Form No. 3417-368 Rev A TimeCutter® ZS 4200T or ZS 5000 Riding Mower Model No. 74661—Serial No. 400900000 and Up Model No. 74667—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 This manual identifies potential hazards and has safety messages identified by the safety-alert symbol (Figure 2), which signals a hazard that may cause serious injury or death if you do not follow the recommended precautions. Safety ....................................................................... 4 General Safety ................................................... 4 Slope Indicator ................................................... 5 Safety and Instructional Decals ......................
Safety Belt Maintenance ................................................ 47 Replacing the Mower-Deck Belt........................ 47 Mower Maintenance............................................. 48 Servicing the Cutting Blades ............................. 48 Leveling the Mower Deck.................................. 51 Removing the Mower Deck............................... 53 Installing the Mower Deck................................. 54 Replacing the Grass Deflector ..........................
Slope Indicator g011841 Figure 4 This page may be copied for personal use. 1. The maximum slope you can operate the machine on is 15 degrees. Use the slope chart to determine the degree of slope of hills before operating. Do not operate this machine on a slope greater than 15 degrees. Fold along the appropriate line to match the recommended slope. 2. Align this edge with a vertical surface, a tree, building, fence pole, etc. 3.
Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or missing. decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery. 1. Explosion hazard 6. Keep bystanders a safe distance away from the battery. 2. No fire, open flame, or smoking 7. Wear eye protection; explosive gases can cause blindness and other injuries. 3.
decal106-8717 106-8717 decal119-8815 1. Read the instructions before servicing or performing maintenance. 2. Check tire pressure every 25 operating hours. 119-8815 3. Grease every 25 operating hours. 4. Engine 1. Parking position 4. Neutral 2. Fast 3. Slow 5. Reverse decal112-9840 112-9840 For Models with 127 cm (50 inch) Decks 1. Read the Operator's Manual. 3. Remove the key and read the instructions before servicing or performing maintenance. 2.
decal120-5470 120-5470 For Models with 127 cm (50 inch) Decks 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.
decal121-2989b 121-2989 1. Bypass lever position for pushing the machine 2. Bypass lever position for operating the machine decal131-1097 131-1097 1. Oil drain 131-3948 decal131-3948 131-3948 1. Slow 2. Towing 3.
decal132-0869 132-0869 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. The operator must review the instructions for operating the machine on slopes in the Operator’s Manual and review the conditions in which the machine is being operated to determine whether the machine can be operated in the conditions on that day and at that site.
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 parts; keep all guards and shields in place. decal138-2456 138-2456 1. Read the Operator’s Manual. 2. Park the machine on a level surface when filling the fuel tank. 3. Do not overfill the fuel tank.
Product Overview g027829 Figure 5 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 wheels 11. Control panel 4. Smart Speed™ lever 8. Footrest 12. Deflector 13. Rear drive wheel 14. Engine guard Controls Key Switch Become familiar with all the controls before you start the engine and operate the machine. The key switch, used to start and shut off the engine, has 3 positions: OFF, RUN, and START .
Motion-Control Levers Height-of-Cut Lever Use the motion-control levers to drive the machine forward, reverse, and turn either direction (Figure 5). 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 31).
Operation • Note: Determine the left and right sides of the machine from the normal operating position. Before Operation • Before Operation Safety • General Safety • Never allow children or untrained people to • • • • • • • operate or service the machine. Local regulations may restrict the age of the operator. The owner is responsible for training all operators and mechanics. Become familiar with the safe operation of the equipment, operator controls, and safety signs.
Using Stabilizer/Conditioner Use a fuel stabilizer/conditioner in the machine to provide the following benefits: • Keeps fuel fresh during storage of 90 days or less (drain the fuel tank when storing the machine for more than 90 days) • Cleans the engine while it runs • Eliminates gum-like varnish buildup in the fuel system, which causes hard starting Important: Do not use fuel additives containing methanol or ethanol. Add the correct amount of fuel stabilizer/conditioner to the fuel.
