Form No. 3449-683 Rev A TimeCutter® ZS 4200S Riding Mower Model No. 74685—Serial No. 410150000 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.
Using the Smart SpeedTM Control System.......................................................... 21 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 Cleaning the Machine .
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.
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 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 to engage the electric brake (Figure 25).
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 5). 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 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.
Installing the Discharge Cover for Mulching g293897 Figure 12 1. Latch retainer 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. Angle the metal tab on the discharge cover into the slot in the bracket welded to the mower deck (Figure 14). 3. Discharge cover 2. Latch 4.
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 Starting the Engine You can move the throttle control between the FAST and SLOW positions (Figure 22). 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. 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 24). 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 27). 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 29. 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 29).
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 Clean clippings and dirt from the underside of the mower deck after each use.
4. Important: Always push the machine by hand. Do not tow the machine, because towing may damage it. Move both bypass levers forward through the slotted hole and down to lock them in place (Figure 31). 7. Move the motion-control levers outward to the PARK position. Contact with hot surfaces may cause personal injury. 8. Turn the key to the OFF position and remove it to avoid draining the battery charge.
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 32). 4. Back the machine up the ramp (Figure 33). g027995 Figure 33 1. Back the machine up the ramp. 5. Shut off the engine, remove the key, and move the motion-control levers outward to the PARK position. 6.
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 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 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 36) 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 35). Do not use the lower muffler shield to lift or support the machine. g295619 Figure 35 1. Bottom bolt 2.
Lubrication Engine Maintenance Greasing the Bearings Engine Safety Service Interval: Every 25 hours—Grease the caster wheel bearings (more often in sandy soil conditions). • Keep your hands, feet, face, other body parts, and clothing away from the muffler and other hot surfaces. Allow engine components to cool before performing maintenance. Grease Type: No. 2 lithium grease 1.
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 39). 2. Install the foam and paper filter onto the air-cleaner housing. 3. Install the air-cleaner cover, and tighten the 2 knobs (Figure 38). g233265 Figure 39 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 41). g311705 Figure 41 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 44 g027477 Figure 43 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 44). 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 46 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 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 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 52).
3. Belt Maintenance Locate the tracking-adjustment bolt near the motion-control lever on the particular side that needs adjusting (Figure 54). 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 57 1. Cutting edge 3. Wear/slot forming 2. Curved area 4. Crack g014973 Figure 59 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 61 g027833 1. Opposite blade edge (in position for measuring) Figure 62 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 Battery (page 37). Sharpening the Blades 1.
Installing the Blades 1. Install the blade onto the spindle shaft (Figure 62). 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 62). 3. Torque the blade bolt to 81 to 108 N∙m (60 to 80 ft-lb). g294044 Leveling the Mower Deck Figure 65 1.
g294046 Figure 66 1. Blades front to rear 3. Measure from the tip of the blade to the flat surface here. g294196 Figure 67 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.
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 43). 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 43).
8. Attach the front support rod to the mower deck with the clevis pin and hairpin cotter (Figure 71). 9. Install the mower belt onto the engine pulley; refer to Replacing the Mower Belt (page 39). 10. Tighten the bottom 2 bolts for the mower-deck curtain to the mower deck; refer to Releasing the Mower-Deck Curtain (page 29). Replacing the Grass Deflector Service Interval: Before each use or daily—Inspect the grass deflector for damage.
3. Remove the damaged or worn grass deflector and the baffle. Cleaning 4. Install the new grass deflector and the baffle (Figure 73). 5. Slide the rod, straight end, through the rear grass deflector pivot and baffle. Washing the Underside of the Mower Deck 6. Place the spring on the rod, with end wires down, and between the grass deflector pivots. 7. Slide the rod through the baffle and second grass-deflector pivot(Figure 73). 8.
8. Turn the water off and remove the coupling from the washout fitting. Storage Note: If the mower is not clean after 1 washing, Storage Safety soak it and let it stand for 30 minutes. Then repeat the process. 9. • 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. Run the mower again for 1 to 3 minutes to remove excess water.
Storing the Battery Note: Run the machine with the blade-control switch (PTO) engaged and the engine at high idle for 2 to 5 minutes after washing. 12. Check the condition of the blades; refer to Servicing the Cutting Blades (page 40). 13. Prepare the machine for storage for over 30 days as follows: A. Run the engine to distribute conditioned fuel through the fuel system for 5 minutes. C.
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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