Form No. 3449-794 Rev A TimeCutter® ZS 4200S Riding Mower Model No. 74683—Serial No. 400000000 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. Gross or Net Torque: The gross or net torque of this engine was laboratory rated by the engine manufacturer in accordance with the Society of Automotive Engineers (SAE) J1940 or J2723. As configured to meet safety, emission, and operating requirements, the actual engine torque on this class of mower will be significantly lower.
Contents Electrical System Safety ................................... 37 Servicing the Battery......................................... 37 Servicing the Fuses .......................................... 38 Drive System Maintenance .................................. 39 Checking the Tire Pressure............................... 39 Releasing the Electric Brake ............................. 39 Adjusting the Tracking ...................................... 39 Belt Maintenance ......................................
Safety This machine has been designed in accordance with EN ISO 5395:2013. General Safety This product is capable of amputating hands and feet and of throwing objects. Always follow all safety instructions to avoid serious personal injury or death. • Read and understand the contents of this Operator’s Manual before starting the engine. • Keep bystanders and children away. • Do not allow children or untrained people to operate or service the machine.
Slope Indicator g011841 Figure 3 You may copy this page for personal use. 1. The maximum slope you can operate the machine on is 15 degrees. Use the slope chart to determine the degree of slope of hills before operating. Do not operate this machine on a slope greater than 15 degrees. Fold along the appropriate line to match the recommended slope. 2. Align this edge with a vertical surface, a tree, building, fence pole, etc. 3.
Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or missing. decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery. 1. Explosion hazard 6. Keep bystanders away from the battery. 2. No fire, open flame, or smoking 7. Wear eye protection; explosive gases can cause blindness and other injuries. 3. Caustic liquid/chemical burn hazard 4.
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 deflector—do not operate the machine with an open deck; use a bagger or a deflector. 4. Entanglement hazard—keep away from moving parts; keep all guards and shields in place. Decal 138-6074 is molded into the fuel tank. decal139-2388 139-2388 1. Slow 2. Hauling 3. Fast decal138-2456 138-6074 1.
decal140-2716 140-2716 1. Choke 2. Fast 3. Slow decal144-5288 144-5288 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 the conditions on that day and at that site.
Product Overview g378562 Figure 4 1. Engine 4. Motion-control levers 7. Deflector 2. Operator seat 5. Rear drive wheel 8. Smart Speed™ lever 3. Fuel-tank cap 6. Front caster wheels 9. Height-of-cut lever 9 10.
Controls Motion-Control Levers Become familiar with all the controls before you start the engine and operate the machine. Use the motion-control levers to drive the machine forward, reverse, and turn either direction (Figure 4). Control Panel Park Position Move the motion-control levers outward from the center to the PARK position when exiting the machine to engage the electric brake (Figure 24).
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 28). Note: Determine the left and right sides of the machine from the normal operating position.
Adding Fuel Fuel Safety • Fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. Recommended Fuel – To prevent a static charge from igniting the fuel, remove the machine from the truck or trailer and refuel it on the ground, away from all vehicles.
Understanding the Safety-Interlock System The safety-interlock system is designed to prevent the engine from starting unless: • The blade-control switch (PTO) is disengaged. • The motion-control levers are in the PARK position. The safety-interlock system also is designed to shut off the engine whenever the control levers are out of the PARK position and you rise from the seat. Testing the Safety-Interlock System Test the safety-interlock system before you use the machine each time.
Positioning the Seat Adjusting the Tilt The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable (Figure 8). You can adjust the motion-control levers forward or rearward for your comfort. 1. Loosen the upper bolt holding the control lever to the control-arm shaft. 2. Loosen the lower bolt just enough to pivot the control lever forward or rearward.
