Form No. 3433-551 Rev C TimeCutter® ZS 4200T Riding Mower Model No. 74687—Serial No. 400000000 and Up Register at www.Toro.com.
Introduction This product complies with all relevant European directives; for details, please see the separate product specific Declaration of Conformity (DOC) sheet. 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. Using this product for purposes other than its intended use could prove dangerous to you and bystanders.
Cleaning the Cooling System............................ 36 Fuel System Maintenance ................................... 36 Replacing the In-Line Fuel Filter ....................... 36 Electrical System Maintenance ........................... 37 Electrical System Safety ................................... 37 Servicing the Battery......................................... 37 Servicing the Fuses .......................................... 39 Drive System Maintenance ..................................
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. This machine has been designed in accordance with EN ISO 5395:2013. 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. decalbatterysymbols Battery Symbols Some or all of these 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 4.
decal139-2391 139-2391 decal131-1097 131-1097 1. Fast 2. Slow 1. Oil drain decal139-2394 139-2394 decal132-0872 1. Traction controls 2. Fast 3. Slow 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. 4. Neutral 5.
decal139-2388 139-2388 1. Slow 2. Hauling 3. Fast decal140-2748 140-2748 decal135-3295 135-3295 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.
Product Overview g293302 Figure 5 1. Engine 4. Motion-control levers 7. Deflector 2. Operator seat 5. Rear drive wheel 8. Smart Speed™ lever 3. Fuel-tank cap 6. Front caster wheels 9. Height-of-cut lever 9 10.
Controls Motion-Control Levers Become familiar with all the controls before you start the engine and operate the machine. Use the motion-control levers to drive the machine forward, reverse, and turn either direction (Figure 5). Control Panel Park Position Move the motion-control levers outward from the center to the PARK position when exiting the machine (Figure 23). Always position the motion-control levers into the PARK position when you stop the machine or leave it unattended.
Height-of-Cut Lever Operation Use the height-of-cut lever to lower and raise the deck from the seated position. Moving the lever up (toward you) raises the deck from the ground and moving the lever down (away from you) lowers the deck toward the ground. Adjust the height-of-cut only while the machine is not moving (Figure 27). Note: Determine the left and right sides of the machine from the normal operating position.
Pre-Start Fuel Safety Fill fuel tank on level ground. See Fuel Recommendations in the Specifications section for additional gasoline information. Use extreme care when handling fuel. Do Not add oil to gasoline. In certain conditions gasoline is extremely flammable and vapors are explosive. DANGER 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.
flame or any enclosed area where open pilot lights or heat appliances are present. 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. Adding Fuel • Always place gasoline containers on the ground away from your vehicle before filling.
Understanding the Safety-Interlock System The safety-interlock system is designed to prevent the engine from starting unless: • The blade-control switch (PTO) is disengaged. • The motion-control levers are in the PARK position. The safety-interlock system also is designed to shut off the engine whenever the control levers are out of the PARK position and you rise from the seat. Testing the Safety-Interlock System Test the safety-interlock system before you use the machine each time.
Positioning the Seat Adjusting the Tilt The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable (Figure 9). 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. Loosen the lower bolt just enough to pivot the control lever forward or rearward (Figure 10). 3.
g230249 Figure 14 g230250 Figure 12 1. Discharge cover 5. 3. Bracket on the mower deck 2. Metal tab On the top of the discharge cover, engage the hook-shaped latch around the pivot rod of the deflector assembly (Figure 15). Installing the Discharge Cover for Mulching 1. Park the machine on a level surface, disengage the blade-control switch, and move the motion-control levers outward to the PARK position. 2.
During Operation • Be sure all drives are in neutral and parking brake • During Operation Safety • General Safety 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. Severe burns can occur on contact and debris, such as leaves, grass, brush, etc. can catch fire.
• • 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. – 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.
Towing Safety Operating the Mower Blade-Control Switch (PTO) • Do not attach towed equipment except at the hitch point. The blade-control switch (PTO) starts and stops the mower blades and any powered attachments. • Do not use the machine as a towing vehicle unless it has a hitch installed. • Do not exceed the weight limits for towed Engaging the Blade-Control Switch (PTO) equipment and towing on slopes. The towed weight must not exceed the weight of the machine and operator.
Operating the Throttle Starting the Engine You can move the throttle control between the FAST and SLOW positions (Figure 20). Note: A warm or hot engine may not require choking. Always use the FAST position when engaging the PTO. 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 sometime for you to adapt to how it moves.
Driving Backward 1. Move the levers to the center, unlocked position. 2. To go backward, slowly pull the motion-control levers rearward (Figure 25). 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.
Using the Side Discharge Adjusting the Height of Cut The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. Note: The transport position is the highest height-of-cut position or cutting height at 114 mm (4-1/2 inches) as shown in Figure 27. Height of cut is controlled by the lever located to the right of the operating position (Figure 27).
Adjusting the Anti-Scalp Rollers Operating Tips Using the Fast Throttle Setting Whenever you change the height of cut, adjust the height of the anti-scalp rollers. 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 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 • Park machine on level ground, disengage drives, 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.
WARNING WARNING Driving on the street or roadway without turn signals, lights, reflective markings, or a slow moving vehicle emblem is dangerous and can lead to accidents causing personal injury. Loading a machine onto a trailer or truck increases the possibility of tip-over and could cause serious injury or death. Do not drive machine on a public street or roadway. • Use only a full-width ramp; do not use individual ramps for each side of the machine.
motion-control levers outward to the PARK position. 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 32). Note: Do this for each lever. WARNING Contact with hot surfaces may cause personal injury.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. WARNING Maintenance Safety 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.
