Form No. 3425-600 Rev A TimeCutter® ZS 3200S or ZS 4200S Riding Mower Model No. 74682—Serial No. 400000000 and Up Model No. 74684—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.
Contents This manual uses 2 words to highlight information. Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention. Safety ....................................................................... 4 Safety Alert Symbol ............................................ 4 General Safety ................................................... 5 Slope Indicator ................................................... 6 Safety and Instructional Decals ..
Safety Releasing the Electric Brake ............................. 43 Belt Maintenance ................................................ 43 Inspecting the Belts .......................................... 43 Replacing the Mower Belt ................................. 43 Mower Maintenance............................................. 45 Blade Safety ..................................................... 45 Servicing the Cutting Blades ............................. 45 Leveling the Mower Deck.......................
General 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. • Read, understand, and follow all instructions and warnings in the Operator’s Manual and other training material, on the machine, engine, and attachments. All operators and mechanics should be trained.
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 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.
decal119-8815 119-8815 1. Parking position 4. Neutral 2. Fast 3. Slow 5. Reverse decal120-5469 120-5469 1. Height of cut decal121-0771 121-0771 1. Choke 4. SLOW position 2. FAST position 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 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. Review the instructions for operating the machine on slopes in the Operator’s Manual as well as the conditions in which you would operate the machine to determine whether you can operate the machine in those 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 g020240 Figure 5 1. Footrest 5. Control panel 2. Height-of-cut lever 6. Operator seat 10. Engine 3. Motion-control lever 7. Rear drive wheel 11. Washout fitting 8. Fuel-tank cap 12. Mower deck 4. Smart SpeedTM lever 13. Front caster wheels 9. Deflector Controls Control Panel Become familiar with all the controls before you start the engine and operate the machine. g027890 Figure 6 Control Panel 1. Throttle/choke control 2. Key switch 12 3.
Key Switch Park Position The key switch, used to start and shut off the engine, has 3 positions: OFF, RUN, and START . Refer to Starting the Engine (page 24). 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. Throttle/Choke Control The throttle and choke controls are combined into 1 control lever.
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.
Adding Fuel 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. • Always place gasoline containers on the ground away from your vehicle before filling.
Using the Safety-Interlock System 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. 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.
Adjusting the Motion-Control Levers rise slightly from the seat; the engine should shut off. Positioning the Seat Adjusting the Height 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 higher or lower for maximum comfort (Figure 10). g027252 Figure 10 Adjusting the Tilt You can adjust the motion-control levers forward or rearward for your comfort.
Converting to Side Discharge Installing the Discharge Cover for Mulching 1. Machines with 81 cm (32-inch) Mower Decks 2. The mower deck and mower blades shipped with the machine were designed for optimum mulching and side-discharge performance. 3. Removing the Discharge Cover for Side Discharging 1. 2. 3. 4. 5. Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake.
5. Angle the metal tab on the discharge cover out of the slot in the bracket welded to the mower deck (Figure 13). g230249 Figure 15 5. g230250 Figure 13 1. Discharge cover On the top of the discharge cover, engage the hook-shaped latch around the pivot rod of the deflector assembly (Figure 16). 3. Bracket on the mower deck 2. Metal tab 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.
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.
Operating the Mower Operating the Throttle Blade-Control Switch (PTO) You can move the throttle control between FAST and SLOW positions (Figure 21). The blade-control switch (PTO) starts and stops the mower blades and any powered attachments. Always use the FAST position when engaging the PTO. Engaging the Blade-Control Switch (PTO) g187361 Figure 21 g008945 Figure 18 Note: Always engage the blades with the throttle in the FAST position (Figure 19).
Starting the Engine Shutting Off the Engine 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. Note: It may be necessary to hold the lever against the stop, in the choke position, while trying to start the engine (Figure 22). 1.
Driving the Machine 2. To go backward, slowly pull the motion-control levers rearward (Figure 25). 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. The throttle control regulates the engine speed as measured in rpm (revolutions per minute).
Using the Side Discharge The following are only recommendations for use. Adjustments vary by grass type, moisture content, and the height of the grass. Suggested uses: Trim Parking X Heavy, wet grass X Training X Trimming grass X Tow The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf.
Adjusting the Height of Cut Adjusting the Anti-Scalp Rollers Note: The transport position is the highest height-of-cut position or cutting height at 115 mm (4-1/2 inches) as shown in Figure 27. For Machines with 107 cm (42-inch) Mower Decks Height of cut is controlled by the lever located to the right of the operating position (Figure 27). 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 • Park machine on level ground, disengage drives, set parking brake, stop engine, remove key or disconnect spark plug wire. Wait for all movement to stop and allow the machine to cool before adjusting, cleaning, repairing, or storing. Never allow untrained personnel to service machine. g027708 Figure 29 1. Tie-down location • Secure a trailer to the towing vehicle with safety • Clean the machine as stated in the Maintenance chains. section.
on the down side of the slope and the ramp extends up the slope. This will minimize the ramp angle. 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.
and loss of control. Reduce the towed weight and slow down. • Stopping distance increases with the weight of the towed load. Travel slowly and allow extra distance to stop. • Make wide turns to keep the attachment clear of the machine. Pushing the Machine by Hand Important: Always push the machine by hand. Do not tow the machine, because towing may damage it. g017303 Figure 32 This machine has an electric-brake mechanism, and to push the machine, the ignition key must be in the RUN position.
