Form No. 3409-396 Rev A TimeCutter® ZS 4200T or ZS 5000 Riding Mower Model No. 74657—Serial No. 400000000 and Up Model No. 74661—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 machine is a ride-on, rotary-blade intended to be used by homeowners in residential applications. It is primarily designed for cutting grass on well-maintained lawns. It is not designed for cutting brush, mowing grass and other growth alongside highways, or for agricultural uses.
Contents Safety ........................................................................... 4 General Safety......................................................... 4 Slope Indicator ....................................................... 5 Safety and Instructional Decals ................................. 6 Product Overview .........................................................12 Controls ...............................................................12 Before Operation .................................
Safety Servicing the Battery...............................................38 Servicing the Fuses .................................................40 Drive System Maintenance .........................................40 Checking the Tire Pressure ......................................40 Releasing the Electric Brake .....................................41 Mower Maintenance ...................................................41 Servicing the Cutting Blades.....................................
Slope Indicator G011841 g011841 Figure 4 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 missing. decal93-7009 93-7009 1. Warning—do not 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. Parking position 4. Neutral 2. Fast 3. Slow 5. Reverse decal119-8815 119-8815 1. Parking position 4. Neutral 2. Fast 3. Slow 5.
decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery. decal121-2989b 1. Explosion hazard 6. Keep bystanders a safe distance 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. Wear eye protection. 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. 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 takeoff (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 takeoff (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 5 1. Height-of-cut lever 5. Mower deck 2. Motion-control levers 6. Anti-scalp roller 9. Fuel-tank cap 10. Engine 3. Operator seat 7. Front caster wheel 11. Control panel 4. Smart Speed™ lever 8. Footrest 12. Deflector 13. Rear-drive wheel 14. Engine guard Controls Ignition Switch Become familiar with all the controls in Figure 5 and Figure 6 before you start the engine and operate the machine. Use this switch to start the mower engine.
Motion-Control Levers Operation Use the motion-control levers to drive the machine forward, reverse, and turn either direction. Note: Determine the left and right sides of the machine from the normal operating position. Park Position Before Operation Move the motion-control levers outward from the center to the PARK position when exiting the machine (Figure 5). Always position the motion-control levers into the PARK position when you stop the machine or leave it unattended.
Using Stabilizer/Conditioner • Keep the fuel-dispenser nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. Do not use a nozzle lock-open device. Use a fuel stabilizer/conditioner in the machine to provide the following benefits: • If you spill fuel on your clothing, change your clothing • Keeps fuel fresh during storage of 90 days or less (drain immediately. Wipe up any fuel that spills.
Checking the Engine-Oil Level Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking the Engine-Oil Level (page 33). Breaking in a New Machine New engines take time to develop full power. Mower decks and drive systems have higher friction when 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.
Positioning the Seat Using the Safety-Interlock System A B WARNING If the safety-interlock switches are disconnected or damaged, the machine could operate unexpectedly, causing personal injury. • Do not tamper with the interlock switches. • Check the operation of the interlock switches daily and replace any damaged switches before operating the machine.
Adjusting the Tilt 4. Remove the discharge cover. You can adjust the motion-control levers forward or rearward for your comfort. 5. Lift up the grass deflector, and locate the lock nut on the deflector pivot rod. 6. Remove the existing thin nut (3/8 inch). 1. Loosen the upper bolt holding the control lever to the control-arm shaft. 7. Install the cutoff baffle to the exposed pivot rod (Figure 14). 2. Loosen the lower bolt just enough to pivot the control lever forward or rearward (Figure 12).
g005655 Figure 16 1. Knob 3. Baffle stud coming through the mower 2. Curved washer 5. Remove the right baffle and lower the grass deflector over the discharge opening as shown in Figure 16 and Figure 17. g005652 Figure 15 1. Discharge cover 3. Bolt (1/4 x 2-1/2 inches) 2. Cap nut (1/4 inch) 6. Secure the discharge cover to the lower lip of the mower with 2 bolts (1/4 x 2-1/2 inches) and 2 cap nuts (1/4 inch) as shown in Figure 15.
4. Remove the right mower blade; refer to Removing the Blades (page 43). WARNING Open holes in the mower expose you and others to thrown debris that can cause severe injury. 5. Slide the right baffle under the mower deck, and secure it using 2 knobs and the curved washers (cupped side facing the mower) as shown in Figure 16 and Figure 17. • Never operate the mower without hardware mounted in all holes in the mower housing.
During Operation – Disengage the power take-off and lower the attachments. During Operation Safety – Engage the parking brake. – Shut off the engine and remove the key. – Wait for all moving parts to stop. General Safety • Do not operate the machine when there is the risk of • The owner/operator can prevent and is responsible for lightning. accidents that may cause personal injury or property damage. • Do not use the machine as a towing vehicle.
