Form No. 3425-565 Rev A TimeCutter® ZS 4200T or ZS 5000 Riding Mower Model No. 74686—Serial No. 400000000 and Up Model No. 74688—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 Checking the Tire Pressure............................... 48 Releasing the Electric Brake ............................. 49 Belt Maintenance ................................................ 49 Inspecting the Belts .......................................... 49 Replacing the Mower-Deck Belt........................ 49 Mower Maintenance............................................. 51 Blade Safety ..................................................... 51 Servicing the Cutting Blades .......................
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.
decal106-8717 106-8717 decal119-8815 1. Read the instructions before servicing or performing maintenance. 2. Check tire pressure every 25 operating hours. 119-8815 3. Grease every 25 operating hours. 4. Engine 1. Parking position 4. Neutral 2. Fast 3. Slow 5. Reverse decal112-9840 112-9840 For Models with 127 cm (50 inch) Decks 1. Read the Operator's Manual. 3. Remove the key and read the instructions before servicing or performing maintenance. 2.
decal120-5470 120-5470 For Models with 127 cm (50 inch) Decks 1.
decal121-0772 121-0772 For Models with 107 cm (42 inch) Decks 1. Fast 2. Continuous-variable setting 4. Choke 5. Power takeoff (PTO), blade-control switch 3.
decal121-0773 121-0773 For Models with 127 cm (50 inch) Decks 1. Fast 2. Continuous-variable setting 4. Choke 5. Power takeoff (PTO), blade-control switch 3.
decal121-2989b 121-2989 1. Bypass lever position for pushing the machine 2. Bypass lever position for operating the machine decal131-1097 131-1097 1. Oil drain 131-3948 decal131-3948 131-3948 1. Slow 2. Towing 3.
decal132-0869 132-0869 Note: This machine complies with the industry standard stability test in the static lateral and longitudinal tests with the maximum recommended slope indicated on the decal. 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 g027829 Figure 5 1. Height-of-cut lever 5. Mower deck 9. Fuel-tank cap 2. Motion-control levers 6. Anti-scalp roller 10. Engine 3. Operator seat 7. Front caster wheels 11. Control panel 4. Smart Speed™ lever 8. Footrest 12. Deflector 13. Rear drive wheel 14. Engine guard Controls Key Switch Become familiar with all the controls before you start the engine and operate the machine. The key switch, used to start and shut off the engine, has 3 positions: OFF, RUN, and START .
Motion-Control Levers Height-of-Cut Lever Use the motion-control levers to drive the machine forward, reverse, and turn either direction (Figure 5). Use the height-of-cut lever to lower and raise the deck from the seated position. Moving the lever up (toward you) raises the deck from the ground and moving the lever down (away from you) lowers the deck toward the ground. Adjust the height-of-cut only while the machine is not moving (Figure 30).
Operation Pre-Start Note: Determine the left and right sides of the Fill fuel tank on level ground. See Fuel Recommendations in the Specifications section for additional gasoline information. machine from the normal operating position. Do Not add oil to gasoline. Before Operation 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. Overfilling may result in fuel leakage or damage to the engine or emission system.
Fuel Safety 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.
Adding Fuel Note: Do not fill the fuel tank completely full. The empty space in the tank allows the fuel to expand. Recommended Fuel • For best results, use only clean, fresh (less than 30 days old), unleaded gasoline with an octane rating of 87 or higher ((R+M)/2 rating method). • Ethanol: Gasoline with up to 10% ethanol (gasohol) or 15% MTBE (methyl tertiary butyl ether) by volume is acceptable. Ethanol and MTBE are not the same. Gasoline with 15% ethanol (E15) by volume is not approved for use.
Using the Safety-Interlock System motion-control levers to the center, unlocked position, engage the blade-control switch, and rise slightly from the seat; the engine should shut off. WARNING Positioning the Seat If the safety-interlock switches are disconnected or damaged, the machine could operate unexpectedly, causing personal injury. The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable (Figure 9).