Removing the Discharge Cover for Side-Discharging Installing the Discharge Cover for Mulching 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and move the motion-control levers outward to the PARK position. 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and move the motion-control levers outward to the PARK position. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
• Do not mow with the discharge deflector • • • • g297786 • Figure 15 1. Deflector 2. Latch 6. 3. Pivot rod 4. Discharge cover • Secure the discharge cover to the deck by hooking the flexible latch on the discharge cover into the retainer on the deck (Figure 11). During Operation During Operation Safety • General Safety • The owner/operator can prevent and is responsible • • for accidents that may cause personal injury or property damage.
• Clean grass and debris from the cutting unit, • • • • • • • • • machine could suddenly roll over if a wheel goes over the edge or the edge collapses. Keep a safe 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. drives, muffler, and engine to help prevent fires. Start the engine with your feet well away from the blades. Be aware of the mower discharge path and direct the discharge away from others.
Towing Safety Operating the Mower Blade-Control Switch (PTO) • Do not attach towed equipment except at the hitch point. The blade-control switch (PTO) starts and stops the mower blades and any powered attachments. • Do not use the machine as a towing vehicle unless it has a hitch installed. • Do not exceed the weight limits for towed Engaging the Blade-Control Switch (PTO) equipment and towing on slopes. The towed weight must not exceed the weight of the machine and operator.
Operating the Throttle Starting the Engine You can move the throttle control between the FAST and SLOW positions (Figure 21). 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 1 minute before operating the engine starter again. Always use the FAST position when engaging the PTO.
Driving the Machine Shutting Off the Engine 1. Disengage the blades by moving the blade-control switch to the OFF position (Figure 23). 2. Move the motion-control levers outward to the PARK position. 3. Move the throttle control to the FAST position. 4. Turn the key to the OFF position and remove the key. 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.
Driving Backward To change speeds, do the following: Note: Always use caution when backing up and 1. Move the motion-control levers to neutral and outward to the PARK position. turning. 1. Move the levers to the center, unlocked position. 2. Disengage the blade-control switch. 2. To go backward, slowly pull the motion-control levers rearward (Figure 26). 3. Adjust the lever to the desired position. The following are only recommendations for use.
Using the Side Discharge Adjusting the Height of Cut The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. Note: The transport position is the highest height-of-cut position or cutting height at 114 mm (4-1/2 inches) as shown in Figure 28. You can adjust the height of cut from 38 to 114 mm (1-1/2 to 4-1/2 inches) in 13 mm (1/2 inch) increments. The height of cut is controlled by the lever located to the right of the operating position (Figure 28).
Adjusting the Anti-Scalp Rollers Operating Tips Maximizing Air Circulation Whenever you change the height of cut, adjust the height of the anti-scalp rollers. For best mowing and maximum air circulation, operate the engine at the FAST position. Air is required to thoroughly cut grass clippings, so do not set the height-of-cut so low as to totally surround the mower deck in uncut grass. Always try to have 1 side of the mower deck free from uncut grass, which allows air to be drawn into the mower deck.
Stopping the Machine After Operation If you must stop the forward motion of the machine while mowing, a clump of grass clippings may drop onto your lawn. To avoid this, move onto a previously cut area with the blades engaged or you can disengage the mower deck while moving forward. After Operation Safety General Safety • Shut off the engine, remove the key, and wait Keeping the Underside of the Mower Deck Clean for all moving parts to stop before leaving the operator’s position.
Pushing the Machine by Hand This machine has an electric-brake mechanism, and to push the machine, the key must be in the RUN position. The battery needs to be charged and functioning to disengage the electric brake. 1. Park the machine on a level surface, disengage the blade-control switch, and move the motion-control levers outward to the PARK position. 2. Shut off the engine and wait for all moving parts to stop before leaving the operating position. 3.
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 you are 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 31). 4. Back the machine up the ramp (Figure 32). g027995 Figure 32 1. Back the machine up the ramp. 2. Drive the machine forward down the ramp. 5.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Maintenance Safety • If you leave the key in the switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the switch before you perform any maintenance. • Before you leave the operator’s position, do the following: – Park the machine on a level surface. – Disengage the drives. – Engage the parking brake. – Shut off the engine and remove the key.
