Form No. 3400-729 Rev C TimeCutter® ZS 4200T or ZS 5000 Riding Mower Model No. 74657—Serial No. 316000001 and Up Model No. 74661—Serial No. 316000001 and Up Register at www.Toro.com.
This product complies with all relevant European directives; for details, please see the separate product specific Declaration of Conformity (DOC) sheet. injury and product damage. You are responsible for operating the product properly and safely. You may contact Toro directly at www.Toro.com for product safety and operation training materials, accessory information, help finding a dealer, or to register your product.
Contents Installing the Mower.......................................... 50 Replacing the Grass Deflector .......................... 51 Mower Belt Maintenance...................................... 52 Inspecting the Belts .......................................... 52 Replacing the Mower Belt ................................. 52 Cleaning .............................................................. 53 Washing the Underside of the Mower................ 53 Storage ..............................................
Safety • Turn off the blades when not mowing. Shut off the engine, wait for all parts to come to a complete stop and remove the key before cleaning the machine, removing the grass catcher or unclogging the discharge chute. This machine has been designed in accordance with EN ISO 5395:2013. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety-alert symbol, which means Caution, Warning, or Danger—personal safety instruction.
• Always avoid sudden starting or stopping on a operator, and ballast. Use counterweights or wheel weights as described in the attachment, or in towing the machine Operator’s Manual. slope. If the tires lose traction, stop the machine, disengage the blades and proceed slowly off down the slope. • Never allow children or others in or on towed • Use extreme care with grass catchers or other equipment. attachments. These can change the stability of the machine and cause loss of control.
Safe Handling of Gasoline General Service To avoid personal injury or property damage, use extra care when handling gasoline and other fuels. They are flammable and the vapors are explosive. • Never operate a machine inside a closed area. • Extinguish all cigarettes, cigars, pipes and other • Keep nuts and bolts tight, especially the blade Engine exhaust contains carbon monoxide, which is an odorless, deadly poison that can kill you. attachment bolts. Keep equipment in good condition.
Hand/Arm Vibration Measured vibration level for left hand = 1.1 m/s2 Measured vibration level for right hand = 1.2 m/s2 Uncertainty Value (K) = 0.6 m/s2 Measured values were determined according to the procedures outlined in EN ISO 5395:2013. Whole-Body Vibration Measured vibration level = 0.36 m/s2 Uncertainty Value (K) = 0.18 m/s2 Measured values were determined according to the procedures outlined in EN ISO 5395:2013.
Slope Indicator g011841 Figure 3 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 lost. decal93-7009 93-7009 1. Warning—don't operate the mower with the deflector up or removed; keep the deflector in place. 2. Cutting/dismemberment hazard of hand or foot, mower blade—stay away from moving parts. decaloemmarkt Manufacturer's Mark decal105-7015 105-7015 For Models with 107 cm (42 inch) Decks 1.
decal112-9840 112-9840 For Models with 127 cm (50 inch) Decks 1. Read the Operator's Manual. 3. Remove the ignition key and read the instructions before servicing or performing maintenance. 2. Height of cut decal120-5469 120-5469 For Models with 107 cm (42 inch) Decks 1. Height of cut decal119-8814 119-8814 1. PARK 2. FAST 3. SLOW 4. NEUTRAL 5. REVERSE decal119-8815 119-8815 1. PARK 2. FAST 3. SLOW 4. NEUTRAL 5. REVERSE decal120-5470 120-5470 For Models with 127 cm (50 inch) Decks 1.
decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery. 1. Explosion hazard 6. Keep bystanders a safe distance 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. Wear eye protection. 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. decal121-2989b 121-2989 1.
decal121-0772 121-0772 For Models with 107 cm (42 inch) Decks 1. Fast 2. Continuous-variable setting 4. Choke 5. Power take-off (PTO), blade-control switch 3.
decal121-0773 121-0773 For Models with 127 cm (50 inch) Decks 1. Fast 2. Continuous-variable setting 4. Choke 5. Power take-off (PTO), blade-control switch 3.
decal132-0869 132-0869 1. Warning—read the Operator's Manual. 5. Ramp tipping 3. Cutting hazard of hand, hazard—when loading mower blade; pinching onto a trailer, do not use hazard of hand, belt—keep dual ramps; only use a hands and feet away from single ramp wide enough moving parts; keep all for the machine and that guards and shields in place. has an incline less than 15 degrees; back up the ramp (in reverse) and drive forward off the ramp. 2.