Adjusting the Motion-Control Levers Converting to Side Discharge Adjusting the Height Machines with 107 cm (42-inch) Mower Decks You can adjust the motion-control levers higher or lower for maximum comfort (Figure 10). The mower deck and mower blades shipped with the machine were designed for optimum mulching and side-discharge performance. Removing the Discharge Cover for Side-Discharging g027252 Figure 10 1.
g230249 Figure 14 g230250 Figure 12 1. Discharge cover 5. 3. Bracket on the mower deck 2. Metal tab On the top of the discharge cover, engage the hook-shaped latch around the pivot rod of the deflector assembly (Figure 15). Installing the Discharge Cover for Mulching 1. Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3.
Removing the Right Baffle for Side-Discharging 1. Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the right mower blade; refer to Removing the Blades (page 52). 4. Remove the 2 knobs and curved washers that secure the right baffle to the mower (Figure 16). g024261 Figure 17 1. Right baffle 3. Discharge opening 2.
During Operation During Operation Safety General Safety The 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. g015321 Figure 18 1. Bolt (5/16 x 3/4 inch) WARNING 3. Locknut (5/16 inch) 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.
• Be sure all drives are in neutral and parking brake • • • • is engaged before starting engine. Start the engine carefully according to instructions with feet well away from the blades. Never operate the mower with damaged guards, shields, or covers. Always have safety shields, guards, switches and other devices in place and in proper working condition. Keep clear of the discharge opening at all times.
Operating the Mower Blade-Control Switch (PTO) 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. The blade-control switch (PTO) starts and stops the mower blades and any powered attachments. Engaging the Blade-Control Switch (PTO) g008945 Figure 20 g221745 Figure 19 Note: Always engage the blades with the throttle in 1.
Operating the Throttle Operating the Choke You can move the throttle control between FAST and SLOW positions (Figure 23). Use the choke to start a cold engine. 1. Always use the FAST position when engaging the PTO. Pull up the choke knob to engage the choke before using the key switch (Figure 24). Note: Ensure that you fully engage the choke. You may need to hold the knob up when you use the key switch. 2. Push down the choke to disengage the choke after the engine has started (Figure 24).
Starting the Engine CAUTION Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. Note: A warm or hot engine may not require choking. Important: Do not engage the starter for more than 5 seconds at a time. Engaging the starter motor for more than 5 seconds can damage the starter motor. If the engine fails to start, wait 10 seconds before operating the engine starter again.
performance. Always operate in the full throttle position when mowing. WARNING The machine can spin very rapidly. You may lose control of the machine and cause personal injury or damage to the machine. • Use caution when making turns. • Slow the machine down before making sharp turns. Driving Forward Note: Always use caution when backing up and turning. 1. Move the levers to the center, unlocked position. 2. To go forward, slowly push the motion-control levers forward (Figure 27).
Suggested uses: Trim Parking X Heavy, wet grass X Training X Trimming grass X Tow Using the Side Discharge Mow The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. DANGER Bagging X Mulching X Towing attachments X Without a grass deflector, discharge cover, or a complete grass-catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris.
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 30. Adjusting the Anti-Scalp Rollers Height of cut is controlled by the lever located to the right of the operating position (Figure 30). Machines with 107 cm (42-inch) Mower Decks Whenever you change the height of cut, adjust the height of the anti-scalp rollers.
1. Park the machine on a level surface, disengage the blade-control switch and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Adjust the anti-scalp rollers (Figure 32) to match the closest height-of-cut position. Operating Tips Using the Fast Throttle Setting For best mowing and maximum air circulation, operate the engine at the FAST position.
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 • Park machine on level ground, disengage drives, 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.
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. g027708 Figure 33 • Use only a full-width ramp; do not use individual ramps for each side of the machine. 1. Tie-down location • Secure a trailer to the towing vehicle with safety chains.
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. g027996 Figure 35 1. Full-width ramp in stowed position 4. Ramp is at least four times (4X) as long as the height of the trailer or truck bed to the ground 2. Side view of full-width ramp in loading position 5. H= height of the trailer or truck bed to the ground 3.
Pushing the Machine by Hand brake manually if necessary; refer to Releasing the Electric Brake (page 49). Important: Always push the machine by hand. Operating the Machine Do not tow the machine, because towing may damage it. Move the bypass levers rearward through the keyhole and down to lock them in place as shown in Figure 36. 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. Check the air cleaner for dirty, loose, or damaged parts. Check the engine-oil level. Clean the air intake screen. Inspect the blades. Inspect the grass deflector for damage.