Recommended Maintenance Schedule(s) Maintenance Service Interval Before each use or daily Maintenance Procedure • • • • • Check the safety-interlock system. Check the engine-oil level. Clean the cooling system (more often in dusty, dirty conditions). Inspect the blades. Inspect the grass deflector for damage. After each use • Clean grass and debris from the cutting unit, muffler, drives, grass catcher, and engine. • Clean the mower-deck housing.
Pre-Maintenance Procedures Raising the Machine Use jackstands to support the machine when you raise it. Releasing the Mower-Deck Curtain WARNING Supporting the machine on the lower muffler shield (Figure 35) may damage the shield and cause the machine to fall, injuring you or bystanders. Loosen the 2 bottom bolts of the curtain to access the top of the mower deck (Figure 34). Do not use the lower muffler shield to lift or support the machine. g295619 Figure 34 1. Bottom bolt 2.
Lubrication Engine Maintenance Greasing the Bearings Engine Safety • Keep your hands, feet, face, other body parts, Service Interval: Every 25 hours—Grease the caster wheel bearings (more often in sandy soil conditions). • Grease Type: No. 2 lithium grease 1. and clothing away from the muffler and other hot surfaces. Allow engine components to cool before performing maintenance. Do not change the engine governor speed or overspeed the engine.
5. Installing the Air Cleaner Lift the end of the filter and remove it from the air intake. 1. Install the foam pre-cleaner element over the paper element. Note: Ensure that you do not damage the elements. 2. Install the air-cleaner elements onto the air-cleaner base. 3. Install the cover and secure it with the latches (Figure 37). Servicing the Engine Oil Engine-Oil Specifications g374187 Figure 38 6.
g373547 Figure 42 g373146 Figure 41 5. Note: Ensure that the oil-filter gasket touches Changing the Engine Oil and Oil Filter the engine and then turn the filter an extra 3/4 turn. Service Interval: Every 100 hours or 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.
g373565 Figure 44 7. Dispose of the used oil at a recycling center. g373564 Figure 43 6. Servicing the Spark Plug Service Interval: Yearly—Change the spark plug(s). 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 44). Ensure that the air gap between the center and side electrodes is correct before installing the spark plug.
Cleaning the Cooling System 1. Park the machine on a level surface, disengage the blade-control switch, and move the motion-control levers outward to the PARK position. 2. 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. Checking the Spark Plug 4. Remove the engine shroud. Important: Do not clean the spark plug(s).
Fuel System Maintenance DANGER g374198 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. Refer to Fuel Safety (page 12) for a complete list of fuel related precautions. Replacing the In-Line Fuel Filter Service Interval: Yearly—Replace the in-line fuel filter. Never install a dirty filter after removing it from the fuel line. 1.
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 cable from the negative terminal of • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. the battery before repairing the machine.
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 37). Fuse type: Charge the battery for a minimum of 1 hour at 6 to 10 A.
Drive System Maintenance Checking the Tire Pressure Service Interval: Every 25 hours—Check tire pressure. 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 52). Check the tires when they are cold to get the most accurate pressure reading. g294417 Figure 53 1. Brake-link arm on the electric brake control module 2.
Belt Maintenance Inspecting the Belts Service Interval: Every 25 hours—Check the belts for wear or cracks. Replace the belt if it is worn. The signs of a worn belt include squealing while the belt is rotating; the blades slipping while cutting grass; and frayed edges, burn marks, and cracks on the belt. 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.
8. Route the new belt around the engine pulley and mower pulleys (Figure 57). 9. Using a spring-removal tool (Toro Part No. 92-5771), install the idler spring over the deck hook and place tension on the idler pulley and the mower belt (Figure 57). 10. Tighten the nut securing the wire form to the idler pulley . Note: Position the wire form against the idler arm as shown in Figure 56. g336421 Figure 56 3. Idler pulley 1. Wire form 2. Nut 7. Using a spring-removal tool (Toro Part No.