Product Overview g027829 Figure 4 1. Height-of-cut lever 5. Mower deck 9. Fuel-tank cap 2. Motion-control levers 6. Anti-scalp roller 10. Engine 3. Operator seat 7. Front caster wheel 11. Control panel 4. Smart Speed™ lever 8. Footrest 12. Deflector Controls Become familiar with all of the controls in Figure 4 and Figure 5 before you start the engine and operate the machine. 15 13. Rear-drive wheel 14.
Blade-Control Switch (Power Takeoff) The blade-control switch, represented by a power takeoff (PTO) symbol, engages and disengages power to the mower blades (Figure 5). Motion-Control Levers and Park Position The motion-control levers are speed-sensitive controls of independent-wheel motors. Moving a lever forward or backward turns the wheel on the same side forward or in reverse; wheel speed is proportional to the amount the lever is moved.
Operation from the operator), it is lowered toward the ground. Adjust the height of cut only while the machine is not moving. Note: Determine the left and right sides of the machine from the normal operating position. Adding 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.
Add the correct amount of gas stabilizer/conditioner to the gas. DANGER In certain conditions during fueling, static electricity can be released causing a spark which can ignite the gasoline vapors. A fire or explosion from gasoline can burn you and others and can damage property. • Always place gasoline containers on the ground away from your vehicle before filling.
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. 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. Think Safety First Wear hearing protection when operating this machine. Please read all safety instructions and symbols in the safety section. Knowing this information could help you or bystanders avoid injury.
Testing the Safety-Interlock Starting the Engine Note: A warm or hot engine may not require choking System (Figure 10). Test the safety-interlock system before you use the machine each time. If the safety system does not operate as described below, have an Authorized Service Dealer repair the safety system immediately. 1. While sitting on the seat, with the control levers in the PARK position, and move the blade-control switch to the ON position. Try starting the engine; the engine should not crank. 2.
Operating the Blades Shutting Off the Engine The blade-control switch engages and disengages power to the mower blades. This switch controls power to any attachments that draw power from the engine, including the mower deck and cutting blades. Engaging the Blades 1. Disengage the blades by pushing the blade-control switch to the OFF position (Figure 11). 2. Move the throttle lever to the FAST position. 3. Turn the ignition key to the OFF position and remove the key.
Driving Forward Note: Always use caution when backing up and turning. 1. Move the levers to the center, unlocked position. 2. To go forward, slowly push the motion-control levers forward (Figure 14). g004532 Figure 13 g008952 1. PARK position 4. Backward 2. Center, unlock position 5. Front of the machine Figure 14 3. Forward To go straight, apply equal pressure to both motion-control levers (Figure 14).
Driving Backward Note: Always use caution when backing up and turning. 1. Move the levers to the center, unlocked position. 2. To go backward, look behind you and down, as you slowly pull the motion-control levers rearward (Figure 15). g027625 Figure 16 1. Smart-speed lever g008953 Figure 15 To go straight, apply equal pressure to both motion-control levers (Figure 15). To turn, release the pressure on the motion-control lever toward the direction you want to turn.
Shutting Off the Machine To change speeds, do the following: 1. Move the motion-control levers to the NEUTRAL position and outward to the PARK position. 2. Disengage the blade-control switch. 3. Adjust the lever to the desired position. To shut off the machine, move the motion-control levers to the NEUTRAL position and outward to the PARK position, disengage the blade-control switch, ensure that the throttle is between half and full throttle, and turn the ignition key to off.
Adjusting the Anti-Scalp Rollers Note: Adjust the anti-scalp rollers so the rollers do not touch the ground in normal, flat mowing areas. 1. Disengage the blade-control switch (PTO), move the motion-control levers to the NEUTRAL-LOCK position, and set the parking brake. Whenever you change the height of cut, it is recommended to adjust the height of the anti-scalp rollers. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
Adjusting the Motion-Control Levers 3. Locate the bypass levers on the frame on both sides of the engine. Adjusting the Height 4. Move the bypass levers forward through the keyhole and down to lock them in place (Figure 22). for all moving parts to stop before leaving the operating position. You can adjust the motion-control levers higher or lower for maximum comfort (Figure 21). Note: Do this for each lever. 5.
