Form No. 3433-604 Rev D TimeCutter® ZS 4200S Riding Mower Model No. 74685—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. Using this product for purposes other than its intended use could prove dangerous to you and bystanders.
information and Note emphasizes general information worthy of special attention. Using the Side Discharge ................................. 22 Adjusting the Height of Cut ............................... 22 Adjusting the Anti-Scalp Rollers........................ 23 Operating Tips ................................................. 23 After Operation .................................................... 24 After Operation Safety ...................................... 24 Pushing the Machine by Hand ............
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 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 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.
decal139-2394 139-2394 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. 1. Traction controls 2. Fast 3. Slow 4. Neutral 5. Reverse 6.
decal140-2748 140-2748 decal135-3295 135-3295 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 g295991 Figure 5 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 5). Control Panel Park Position Move the motion-control levers outward from the center to the PARK position when exiting the machine (Figure 24). Always position the motion-control levers into the PARK position when you stop the machine or leave it unattended.
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.
Fuel Safety compartment to help prevent fires. Clean up oil or fuel spills. • Fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. Adding Fuel – To prevent a static charge from igniting the fuel, place the container and/or machine directly on the ground before filling, not in a vehicle or on an object. Recommended Fuel – Fill the fuel tank outdoors on level ground, in an open area, and when the engine is cold.
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 9). 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. g333846 Figure 11 g027249 Figure 9 Adjusting the Motion-Control Levers 3.
g230248 Figure 14 g293897 1. Discharge cover Figure 12 1. Latch retainer 3. Discharge cover 3. Bracket on the mower deck 2. Metal tab 2. Latch 4. 4. Release the hook-shaped latch on top of the discharge cover from the pivot rod (Figure 16). 5. Angle the metal tab on the discharge cover out of the slot in the bracket welded to the mower deck (Figure 13). Pivot the discharge cover back and toward the deck so that the discharge cover aligns with the mower deck (Figure 15). g230249 Figure 15 5.
During Operation During Operation Safety General Safety • The owner/operator can prevent and is responsible • • g297786 • Figure 16 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 12). • • • • • • • • • 16 for accidents that may cause personal injury or property damage. Use your full attention while operating the machine.
• Before backing up or turning the machine, look – Shut off the engine and remove the key. down and all around for small children. – Wait for all moving parts to stop. • Do not carry children on the machine, even when • Operate the engine only in well-ventilated areas. the blades are not moving. Children could fall off and be seriously injured or prevent you from safely operating the machine.
Operating the Mower Blade-Control Switch (PTO) • Use extra care while operating with accessories or • attachments, such as grass-collection systems. These can change the stability of the machine and cause a loss of control. Follow directions for counterweights. If possible, keep the deck lowered to the ground while operating on slopes. Raising the deck while operating on slopes can cause the machine to become unstable.
Operating the Throttle You can move the throttle control between the FAST and SLOW positions (Figure 22). Always use the FAST position when engaging the PTO. g296056 Figure 22 Starting 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.
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 1. Move the levers to the center, unlocked position. 2. To go backward, slowly pull the motion-control levers rearward (Figure 26). 2. Disengage the blade-control switch. 3. Adjust the lever to the desired position. The following are only recommendations for use. Adjustments vary by grass type, moisture content, and the height of the grass.
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 Using the Fast Throttle Setting 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.
After Operation 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 Keeping the Underside of the Mower Deck Clean General Safety Clean clippings and dirt from the underside of the mower deck after each use. If grass and dirt build up inside the mower deck, cutting quality will eventually become unsatisfactory.
5. Transporting the Machine Turn the ignition key on and disengage the parking brake by moving 1 motion-control lever out of the PARK position. 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.
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 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. 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. Maintenance Safety • Never tamper with safety devices. Check their proper operation regularly. • 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.
Maintenance Service Interval Maintenance Procedure Every 200 hours • Replace the in-line fuel filter. Every 300 hours • Check and adjust the valve clearance. Contact an Authorized Service Dealer. Before storage • Charge the battery and disconnect the battery cables. • Perform all maintenance procedures listed above before storage. • Paint any chipped surfaces. CAUTION If you leave the key in the switch, someone could accidently start the engine and seriously injure you or other bystanders.
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 Service Interval: Every 25 hours—Grease the caster wheel bearings. • Keep your hands, feet, face, clothing, and other body parts away from the muffler and other hot surfaces. Allow engine components to cool before performing maintenance. Grease Type: No. 2 lithium grease 1. 2. 3. Park the machine on a level surface, disengage the blade-control switch, and move the motion-control levers outward to the PARK position.