Using the Safety-Interlock System motion-control levers to the center, unlocked position, engage the blade-control switch, and rise slightly from the seat; the engine should shut off. WARNING Positioning the Seat If the safety-interlock switches are disconnected or damaged, the machine could operate unexpectedly, causing personal injury. 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).
Adjusting the Motion-Control Levers Converting to Side Discharge Adjusting the Height Machines with 107 cm (42-inch) Mower Decks You can adjust the motion-control levers higher or lower for maximum comfort (Figure 10). The mower deck and mower blades shipped with the machine were designed for optimum mulching and side-discharge performance. Removing the Discharge Cover for Side-Discharging g027252 Figure 10 1.
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 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.
Removing the Right Baffle for Side-Discharging 1. Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the right mower blade; refer to Removing the Blades (page 50). 4. Remove the 2 knobs and curved washers that secure the right baffle to the mower (Figure 16). g024261 Figure 17 1. Right baffle 3. Discharge opening 2.
During Operation During Operation Safety General Safety • The owner/operator can prevent and is responsible • g015321 Figure 18 1. Bolt (5/16 x 3/4 inch) 3. Locknut (5/16 inch) 2. Cutoff baffle 10. Torque the fasteners to 7 to 9 N∙m (14 to 18 ft-lb). 11. Lower the grass deflector over the discharge opening. • • • Important: Ensure that the mower has • a hinged grass deflector that disperses clippings to the side and down toward the turf while in side-discharge mode.
• Before leaving the operating position (including quickly affect the operation of the machine on a slope. to empty the catchers or to unclog the chute), do the following: • Identify hazards at the base of the slope. Do – Stop the machine on level ground. not operate the machine near drop-offs, ditches, embankments, water, or other hazards. The machine could suddenly roll over if a wheel goes over the edge or the edge collapses.
Operating the Mower Blade-Control Switch (PTO) The blade-control switch (PTO) starts and stops the mower blades and any powered attachments. Engaging the Blade-Control Switch (PTO) g229111 Figure 20 1. Safe Zone—use the machine here on slopes less than 15 degrees or flat areas. 2. Danger Zone—use a walk-behind mower and/or a hand trimmer on slopes greater than 15 degrees and near drop-offs or water. 3. Water 4. W=width of the machine g008945 Figure 21 5.
Disengaging the Blade-Control Switch (PTO) 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 25). 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 the engine has started (Figure 25). g027538 Figure 23 Operating the Throttle You can move the throttle control between FAST and SLOW positions (Figure 24).
Starting the Engine CAUTION Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. 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.
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 making turns. • Slow the machine down before making sharp turns. 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 28).
Suggested uses: Trim Parking X Heavy, wet grass X Training X Tow Tow Mow This is the medium speed. The suggested uses for this speed are as follows: • Bagging • Mulching Bagging X Mulching X Mow Normal mowing X Transport X This is the fastest speed. The suggested uses for this speed are as follows: • Normal mowing • Transporting the machine Trim This is the lowest speed.
Using the Side Discharge The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. DANGER Without a grass deflector, discharge cover, or a complete grass-catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris. Contact with rotating mower blade(s) and thrown debris will cause injury or death. • Never remove the grass deflector from the mower deck because the grass deflector routes material down toward the turf.
Adjusting the Anti-Scalp Rollers 1. Park the machine on a level surface, disengage the blade-control switch 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. Adjust the anti-scalp rollers (Figure 33) to match the closest height-of-cut position. Adjusting the Anti-Scalp Rollers Machines with 107 cm (42-inch) Mower Decks Whenever you change the height of cut, adjust the height of the anti-scalp rollers.
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 deck in uncut grass.
After Operation After Operation Safety General Safety • Clean grass and debris from the cutting units, mufflers, and engine compartment to help prevent fires. Clean up oil or fuel spills. • Shut off the fuel before storing or transporting the machine. • Disengage the drive to the attachment whenever you are transporting or not using the machine. g017303 Figure 34 • Allow the engine to cool before storing the machine 1. Bypass-lever locations in any enclosure.