Converting to Side Discharge Note: The cutoff baffle was shipped with the machine as a loose part. For Models with 107 cm (42-inch) Mower Decks The mower deck and mower blades shipped with this machine were designed for optimum mulching and side-discharge performance. Removing the Discharge Cover for the Side Discharge 1. Park the machine on a level surface and disengage the blade-control switch. 2.
key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the right mower blade; refer to Removing the Blades (page 47). 4. Remove the 2 knobs and curved washers that secure the right baffle to the mower (Figure 26). g005655 Figure 26 1. Knob 3. Baffle stud coming through the mower 2. Curved washer 5. g005652 Figure 25 1. Discharge cover Remove the right baffle and lower the grass deflector over the discharge opening (Figure 26 and Figure 27). 3.
7. Install the right mower blade; refer to Installing the Blades (page 47). (cupped side facing the mower) as shown in Figure 26 and Figure 27. 8. Lift up the grass deflector and install 2 bolts (5/16 x 3/4 inch) into the 2 holes along the deck cutout. Important: Ensure that the tab on the far 9. right side of the right baffle is outside of the mower and is flush with the mower wall. Install the cutoff baffle to the mower deck (Figure 28). 6.
Transporting the Machine Loading the Machine Use a heavy-duty trailer or truck to transport the machine. Ensure that the trailer or truck has all necessary brakes, 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. 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.
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. • Ensure that the length of ramp is at least 4 times as long as the height of the trailer or truck bed to the ground.
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 in uncut grass.
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 engine-oil level. Clean the air intake screen. Check the cutting blades. Inspect the grass deflector for damage. After each use • Clean the mower-deck housing.
Pre-Maintenance Procedures Lubrication Raising the Seat Service Interval: Every 25 hours—Grease all lubrication points. Make sure that the motion-control levers are locked in the PARK position, and lift the seat forward. Grease Type: No. 2 lithium grease Greasing the Bearings The following components can be accessed by raising the seat: • Serial plate 1. Park the machine on a level surface, and disengage the blade-control switch. 2.
Engine Maintenance ooze out of the bearings (Figure 33 and Figure 34). Servicing the Air Cleaner Note: Service the air cleaner more frequently (every few hours) if operating conditions are extremely dusty or sandy. Removing the Elements 1. Park the machine on a level surface and disengage the blade-control switch (PTO). 2. 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.
Servicing the Engine Oil Oil Type: Detergent oil (API service SF, SG, SH, SJ, or SL) Crankcase Capacity: 2.4 L (2.5 US qt) Viscosity: See the table below. g027802 Figure 36 Servicing the Foam Element Service Interval: Every 25 hours/Monthly (whichever comes first)—Clean the foam element (more often in dusty, dirty conditions). g017470 Figure 37 Every 100 hours/Yearly (whichever comes first)—Replace the foam element (more often in dusty, dirty conditions).
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. Every 100 hours/Yearly (whichever comes first)—Change the engine oil (more often in dusty, dirty conditions). Every 100 hours/Yearly (whichever comes first)—Change the oil filter (more often in dusty, dirty conditions). Note: Change the engine-oil filter more frequently when operating conditions are extremely dusty or sandy.
4. Drain the engine oil. g027799 g027477 Figure 40 Note: Ensure that the oil-filter gasket touches the engine and then turn the filter an extra 3/4 turn. 6. g027823 Figure 39 5. Change the engine-oil filter (Figure 40). 38 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 41).
Servicing the Spark Plug Service Interval: Every 100 hours/Yearly (whichever comes first)—Check the spark plug(s). Every 200 hours/Every 2 years (whichever comes first)—Replace the spark plug(s). Make sure that the air gap between the center and side electrodes is correct before installing the spark plug. Use a spark-plug wrench for removing and installing the spark plug(s) and a gapping tool/feeler gauge to check and adjust the air gap. Install a new spark plug(s) if necessary.
8. g008794 Figure 43 Installing the Spark Plug Tighten the spark plug(s) to 25 to 30 N∙m (18.5 to 22.1 ft-lb). g010687 Figure 44 Cleaning the Cooling System Clean the air intake screen from grass and debris before each use. 1. Disengage the blade-control switch and apply 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.
Fuel System Maintenance DANGER In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline 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 gasoline that spills. • Never smoke when draining gasoline, and stay away from an open flame or where a spark may ignite the gasoline fumes.
Electrical System Maintenance WARNING Incorrect battery-cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. WARNING CALIFORNIA Proposition 65 Warning Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.
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 42). Fuse type: Charge the battery for a minimum of 1 hour at 6 to 10 amps.
Drive System Maintenance Releasing the Electric Brake Checking the Tire Pressure The electric brake releases by manually rotating the link arms forward. Once the electric brake is energized, the brake resets. Service Interval: Every 25 hours—Check tire pressure. 1. Turn the ignition key to the disconnect the battery. Maintain the air pressure in the front and rear tires as specified. Uneven tire pressure can cause an uneven cut. Check the pressure at the valve stem (Figure 49).