Installing the Foam and Paper Elements Important: To prevent engine damage, always operate the engine with the complete foam and paper air cleaner assembly installed. 1. Install the foam filter onto the paper filter (Figure 38). 2. Install the foam and paper filter onto the air-cleaner housing. 3. Install the air-cleaner cover, and tighten the 2 knobs (Figure 37). g233265 Figure 38 1. Foam element 6. Servicing the Engine Oil 2.
3. To keep dirt, grass clippings, etc., out of the engine, clean the area around the oil-fill cap and dipstick before removing it (Figure 40). g311705 Figure 40 Changing the Engine Oil and Filter Service Interval: After the first 5 hours Every 100 hours (more often under a heavy load or in high temperatures). Every 100 hours (more often in dirty or dusty conditions). 1. Park the machine so that the drain side is slightly lower than the opposite side to ensure that the oil drains completely. 2.
g235264 Figure 43 g027477 Figure 42 6. 7. 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 43). 33 Dispose of the used oil at a recycling center.
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. g206628 Figure 45 Installing the Spark Plug Type: Champion® RC12YC or Autolite® 3924 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. g027506 Refer to Fuel Safety (page 12) for a complete list of fuel related precautions. Replacing the In-Line Fuel Filter Service Interval: Every 100 hours or yearly, whichever comes first—Check the in-line fuel filter. Every 200 hours/Every 2 years (whichever comes first)—Replace the in-line fuel filter.
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.
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 36). Fuse type: Charge the battery for a minimum of 1 hour at 6 to 10 A.
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 51).
3. Belt Maintenance Locate the tracking-adjustment bolt near the motion-control lever on the particular side that needs adjusting (Figure 53). Inspecting the Belts Note: Raise the seat for easier access to the adjustment bolt. 4. Service Interval: Every 25 hours—Check the belts for wear or cracks. Rotate the bolt to decrease the speed for that particular wheel. Replace the belt if it is worn.
Mower Maintenance WARNING The spring is under tension when installed and can cause personal injury. Blade Safety Be careful when removing the belt. • 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. • On multi-bladed machines, take care as rotating one blade can cause other blades to rotate.
g006530 Figure 56 1. Cutting edge 3. Wear/slot forming 2. Curved area 4. Crack g014973 Figure 58 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 60 g027833 1. Opposite blade edge (in position for measuring) Figure 61 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 42) and Installing the Blades (page 43). Sharpening the Blades 1.
Installing the Blades 1. Install the blade onto the spindle shaft (Figure 61). 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 61). 3. Torque the blade bolt to 81 to 108 N∙m (60 to 80 ft-lb). g294044 Leveling the Mower Deck Figure 64 1.
g294046 Figure 65 1. Blades front to rear 3. Measure from the tip of the blade to the flat surface here. g294196 Figure 66 1. Wood block—6.6 cm (2-5/8 inches) thick 2. Outside cutting edges 6. Leveling from Side to Side 1. Move to the left side of the machine. 2. Set the anti-scalp rollers to the top holes or remove them completely for this procedure; refer to Adjusting the Anti-Scalp Rollers (page 23). 3.
g294195 Figure 68 8. Install the washer and hairpin cotter (Figure 68). 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. Continue leveling the mower deck by checking the front-to-rear blade slope; refer to Checking the Front-to-Rear Blade Slope (page 43). Adjusting the Front-to-Rear Blade Slope 1. Rotate the adjustment nut in the front of the mower (Figure 69).
Removing the Mower Deck 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. 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 29). 5.
8. Attach the front support rod to the mower deck with the clevis pin and hairpin cotter (Figure 70). 3. Remove the damaged or worn grass deflector and the baffle. 9. Install the mower belt onto the engine pulley; refer to Replacing the Mower Belt (page 39). 4. Install the new grass deflector and the baffle (Figure 72). 10. Tighten the bottom 2 bolts for the mower-deck curtain to the mower deck; refer to Releasing the Mower-Deck Curtain (page 29). 5.
Cleaning 7. Disengage the blade-control switch, shut off the engine, remove the key, and wait for all moving parts to stop. Washing the Underside of the Mower Deck 8. Turn the water off and remove the coupling from the washout fitting. Note: If the mower is not clean after 1 washing, Service Interval: After each use—Clean the mower-deck housing. soak it and let it stand for 30 minutes. Then repeat the process. 9. Important: You can wash the machine with a mild detergent and water.
Storage 11. Check the condition of the blades; refer to Servicing the Cutting Blades (page 40). Storage Safety 12. 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. A. Add fuel stabilizer/conditioner to fresh fuel in the tank. Follow mixing instructions from the fuel stabilizer manufacturer.
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 g307974 Electrical Diagram—139–2356 (Rev.
Notes:
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