• 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 16). 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. g027800 Servicing the Air Cleaner Service Interval: Before each use or daily Note: Service the air cleaner more frequently (every few hours) if operating conditions are extremely dusty or sandy. Removing the Foam and Paper Elements 1.
Servicing the Foam Air-Cleaner Element Installing the Air Cleaner 1. Note: Ensure that you do not damage the elements. Service Interval: Every 25 hours/Monthly (whichever comes first)—Clean the air-cleaner foam element (more often in dusty, dirty conditions). Every 100 hours/Yearly (whichever comes first)—Replace the air-cleaner foam element (more often in dusty, dirty conditions). 1. Wash the foam element in liquid soap and warm water. When the element is clean, rinse it thoroughly. 2.
Servicing the Engine Oil Engine-Oil Specifications Oil Type: Detergent oil (API service SF, SG, SH, SJ, or SL) Crankcase Capacity: 2.4 L (81 fl oz) with oil filter Viscosity: See the table below. g029683 Figure 43 Checking the Engine-Oil Level Service Interval: Before each use or daily Note: Check the oil when the engine is cold. Important: If you overfill or underfill the engine crankcase with oil and run the engine, you may damage the engine. 1. 2.
5. Change the engine-oil filter (Figure 46). Note: Ensure that the oil-filter gasket touches the engine and then turn the filter an extra 3/4 turn. g027799 g027477 Figure 46 6. g029570 Figure 45 43 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 47).
g027478 Figure 48 Checking the Spark Plug Important: Do not clean the spark plug(s). Always replace the spark plug(s) when it has a black coating, worn electrodes, an oily film, or cracks. If you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means the air cleaner is dirty. g193530 Figure 47 7. Set the gap to 0.75 mm (0.03 inch). Dispose of the used oil at a recycling center.
Cleaning the Cooling System 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the air filter from the engine. 4. Remove the engine shroud. 5. To prevent debris entering the air intake, install the air filter to the filter base. 6. Clean debris and grass from the parts. 7.
Electrical System Maintenance Electrical System Safety • Disconnect the battery before repairing the g027939 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. 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 39). 3. Locate the shaft on the electric brake where the brake link arms are connected (Figure 56). 4.
WARNING The spring is under tension when installed and can cause personal injury. Be careful when removing the belt. g014931 Figure 59 Mower Decks with 3 Blades 1. Idler pulley 4. Spring 2. Mower belt 5. Engine pulley 3. Outside pulley 6. Spring-removal tool g014930 Figure 58 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 59). 8.
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 60 • 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 62 Figure 64 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 63). A.
Installing the Blades 1. Install the blade onto the spindle shaft (Figure 65). 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 47 to 88 N∙m (35 to 65 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.
g009682 Figure 68 Mower Decks with 2 Blades g027588 1. Blades side to side 3. Outside cutting edges 2. Sail area of the blade 4. Measure from the tip of the blade to the flat surface here. Figure 70 1. Hanger bracket 3. Rear nut 2. Side locking nut 9. Check the side-to-side adjustments again. Repeat this procedure until the measurements are correct. 10. Continue leveling the mower deck by checking the front-to-rear blade slope; refer to Adjusting the Front-to-Rear Blade Slope (page 54).
g009658 Figure 71 Mower Decks with 2 Blades 1. Blades front to rear 2. Measure from the tip of the blade to the flat surface here. g014634 Figure 73 1. Adjusting rod 3. Locknut 2. Adjusting block g009659 Figure 72 Mower Decks with 3 Blades 1. Blades front to rear 3. Measure from the tip of the blade to the flat surface here. 2. Outside cutting edges 5. Measure from the tip of the front blade to the flat surface, and the tip of the rear blade to the flat surface (Figure 71 and Figure 72). 7.
9. Slide the mower deck out from underneath the machine. Note: Retain all parts for future installation. Installing the Mower Deck g014635 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Slide the mower under the machine. 4. Lower the height-of-cut lever to the lowest position. 5.
Cleaning 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. 1.
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. • Let the engine cool before storing the machine. • Do not store the machine or fuel near flames or Run the mower again for 1 to 3 minutes to remove excess water. drain the fuel indoors.
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:
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