Mower Maintenance Servicing the Cutting Blades Maintain sharp blades throughout the cutting season, because sharp blades cut cleanly without tearing or shredding the grass blades. Tearing and shredding turns grass brown at the edges, which slows growth, and increases the chance of disease. g006530 Figure 51 Check the cutter blades daily for sharpness, and for any wear or damage. File down any nicks and sharpen the blades as necessary.
3. Measure from the tip of the blade to the flat surface (Figure 53). g014973 Figure 55 1. Opposite blade edge (in position for measuring) g014973 Figure 53 2. Level surface 3. Second measured distance between blade and surface (B) 1. Blade (in position for measuring) 2. Level surface 3. Measured distance between blade and the surface (A) 4. A. Rotate the same blade 180 degrees so that the opposing cutting edge is now in the same position (Figure 54).
Removing the Blades 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. 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.
Leveling the Mower Deck 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 mower deck for bent blades prior to leveling; remove and replace any bent blades; refer to the Servicing the Cutting Blades (page 45) before continuing. Level the mower deck side-to-side before adjusting the front-to-rear slope. g005278 Requirements: Figure 60 Mower decks with 3 blades • The machine must be on a level surface.
9. Check the side-to-side adjustments again. Repeat this procedure until the measurements are correct. 10. Continue leveling the deck by checking the front-to-rear blade slope; refer to Adjusting the Front-to-Rear Blade Slope (page 49). Adjusting the Front-to-Rear Blade Slope g009659 Figure 63 Mower decks with 3 blades Check the front-to-rear blade level any time you install the mower. If the front of the mower is more than 7.
8. When the front-to-rear blade slope is correct, check the side-to-side level of the mower again, refer to Leveling from Side to Side (page 48). Removing the Mower 1. 2. Park the machine on a level surface and disengage the blade-control switch. Move the motion-control levers outward to the position, shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. PARK 3. Lower the height-of-cut lever to the lowest position. 4.
Replacing the Grass Deflector Service Interval: Before each use or daily—Inspect the grass deflector for damage. WARNING Never operate the machine without the grass deflector, the discharge cover, or the grass-collection system in place. Inspect the grass deflector for damage before each use. Replace any damaged parts before use. 1. Remove the nut (3/8 inch) from the rod under the mower (Figure 67). g005192 Figure 67 5. Spring 2. Grass deflector 6. Nut (3/8 inch) 3. Grass-deflector bracket 4. Rod 7.
Mower Belt Maintenance 8. Install the pulley covers (Figure 68). 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 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. Replace the mower belt if any of these conditions are evident. 1.
Cleaning 7. Disengage the blade-control switch, shut off the engine, remove the ignition key, and wait for all moving parts to stop. Washing the Underside of the Mower 8. Turn the water off and remove the coupling from the washout fitting. Note: If the mower is not clean after a washing, Service Interval: After each use—Clean the mower-deck housing. soak it and let it stand for 30 minutes. Then, repeat the process. 9.
Storage Important: Do not store gasoline with stabilizer/conditioner for over 30 days. Cleaning and Storage 1. Disengage the blade-control switch, move the motion controls outward to the PARK position, shut off the engine, and remove the key. 2. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine. 3. Clean dirt and chaff from the outside of the engine cylinder-head fins and blower housing.
Troubleshooting Problem The engine overheats. Possible Cause 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. Remove the obstruction from the cooling fins and air passages. 5. Dirt, water, or stale fuel is in the fuel system. The starter does not crank.
Problem The cutting height is uneven. Possible Cause 1. The blade(s) is not sharp. 1. Sharpen the blade(s). 2. A cutting blade(s) is/are bent. 3. The mower is not level. 2. Install a new cutting blade(s). 3. Level the mower from side-to-side and front-to-rear. 4. Adjust the anti-scalp wheel height. 5. Clean the underside of the mower. 6. Adjust the tire pressure. 7. Contact an Authorized Service Dealer. 4. 5. 6. 7. The blades do not rotate. Corrective Action An anti-scalp wheel is not set correctly.
Schematics g028022 Electrical Diagram (Rev.
Notes:
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TimeCutter and TITAN Mowers The Toro Warranty Limited Warranty (see warranty periods below) Conditions and Products Covered 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. 1. Contact any Authorized Toro Service Dealer to arrange service at their dealership. To locate a dealer convenient to you, access our web site at www.Toro.com.