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. Clean and check the air-cleaner foam element. Check the engine-oil level. Inspect the blades. Inspect the grass deflector for damage. After each use • Clean the mower-deck housing.
• Park machine on level ground, disengage drives, set parking brake, stop engine, remove key or disconnect spark plug wire. Wait for all movement to stop and allow the machine to cool before adjusting, cleaning or repairing. Never allow untrained personnel to service machine. • Disconnect battery or remove spark plug wire before making any repairs. Disconnect the negative terminal first and the positive last. Reconnect positive first and negative last.
Pre-Maintenance Procedures Lubrication Raising the Seat Service Interval: Every 25 hours—Grease all the lubrication points. Ensure that the parking brake is engaged. Lift the seat forward. Grease Type: No. 2 lithium grease Greasing the Bearings You can access following components by raising the seat: • Serial plate 1. Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake; refer to Park Position (page 13). 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. Servicing the Air Cleaner Note: Service the air cleaner more frequently (every g233265 Figure 37 few hours) if operating conditions are extremely dusty or sandy. 1. Foam element Removing the Foam and Paper Elements 6. 1.
1. Install the foam filter onto the paper filter (Figure 37). 2. Install the foam and paper filter onto the air-cleaner housing. 3. Install the air-cleaner cover, and tighten the 2 knobs (Figure 36). Servicing the Engine Oil Engine-Oil Specifications Oil Type: Detergent oil (API service SF, SG, SH, SJ, or higher) Crankcase Capacity: 1.4 L (47 fl oz) with oil filter Viscosity: See the table below.
g027477 Figure 41 6. g029369 Figure 40 5. Change the engine-oil filter (Figure 41). Note: Ensure the oil-filter gasket touches the engine, and then turn the filter an extra 3/4 turn. 37 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).
Servicing the Spark Plug Service Interval: Every 50 hours—Check the spark plug. Every 100 hours—Replace the spark plug. Ensure 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 and a gapping tool or feeler gauge to check and adjust the air gap. Install a new spark plug if necessary. Type: Champion® RC12YC, Autolite® 3924, or NGK® BCPR6ES Air Gap: 0.75 mm (0.
Fuel System Maintenance DANGER In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. g206628 Figure 44 Refer to Adding Fuel (page 16) for a complete list of fuel related precautions. Installing the Spark Plug Replacing the In-Line Fuel Filter Service Interval: Every 100 hours/Yearly (whichever comes first)—Check the in-line fuel filter.
Electrical System Maintenance Electrical System Safety • Disconnect the battery before repairing the g027506 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.
2. 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. Charge the battery for a minimum of 1 hour at 6 to 10 A. Note: Do not overcharge the battery. 3. • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable.
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 (30 A, blade-type) Service Interval: Every 25 hours—Check tire pressure. • Charge Circuit—F2 (25 A, blade-type) 1. Maintain the air pressure in the front and rear tires as specified. Uneven tire pressure can cause an uneven cut.
Belt Maintenance Releasing the Electric Brake Inspecting the Belts 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 the belts for wear or cracks. 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 34). 3.
WARNING The spring is under tension when installed and can cause personal injury. Be careful when removing the belt. g014930 Figure 54 Mower Decks with 2 Blades 1. Idler pulley 4. Spring 2. Mower belt 5. Engine pulley 3. Outside pulley 6. Spring-removal tool 7. Route the new belt around the engine pulley and mower pulleys (Figure 53 and Figure 54). 8. Using a spring-removal tool (Toro Part No.
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.
2. Check the balance of the blade by putting it on a blade balancer (Figure 63). Note: If the blade stays in a horizontal position, the blade is balanced and can be used. Note: If the blade is not balanced, file some metal off the end of the sail area only (Figure 62). g000551 Figure 60 81 cm (32-Inch) Decks g000553 Figure 63 4. Blade bolt 5. Blade stiffener 1. Sail area of the blade 2. Blade 3. Curved washer 1. Blade 3. 2. Balancer Repeat this procedure until the blade is balanced.
Leveling the Mower Deck Check to ensure that the mower deck is level whenever you install the mower 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 first, then adjust the front to rear slope. Requirements: g009682 Figure 65 Mower Decks with 2 Blades • The machine must be on a level surface.
g014631 Figure 67 Mower Decks with 1 Blade g027588 Figure 66 1. Hanger bracket 1. Blade front to rear 2. Measure from the tip of the blade to the flat surface here. 3. Rear locking 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 49).
Removing 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. 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. Refer to Releasing the Mower-Deck Curtain (page 34). 5.
Replacing the Grass Deflector Service Interval: Before each use or daily—Inspect the grass deflector for damage. WARNING An uncovered discharge opening could allow the machine to throw objects toward you or bystanders, resulting in serious injury. Also, contact with the blade could occur. Never operate the machine without the grass deflector, the discharge cover, or the grass-collection system in place. g015338 Figure 71 1. Mower deck 2. Hanger bracket 1. 3. Rear lift rod 8.
Cleaning Washing the Underside of the Mower Deck 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. Wash the underside of the mower deck after each use to prevent grass buildup for improved mulch action and clipping dispersal.
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 an alcohol-based stabilizer (ethanol or methanol). Note: A fuel stabilizer/conditioner is most effective when mixed with fresh fuel and used at all times. B. C. 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, Run the engine to distribute conditioned fuel through the fuel system (5 minutes). repeat steps 1 and 2. Shut off the engine, allow it to cool, and drain the fuel tank. D.
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.
Notes:
Notes:
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