WARNING Contact with moving parts or hot surfaces may cause personal injury. Keep your fingers, hands, and clothing clear of rotating components and hot surfaces. • Check all bolts frequently to maintain proper tightness. 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.
Pre-Maintenance Procedures Lubrication Releasing the Mower-Deck Curtain Service Interval: Every 25 hours—Grease the caster wheel bearings. Greasing the Bearings Grease Type: No. 2 lithium grease Loosen the 2 bottom bolts of the curtain to access the top of the mower deck (Figure 33). 1. Park the machine on a level surface, disengage the blade-control switch, and move the motion-control levers outward to the PARK position. 2.
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.
Installing the Air Cleaner Servicing the Foam Air-Cleaner Element 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 or 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.
Servicing the Engine Oil Engine-Oil Specifications Oil Type: Detergent oil (API service SF, SG, SH, SJ, or SL) Crankcase Capacity: 2.4 L (81 fl oz) with oil filter Viscosity: See the table below. g029683 Figure 38 Checking the Engine-Oil Level Service Interval: Before each use or daily 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. 2.
5. Change the engine-oil filter (Figure 41). Note: Ensure that the oil-filter gasket touches the engine and then turn the filter an extra 3/4 turn. g027799 g027477 Figure 41 6. g029570 Figure 40 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 42).
g027478 Figure 43 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. g193530 Figure 42 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. Fuel System Maintenance Park the machine on a level surface, disengage the blade-control switch, and move the motion-control levers outward to the PARK position. 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.
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 WARNING 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. Service Interval: Before storage—Charge the battery and disconnect the battery cables. • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. 1. Remove the battery from the chassis; refer to Removing the Battery (page 37). 2.
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 (25 A, blade-type) Service Interval: Every 25 hours—Check tire pressure. • Charge Circuit—F2 (15 A, blade-type) 1. Park the machine on a level surface, disengage the blade-control switch, and move the motion-control levers outward to the PARK position. 2.
Releasing the Electric Brake 3. Note: Raise the seat for easier access to the adjustment bolt. You can manually release the electric brake by rotating the link arms forward. Once the electric brake is energized, the brake resets. 1. Turn the key to the the battery. 2. Loosen the bottom 2 bolts holding the mower-deck curtain to the mower deck. Refer to Releasing the Mower-Deck Curtain (page 30). 3. Locate the shaft on the electric brake where the brake link arms are connected (Figure 51). 4.
Belt Maintenance WARNING The spring is under tension when installed and can cause personal injury. Inspecting the Belts Be careful when removing the belt. 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.
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 55 • 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 57 Figure 59 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 58). A.
Installing the Blades 1. Install the blade onto the spindle shaft (Figure 60). Important: The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting. g027833 3. Curved washer 4. Blade bolt 3. Torque the blade bolt to 81 to 108 N∙m (60 to 80 ft-lb). 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.
g294044 g294046 Figure 63 1. Blades side to side Figure 64 3. Measure from the tip of the blade to the flat surface here. 1. Blades front to rear 2. Outside cutting edges 2. Outside cutting edges Checking the Front-to-Rear Blade Slope Leveling from Side to Side 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.
g294195 Figure 67 g294196 Figure 65 1. Wood block—6.6 cm (2-5/8 inches) thick 6. 2. Wood block—7.3 cm (2-7/8 inches) thick Remove the hairpin cotter and washer from the lower lift-arm pin (Figure 66). g294197 Figure 66 1. Height-of-cut plate 3. Washer 2. Hairpin cotter 7. Rotate the height-of-cut plate to a different hole so that it supports the weight of the mower deck after you install the plate (Figure 67). 46 8. Install the washer and hairpin cotter (Figure 67). 9.
Removing the Mower Deck Adjusting the Front-to-Rear Blade Slope 1. 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and move the motion-control levers outward to the PARK position. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Lower the height-of-cut lever to the lowest position. 4. Loosen the bottom 2 bolts holding the mower-deck curtain to the mower deck.
8. Attach the front support rod to the mower deck with the clevis pin and hairpin cotter (Figure 69). 9. Install the mower belt onto the engine pulley; refer to Replacing the Mower Belt (page 41). 10. Tighten the bottom 2 bolts for the mower-deck curtain to the mower deck; refer to Releasing the Mower-Deck Curtain (page 30). Replacing the Grass Deflector Service Interval: Before each use or daily—Inspect the grass deflector for damage.
Cleaning 3. Remove the damaged or worn grass deflector and the baffle. 4. Install the new grass deflector and the baffle (Figure 71). 5. Slide the rod, straight end, through the rear grass deflector bracket and baffle. Washing the Underside of the Mower Deck 6. Place the spring on the rod, with end wires down, and between the grass deflector brackets. Service Interval: After each use—Clean the mower-deck housing. 7. Slide the rod through the baffle and second grass-deflector bracket (Figure 71).
7. Disengage the blade-control switch, shut off the engine, remove the key, 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 Note: If the mower is not clean after 1 washing, drain the fuel indoors. soak it and let it stand for 30 minutes. Then repeat the process. 9.
Storing the Battery use an alcohol-based stabilizer (ethanol or methanol). B. C. D. Run the engine to distribute conditioned fuel through the fuel system for 5 minutes. 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. Dispose of fuel properly. Recycle the fuel according to local codes. stabilizer/conditioner longer than the duration recommended by the fuel-stabilizer manufacturer.
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 g307974 Electrical Diagram—139–2356 (Rev.
Notes:
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