours Replace the paper air cleaner element more often in dirty or dusty conditions Replace the spark plug s Replace the in line ...

Page 31: ...e extremely dusty or sandy Removing the Foam and Paper Elements 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 Clean around the air cleaner cover to prevent dirt from getting into the engine and causing damage 4 Lift the cover...

Page 32: ...ce the paper air cleaner element more often in dirty or dusty conditions 1 Clean the paper element by tapping it gently to remove dust Note If it is very dirty replace the paper element with a new one 2 Inspect the element for tears an oily film or damage to the rubber seal 3 Replace the paper element if it is damaged Important Do not clean the paper filter Installing the Air Cleaner 1 Install the...

Page 33: ...sump 3 To keep dirt grass clippings etc out of the engine clean the area around the oil fill cap and dipstick before removing it Figure 36 g235263 Figure 36 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...

Page 34: ... Note Ensure that the oil filter gasket touches the engine and then turn the filter an extra 3 4 turn 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 34 ...

Page 35: ...emoving the Spark Plug 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 Clean the area around the base of the plug to keep dirt and debris out of the engine 4 Remove the spark plug Figure 40 g027478 Figure 40 Checking the Spark ...

Page 36: ...lammable and highly explosive A fire or explosion from fuel can burn you and others and can damage property Refer to Adding Fuel page 14 for a complete list of fuel related precautions Replacing the In Line Fuel Filter Service Interval Every 100 hours Yearly whichever comes first Check the in line fuel filter Every 200 hours Every 2 years whichever comes first Replace the in line fuel filter Never...

Page 37: ...NING Incorrectly removing the cables from battery could damage the machine and cables causing sparks Sparks can cause the battery gasses to explode resulting in personal injury Always disconnect the negative black battery cable before disconnecting the positive red cable Always connect the positive red battery cable before connecting the negative black cable 1 Park the machine on a level surface d...

Page 38: ... 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 When the battery is fully charged unplug the charger from the electrical outlet then disconnect the charger leads from the battery posts Figure 46 g000538 Figure 46 1 Positive battery post 3 Red charger lead 2 Negative battery post 4 Black c...

Page 39: ...of battery pull out the fuse and install a new 25 A fuse Figure 48 g190589 Figure 48 1 Charge circuit 25 A Drive System Maintenance Checking the Tire Pressure Service Interval Every 25 hours Check tire pressure Maintain the air pressure in the front and rear tires as specified Uneven tire pressure can cause uneven cut Check the pressure at the valve stem Figure 49 Check the tires when they are col...

Page 40: ...access the idler pulley 7 Using a spring removal tool Toro Part No 92 5771 remove the idler spring from the deck post to remove tension on the idler pulley Figure 50 g028279 Figure 50 1 Spring removal tool Toro Part No 92 5771 4 Idler arm 2 Idler spring 5 Mower belt 3 Deck post 8 Lower the mower to the lowest height of cut and place the height of cut pin in the lock position for the lowest height ...

Page 41: ...gage the parking brake 2 Shut off the engine remove the key and disconnect the spark plug wires from the spark plugs Inspecting the Blades Service Interval Before each use or daily 1 Inspect the cutting edges Figure 51 2 If the edges are not sharp or have nicks remove and sharpen the blade refer to Sharpening the Blades page 43 3 Inspect the blades especially in the curved area 4 If you notice any...

Page 42: ...The variance should be no more than 3 mm 1 8 inch g014973 Figure 55 1 Opposite blade edge in position for measuring 2 Level surface 3 Second measured distance between blade and surface B A If the difference between A and B is greater than 3 mm 1 8 inch replace the blade with a new blade refer to Removing the Blades page 43 and Installing the Blades page 43 Note If a bent blade is replaced with a n...

Page 43: ... at original angle 2 Check the balance of the blade by putting it on a blade balancer Figure 58 Note If the blade stays in a horizontal position the blade is balanced and can be used Note If the blade is not balanced file some metal off the end of the sail area only Figure 57 g000553 Figure 58 1 Blade 2 Balancer 3 Repeat this procedure until the blade is balanced Installing the Blades 1 Install th...

Page 44: ... 5 mm 3 16 inch an adjustment is required refer to Leveling the Mower Deck page 45 g229303 Figure 60 1 Blades side to side 3 Measure from the tip of the blade to the flat surface here 2 Outside cutting edges 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 mow...

Page 45: ... the rear edge of the cutting deck skirt 1 on each side of the cutting deck Figure 62 g010336 Figure 62 1 Wood block 6 6 cm 2 5 8 inches thick 3 Front edge 2 Wood block 7 3 cm 2 7 8 inches thick 5 Loosen the adjustment bolts on all 4 corners so that the deck is sitting securely on all 4 blocks Figure 63 g024313 Figure 63 1 Deck lift arm 3 Hook 2 Chain 4 Adjustment bolt 6 Ensure that there is tensi...

Page 46: ...f cut to the transport position 9 Remove the belt from the clutch pulley on the engine 10 Slide the mower out from underneath the machine Note Retain all parts for future installation Installing 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 sp...

Page 47: ...ector with the bracket ends between the welded brackets on the deck as shown in Figure 67 4 Install the spring onto the straight end of the rod 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...

Page 48: ... on 54 inch decks 4 O ring 2 Washout fitting locations on 48 inch decks 5 Hose 3 Washout fitting 4 Lower the mower to the lowest height of cut 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 th...

Page 49: ...ng 10 Check the condition of the blades refer to Servicing the Cutting Blades page 41 11 Prepare the machine for storage when non use occurs over 30 days Prepare the machine for storage as follows A Add a petroleum based stabilizer conditioner to fuel in the tank Follow mixing instructions from the stabilizer manufacturer Do not use an alcohol based stabilizer ethanol or methanol Note A fuel stabi...

Page 50: ... 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 Do not stack batteries directly on top of each other unless they are in cartons Do not stack more than 3 batteries only 2 if the battery type is commercial Test a wet battery every 4 to 6 months and charge it if nece...

Page 51: ...Move the choke lever to the ON position 3 The air cleaner is dirty 3 Clean or replace the air cleaner element 4 The spark plug wire s is loose or disconnected 4 Install the wire s on the spark plug 5 The spark plug s is pitted fouled or the gap is incorrect 5 Install a new correctly gapped spark plug s 6 There is dirt in fuel filter 6 Replace the fuel filter 7 Dirt water or stale fuel is in fuel s...

Page 52: ...ne vibrates abnormally 7 The motor mount is loose or worn 7 Contact an Authorized Service Dealer 1 The blade s is not sharp 1 Sharpen the blade s 2 A cutting blade s is are bent 2 Install a new cutting blade s 3 The mower is not level 3 Level the mower from side to side and front to rear 4 An anti scalp roller if applicable is not set correctly 4 Adjust the anti scalp wheel height 5 The underside ...

Page 53: ...Schematics g289095 Electrical Diagram Rev A 53 ...

Page 54: ...Notes ...

Page 55: ...Notes ...

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Toro TimeCutter HD ZX4800, Operator'S Manual

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