Mower Maintenance Blade Safety • 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. Only replace or sharpen the blades; never straighten or weld them. g006530 Figure 58 • On multi-bladed machines, take care as rotating one blade can cause other blades to rotate. 1. Cutting edge 3. Wear/slot forming 2. Curved area 4.
g014973 g014973 Figure 60 Figure 62 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 61). A.
Installing the Blades 1. Install the blade onto the spindle shaft (Figure 63). Important: The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting. g027833 3. Curved washer 4. Blade bolt 3. Torque the blade bolt to 81 to 108 N∙m (60 to 80 ft-lb). Check to ensure that the mower deck is level any time you install the mower or when you see an uneven cut on your lawn.
g294044 g294046 Figure 66 1. Blades side to side Figure 67 3. Measure from the tip of the blade to the flat surface here. 1. Blades front to rear 2. Outside cutting edges 2. Outside cutting edges Checking the Front-to-Rear Blade Slope Leveling from Side to Side Check the front-to-rear blade level any time you install the mower. If the front of the mower is more than 7.9 mm (5/16 inch) lower than the rear of the mower, adjust the blade level. 1.
g294195 Figure 70 g294196 Figure 68 1. Wood block—6.6 cm (2-5/8 inches) thick 6. 2. Wood block—7.3 cm (2-7/8 inches) thick Remove the hairpin cotter and washer from the lower lift-arm pin (Figure 69). 8. Install the washer and hairpin cotter (Figure 70). 9. Repeat steps 6 through 8 for the other side of the machine. 10. Check the side-to-side level again; repeat this procedure until the measurements are correct. 11.
3. To lower the front of the mower deck, loosen the adjustment nut. 4. 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; refer to Checking the Front-to-Rear Blade Slope (page 45). 5. When the front-to-rear blade slope is correct, check the side-to-side level of the mower deck again; refer to Checking the Side-to-Side Level (page 44). Removing the Mower Deck 1.
8. Attach the front support rod to the mower deck with the clevis pin and hairpin cotter (Figure 72). 5. Slide the straight end of the rod through the rear grass deflector pivot. 9. Install the mower belt onto the engine pulley; refer to Replacing the Mower Belt (page 40). 6. Place the spring on the rod, with end wires down, and between the grass deflector brackets. 7. Slide the rod through the second grass-deflector pivot (Figure 74). 8.
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 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 Note: Run the machine with the blade-control switch (PTO) engaged and the engine at high idle for 2 to 5 minutes after washing. Storage Safety 12. Check the condition of the blades; refer to Servicing the Cutting Blades (page 42). 13. Prepare the machine for storage for over 30 days as follows: • Shut off the engine, remove the key, and wait for all moving parts to stop before you leave the operator’s position. Allow the machine to cool before adjusting, servicing, cleaning, or storing it.
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.
Troubleshooting Problem Possible Cause The fuel tank is showing signs of collapsing or the machine is frequently showing signs of running out of fuel. 1. The air-cleaner paper element clogged. The engine overheats. 1. The engine load is excessive. 1. Reduce the ground speed. 2. The oil level in the crankcase is low. 3. The cooling fins and air passages under the engine-blower housing are plugged. 4. The air cleaner is dirty. 2. Add oil to the crankcase. 3.
Problem The machine does not drive. The machine vibrates abnormally. The cutting height is uneven. The blades do not rotate. Possible Cause Corrective Action 1. The bypass valves are open. 1. Close the tow valves. 2. The traction belts are worn, loose, or broken. 3. The traction belts are off the pulleys. 4. The transmission has failed. 2. Contact an Authorized Service Dealer. 1. The cutting blade(s) is/are bent or unbalanced. 1. Install new cutting blade(s). 2. The blade mounting bolt is loose.
Schematics g307974 Electrical Diagram 139-2356 (Rev.
EEA/UK Privacy Notice Toro’s Use of Your Personal Information The Toro Company (“Toro”) respects your privacy. When you purchase our products, we may collect certain personal information about you, either directly from you or through your local Toro company or dealer.