Transporting the Machine Use a heavy-duty trailer or truck to transport the machine. Use a full-width ramp. Ensure that the trailer or truck has all the necessary brakes, lighting, and marking as required by law. Please carefully read all the safety instructions. Knowing this information could help you or bystanders avoid injury. Refer to your local ordinances for trailer and tie-down requirements.
1. If using a trailer, connect it to the towing vehicle and connect the safety chains. 2. If applicable, connect the trailer brakes and lights. 3. Lower the ramp, ensuring that the angle between the ramp and the ground does not exceed 15 degrees (Figure 35). 4. Back the machine up the ramp (Figure 36). g027995 Figure 36 1. Back the machine up the ramp. 2. Drive the machine forward down the ramp. 5. Shut off the engine, remove the key, and engage the parking brake. 6.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 5 hours • Change the engine oil and filter. Before each use or daily • • • • • • Check the safety-interlock system. Check the air cleaner for dirty, loose, or damaged parts. Check the engine-oil level. Clean the air intake screen. Inspect the blades. Inspect the grass deflector for damage.
Pre-Maintenance Procedures Ensure that the parking brake is engaged. Lift the seat forward. Maintenance Safety You can access following components by raising the seat: • Before repairing the machine do the following: • Serial plate Raising the Seat – Disengage the drives. • Service decal – Engage the parking brake. • Seat-adjustment bolts (if applicable) – Shut off the engine and remove the key. • Fuel filter – Disconnect the spark-plug wire.
Lubrication Engine Maintenance Greasing the Bearings Engine Safety Service Interval: Every 25 hours—Grease all the lubrication points. • Shut off the engine before checking the oil or Grease Type: No. 2 lithium grease • Keep your hands, feet, face, clothing, and other 1. adding oil to the crankcase. body parts away the muffler and other hot surfaces. Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake; refer to Park Position (page 15). 2.
Servicing the Foam Air-Cleaner Element Service Interval: Every 25 hours/Monthly (whichever comes first)—Clean the air-cleaner foam element (more often in dusty, dirty conditions). Every 100 hours/Yearly (whichever comes first)—Replace the air-cleaner foam element (more often in dusty, dirty conditions). g027800 1. Wash the foam element in liquid soap and warm water. When the element is clean, rinse it thoroughly. 2. Dry the element by squeezing it in a clean cloth.
Installing the Air Cleaner 1. Servicing the Engine Oil Install the foam element over the paper element. Engine-Oil Specifications Note: Ensure that you do not damage the elements. Oil Type: Detergent oil (API service SF, SG, SH, SJ, or SL) 2. Align the holes of the filter into the manifold ports. 3. Rotate the filter down into the chamber and fully seat it against the manifold (Figure 43). Crankcase Capacity: 2.4 L (81 fl oz) with oil filter Viscosity: See the table below.
g027799 g193541 Figure 45 Changing the Engine Oil and Oil Filter Service Interval: After the first 5 hours/After the first month (whichever comes first)—Change the engine oil and filter. Every 100 hours/Yearly (whichever comes first)—Change the engine oil and oil filter (more often in dirty or dusty conditions). 1. Park the machine on a level surface to ensure that the oil drains completely. 2. Disengage the blade-control switch (PTO) and engage the parking brake. 3.
5. Change the engine-oil filter (Figure 47). Note: Ensure that the oil-filter gasket touches the engine and then turn the filter an extra 3/4 turn. g193530 Figure 48 7. Dispose of the used oil at a recycling center. Servicing the Spark Plug Service Interval: Every 100 hours/Yearly (whichever comes first)—Check the spark plug(s). g027477 Figure 47 Every 200 hours/Every 2 years (whichever comes first)—Replace the spark plug(s). 6.
Cleaning the Cooling System 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the air filter from the engine. 4. Remove the engine shroud. 5. To prevent debris entering the air intake, install the air filter to the filter base. 6. Clean debris and grass from the parts. 7.
Fuel System Maintenance DANGER In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you, others, and can damage property. g027939 • Perform any fuel-related maintenance when the engine is cold. Do this outdoors in an open area. Wipe up any fuel that spills. • Never smoke when draining fuel, and stay away from an open flame or where a spark may ignite the fuel fumes.