Operating the Mower Blade-Control Switch (PTO) Operating the Throttle You can move the throttle control between the FAST and SLOW positions (Figure 22). The blade-control switch (PTO) starts and stops the mower blades and any powered attachments. Always use the FAST position when turning on the mower deck with the blade-control switch (PTO).
Operating the Ignition Switch Starting and Shutting Off the Engine 1. Turn the ignition key to the START position (Figure 24). Note: When the engine starts, release the key. Starting the Engine Important: Do not engage the starter for more than 5 seconds at a time. If the engine fails to start, wait 15 seconds between attempts. Failure to follow these instructions can burn out the starter motor. Note: A warm or hot engine may not require choking.
Driving Forward Using the Motion-Control Levers 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 27). G008952 g008952 Figure 27 g004532 Figure 26 1. Motion-control lever—PARK position 4. Backward 2. Center, unlocked position 5. Front of machine Driving Backward 1. Move the levers to the center, unlocked position. 2.
Using the Smart SpeedTM Control System Tow This is the medium speed. The suggested uses for this speed are as follows: TM The Smart Speed Control-System lever, located below the operating position (Figure 29), gives the operator a choice to drive the machine at 3 ground speed ranges—trim, tow, and mow. • Bagging • Mulching Mow This is the fastest speed.
Adjusting the Height of Cut Adjusting the Anti-Scalp Rollers Note: The transport position is the highest height-of-cut position at 115 mm (4-1/2 inches) as shown in Figure 30. For Machines with 107 cm (42-inch) Mower Decks Whenever you change the height of cut, adjust the height of the anti-scalp rollers. Note: Adjust the anti-scalp rollers so the rollers do not touch the ground in normal, flat mowing areas. 1. Park the machine on a level surface and disengage the blade-control switch. 2.
Using the Side Discharge 2. Ensure that the parking brake is engaged, shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. 3. Adjust the anti-scalp rollers (Figure 32) to match the closest height-of-cut position.
Mowing at Correct Intervals After Operation Grass grows at different rates at different times of the year. To maintain 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.
Transporting the Machine 3 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.
Loading the Machine 1 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. Back up the ramp and drive forward down the ramp (Figure 35). g027995 Figure 35 1. Back the machine up the ramp. 2 2. Drive the machine forward down the ramp. Important: Do not use narrow individual ramps for each side of the machine.
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 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 Raising the Seat Make sure that the motion-control levers are locked in the PARK position. Lift the seat forward. You can access the following components by raising the seat: Maintenance and Storage • Serial plate • Before repairing the machine do the following: • Service decal – Disengage the drives. • Seat-adjustment bolts – Engage the parking brake. • Fuel filter – Shut off the engine and remove the key. • Battery and battery cables – Disconnect the spark-plug wire.
Lubrication Engine Maintenance Greasing the Bearings Engine Safety Service Interval: Every 25 hours—Grease all lubrication points. Shut off the engine before checking the oil or adding oil to the crankcase. Grease Type: No. 2 lithium grease Servicing the Air Cleaner 1. Park the machine on a level surface and disengage the blade-control switch. Service Interval: Before each use or daily 2.
Servicing the Engine Oil 5. Remove the foam element from the paper element (Figure 41). Oil Type: Detergent oil (API service SF, SG, SH, SJ, or SL) Crankcase Capacity: with filter—2.4 L (2.5 US qt) Viscosity: See the table below. SAE 30 SAE 5W -30, 10W -30 g027802 g027802 SYNTHETIC 5W -20, 5W -30, 10W -30 Figure 41 Servicing the Foam Element g029683 Service Interval: Every 25 hours/Monthly (whichever comes first)—Clean the air-cleaner foam element (more often in dusty, dirty conditions).
A Changing the Engine Oil and Oil Filter B 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). C D E 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.
A B C D E F g027799 g027799 A B D C 3/4 g027477 g027477 Figure 45 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 46). g027823 g027823 Figure 44 5. Change the engine-oil filter (Figure 45). Note: Ensure that the oil-filter gasket touches the engine and then turn the filter an extra 3/4 turn.
A Removing the Spark Plug B 1. Disengage the PTO and move the motion-control levers 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. C D E F A B g027478 g027478 Figure 47 Note: Due to the deep recess around the spark plug, blowing out the cavity with compressed air is the most effective method for cleaning. The spark plug is most accessible when the blower housing is removed for cleaning.
Installing the Spark Plug Fuel System Maintenance Tighten the spark plug(s) to 25 to 30 N∙m (18.5 to 22.1 ft-lb). B A 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. C 25-30 N-m 18.5-22.1 ft-lb • Perform any fuel-related maintenance when the engine is cold. Do this outdoors in an open area. Wipe up any fuel that spills.
Electrical System Maintenance Electrical System Safety • Disconnect the battery before repairing the machine. g027939 g027939 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 Service Interval: Before storage—Charge the battery and disconnect the battery cables. Incorrect battery-cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. 1. Remove the battery from the chassis; refer to Removing the Battery (page 38). • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. 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. Fuse type: Checking the Tire Pressure • Main—F1 (30 A, blade-type) Service Interval: Every 25 hours—Check tire pressure. • Charge Circuit—F2 (25 A, blade-type) Maintain the air pressure in the front and rear tires as specified. Uneven tire pressure can cause uneven cut.
Releasing the Electric Brake Mower Maintenance You can manually release the electric brake by rotating the link arms forward. Once the electric brake is energized, the brake resets. Servicing the Cutting Blades 1. Turn the ignition key to the OFF position or disconnect the battery. To ensure a superior quality of cut, keep the blades sharp. For convenient sharpening and replacement, keep extra blades on hand. 2.
Checking for Bent Blades Note: The machine must be on a level surface for the following procedure. 3 1. Raise the mower deck to the highest height-of-cut position. 2. While wearing thickly padded gloves, or other adequate hand protection, slowly rotate the blade to be measure into a position that allows effective measurement of the distance between the cutting edge and the level surface the machine is on (Figure 57). 2 1 G014974 g014974 Figure 59 1. Blade (side previously measured) 2.
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. g000553 Figure 63 1. Blade 1. Hold the blade end using a rag or thickly padded glove. 2. Balancer 3. Repeat this procedure until the blade is balanced. 2.
1 2 G009682 3 3 2 4 4 g009682 Figure 64 Mower Decks with 2 Blades g027588 1. Blades side to side 3. Outside cutting edges 2. Sail area of blade 4. Measure from the tip of the blade to the flat surface here Figure 66 1. Hanger bracket G005278 2 9. Check the side-to-side adjustments again. Repeat this procedure until the measurements are correct. 10. Continue leveling the mower deck by checking the front-to-rear blade slope; refer to Adjusting the Front-to-Rear Blade Slope (page 44).
2 1 G009658 2 g009658 3 Figure 67 Mower Decks with 2 Blades 1 1. Blades front to rear 2. Measure from the tip of the blade to the flat surface here 2 G014634 g014634 3 Figure 69 1. Adjusting rod 2 1 G009659 2 7. To raise the front of the mower, tighten the adjustment nut. 3 8. To lower the front of the mower, loosen the adjustment nut. g009659 9. After adjustment, check the front-to-rear slope again, continue adjusting the nut until the front blade tip is 1.6 to 7.
9. Slide the mower deck out from underneath the machine. Note: Retain all parts for future installation. Installing the Mower Deck 1. Park the machine on a level surface and disengage the blade-control switch. 2. Move the motion-control levers outward to the PARK position, shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3 1 2 3. Slide the mower under the machine. 4. Lower the height-of-cut lever to the lowest position. 5.
Replacing the Grass Deflector 8. Insert the rod at the front of the grass deflector into the short standoff on the deck. Service Interval: Before each use or daily—Inspect the grass deflector for damage. 9. Secure the rear end of the rod into the mower with a nut (3/8 inch) as shown in Figure 72. WARNING Important: The grass deflector must be spring loaded and in the down position. Lift the deflector up to test that it snaps to the fully down position.
Mower Belt Maintenance 2 Inspecting the Belts 5 Service Interval: Every 25 hours—Check the belts for wear or cracks. 1 3 4 Check the belts for cracks, frayed edges, burn marks, or any other damage. Replace damaged belts. 3 Replacing the Mower-Deck Belt Squealing when the belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks, and cracks are signs of a worn mower belt. Replace the mower belt if any of these conditions are evident. 4 G014930 6 1.
Cleaning 8. Using a spring-removal tool, install the idler spring over the deck hook, and place tension on the idler pulley and mower belt (Figure 74 and Figure 75). Washing the Underside of the Mower 9. Tighten the bottom 2 bolts for the mower-deck curtain to the mower deck. Refer to Releasing the Mower-Deck Curtain (page 31). Service Interval: After each use—Clean the mower-deck housing. 10. Install the pulley covers. Important: You can wash the machine with a mild detergent and water.
Storage 7. Disengage the blade-control switch, shut off the engine, remove the ignition key, and wait for all moving parts to stop. Cleaning and Storage 8. Turn the water off and remove the coupling from the washout fitting. 1. Disengage the blade-control switch, move the motion-control levers 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.
Use the starter to crank the engine and distribute the oil inside the cylinder. Install the spark plug(s). Do not install the wire on the spark plug(s). 11. Clean any dirt and chaff from the top of the mower. 12. Scrape any heavy buildup of grass and dirt from the underside of the mower, then wash the mower with a garden hose. 13. Check the condition of the drive and mower belts. 14. Check and tighten all bolts, nuts, and screws. Repair or replace any part that is worn or damaged. 15.
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.
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Residential Products The Toro Warranty and The Toro GTS Starting Guarantee 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 Product listed below if defective in materials or workmanship or if the Toro GTS (Guaranteed to Start) engine will not start on the first or second pull, provided the routine maintenance required in the Operator's Manual have been performed.