Electrical System Maintenance 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. Electrical System Safety • Disconnect the battery before repairing the • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. machine. Disconnect the negative terminal first and the positive last.
2. 3. Charge the battery for a minimum of 1 hour at 6 to 10 A. Servicing the Fuses Note: Do not overcharge the battery. 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. When the battery is fully charged, unplug the charger from the electrical outlet, then disconnect the charger leads from the battery posts (Figure 54).
Drive System Maintenance Releasing the Electric Brake Checking the Tire Pressure You can manually release the electric brake by 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 key to the 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 56).
Belt Maintenance Replacing the Mower-Deck 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. 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.
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 59 and Figure 60). 9. Tighten the bottom 2 bolts for the mower-deck curtain to the mower deck. Refer to Releasing the Mower-Deck Curtain (page 36). 10. Mower Maintenance Servicing the Cutting Blades To ensure a superior quality of cut, keep the blades sharp. For convenient sharpening and replacement, keep extra blades on hand. Install the pulley covers.
g006530 Figure 61 1. Cutting edge 3. Wear/slot forming 2. Curved area 4. Crack g014973 Figure 63 1. Blade (in position for measuring) Checking for Bent Blades 2. Level surface 3. Measured distance between blade and the surface (A) Note: The machine must be on a level surface for the following procedure. 4. 1. Raise the mower deck to the highest height-of-cut position. 2.
g014973 Figure 65 g027833 1. Opposite blade edge (in position for measuring) Figure 66 2. Level surface 3. Second measured distance between blade and surface (B) A. 1. Sail area of the blade 2. Blade 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 50) and Installing the Blades (page 51). Sharpening the Blades 1.
Installing the Blades 1. Install the blade onto the spindle shaft (Figure 66). Important: The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting. 2. Install the curved washer (cupped side toward the blade) and the blade bolt (Figure 66). 3. Torque the blade bolt to 47 to 88 N∙m (35 to 65 ft-lb).
g009658 Figure 72 Mower Decks with 2 Blades 1. Blades front to rear 2. Measure from the tip of the blade to the flat surface here. g027588 Figure 71 1. Hanger bracket 3. Rear nut 2. Side locking nut 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 52). g009659 Figure 73 Mower Decks with 3 Blades 1.
g014634 Figure 74 1. Adjusting rod 3. Locknut 2. Adjusting block g014635 7. Figure 75 To raise the front of the mower, tighten the adjustment nut. 1. Front support rod 3. Deck bracket 8. To lower the front of the mower, loosen the adjustment nut. 2. Locking nut 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 mm (1/16 to 5/16 inch) lower than the rear blade tip (Figure 72 and Figure 73). 6.
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, 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. Slide the mower under the machine. 4. Lower the height-of-cut lever to the lowest position. 5.
Cleaning 8. Note: If the mower is not clean after 1 washing, Washing the Underside of the Mower Deck soak it and let it stand for 30 minutes. Then, repeat the process. 9. Service Interval: After each use—Clean the mower-deck housing. Important: You can wash the machine with a mild detergent and water. Do not pressure wash the machine. Avoid excessive use of water, especially near the control panel, under the seat, around the engine, hydraulic pumps, and motors.
Storage the stabilizer manufacturer. Do not use an alcohol-based stabilizer (ethanol or methanol). Storage Safety Note: A fuel stabilizer/conditioner is most • Let the engine cool before storing the machine. • Do not store the machine or fuel near flames or effective when mixed with fresh fuel and used at all times. drain the fuel indoors. Cleaning and Storage 1. Disengage the blade-control switch (PTO), and engage the parking brake. 2.
Storing the Battery 1. Fully charge the battery. 2. Let the battery rest for 24 hours, then check the battery voltage. Note: If the battery voltage is below 12.6 V, repeat steps 1 and 2. 3. Disconnect the cables from the battery. 4. Check the voltage periodically to ensure 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.
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 g028022 Electrical Diagram (Rev.
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