TimeCutter® SW 4200 Riding Mower

The safety-interlock system is designed for the following:

• To prevent the engine from starting unless the traction pedal is in the NEUTRAL position.

• To automatically ensure that the parking brake is engaged and the PTO is off when starting the machine.

• To shut off the engine whenever the traction pedal is not in the NEUTRAL position and you rise from the seat.

• To automatically engage the parking brake and disengage the PTO, when you rise out of the seat with the traction pedal in the NEUTRAL position.

• To shut off the engine whenever the parking brake is not engaged and you rise from the seat.

1. Sit in the seat with the engine off and ensure that the PTO switch is in the OFF position.

2. Turn the ignition key to the START position; the starter should crank. Do not start or shut off the engine prior to step 3.

3. Turn the key to the ON position and push the Smart Park switch to the OFF position. The brake should disengage and the brake light should turn off.

4. With the brake disengaged and traction pedal in the NEUTRAL position, turn the ignition switch to the START position. The brake should automatically engage, the engine should crank, and the brake light should turn on.

5. With the engine off and the key in the ON position, engage the PTO by pulling up the blade-control switch; you should hear the clutch engage.

6. Ensure that the traction pedal is in neutral and turn the ignition switch to the START position. The PTO should disengage and the engine should crank and start without the blades moving.

7. With the engine running, rise from the seat. The engine should remain running and the brake light should be on.

8. Return to the seat and disengage the parking brake by pushing the Smart Park switch to the OFF position. The engine should continue to run.

9. Rise from the seat again. The brake should automatically engage and the engine should continue to run.

10. Return to the seat and engage the blades by pulling up the blade-control switch.

11. Rise from the seat. The blades should disengage and the engine should continue to run.

12. Return to the seat and pull up the blade-control switch. The blades should engage. Disengage the blades by pushing down the blade-control switch.

13. Pull up the blade-control switch to engage the blades. Move the traction pedal to the REVERSE position. The blades should disengage. Move the traction pedal to the NEUTRAL position.

14. Pull up the blade-control switch to engage the blades. Turn the Key Choice switch to the ON position and release it. The operating-in-reverse light should illuminate.

15. Move the traction pedal to the REVERSE position. The blades should remain engaged. Push the blade-control switch in to disengage the blades. The operating-in-reverse light should turn off. Move the traction pedal to the NEUTRAL position.

16. If not engaged, push the SmarkPark switch to the ON position and lightly tap the traction pedal in the either the FORWARD or REVERSE position. The brake should disengage and the brake light should turn off.

    Note: Tap the pedal, do not fully engage the pedal as that causes the brake system to bind and not release.

17. With the brake released, engage the traction pedal slightly and rise from the seat. The engine should shut off.

18. Return to the seat and turn the ignition key to the OFF position. After several seconds, the brake system should engage.

    Note: With the key in the OFF position, the brake light does not illuminate.

Figure 12

Note: Always engage the blades with the throttle in the FAST position (Figure 13).

Figure 13

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.

Sit down on the seat and ensure that the parking brake is engaged (Figure 17).

Figure 17

1. Disengage the blades by pushing the blade-control switch to the OFF position (Figure 17).

2. Move the throttle lever to the FAST position.

3. Turn the ignition key to the OFF position and remove the key.

1. Move the throttle to the FAST position.

2. Release the parking brake.

3. Place your foot onto the traction-control pedal and slowly press the top of the pedal to go forward, or press on the bottom of the pedal to move backward (Figure 18).

   Note: The farther you move the pedal in either direction, the faster the machine moves in that direction.

   

   Figure 18

   1. Forward
   2. Traction-control pedal
   3. Backward

4. To slow down, release the pressure on the traction-control pedal.

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.

Cut grass slightly longer than normal to ensure that the cutting height of the mower deck does not scalp any uneven ground. However, the cutting height used in the past is generally the best one to use. When cutting grass longer than 15 cm (6 inches) tall, you may want to cut the lawn twice to ensure an acceptable quality of cut.

It is best to cut only about a third of the grass blade. Cutting more than that is not recommended unless grass is sparse, or it is late fall when grass grows more slowly.

Alternate the mowing direction to keep the grass standing straight. This also helps disperse clippings, which enhances decomposition and fertilization.

Grass grows at different rates at different times of the year. To maintain the same cutting height, mow more often in early spring. As the grass growth rate slows in mid summer, mow less frequently. If you cannot mow for an extended period, first mow at a high cutting height, then mow again 2 days later at a lower height setting.

To improve cut quality, use a slower ground speed in certain conditions.

When mowing uneven turf, raise the cutting height to avoid scalping the turf.

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.

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.

Maintain a sharp blade throughout the cutting season because a sharp blade cuts cleanly without tearing or shredding the grass blades. Tearing and shredding turns grass brown at the edges, which slows growth and increases the chance of disease. Check the mower blades after each use for sharpness, and for any wear or damage. File down any nicks and sharpen the blades as necessary. If a blade is damaged or worn, replace it immediately with a genuine Toro replacement blade.

1. Park the machine on a level surface, and disengage the blade-control switch.

2. Engage the parking brake, shut off the engine, and wait for all moving parts to stop before leaving the operating position.

3. Locate the bypass levers on the frame on both sides of the engine.

4. Move the bypass levers forward through the key hole and down to lock them in place (Figure 21).

   Note: Do this for each lever.

5. Turn the ignition key on and disengage the parking brake.

   Note: Do not start the machine.

   

   Figure 21

   1. Bypass-lever locations
   2. Lever position for operating the machine
   3. Lever position for pushing the machine

6. When finished, ensure that the key has been returned to the STOP position to avoid draining the battery charge.

Note: If the machine fails to move, the electric brake may still be engaged. You can release the electric brake manually if necessary; refer to Releasing the Electric Brake.

Move the bypass levers rearward through the keyhole and down to lock them in place as shown in Figure 21.

Note: Do this for each lever.

1. Park the machine on a level surface and disengage the blade-control switch (PTO).

2. Engage the parking brake, shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3. Clean around the air-cleaner cover to prevent dirt from getting into the engine and causing damage.

4. Lift the cover and rotate the air-cleaner assembly out of the engine (Figure 28).

   

   Figure 28

5. Remove the foam element from the paper element (Figure 29).

   

   Figure 29

Wash the foam element with water and replace the foam element if it is damaged.

1. Lightly tap the element on a flat surface to remove dust and dirt.

2. Inspect the element for tears, an oily film, and damage to the seal.

   Important: Do not clean the paper element with pressurized air or liquids, such as solvent, gasoline, or kerosene. Replace the paper element if it is damaged or cannot be cleaned thoroughly.

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. Park the machine on a level surface, disengage the blade-control switch, shut off the engine, engage parking brake, and remove the key.

2. Make sure that the engine is shut off, level, and is cool, so that the oil has had time to drain into the sump.

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 31).

4. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

Figure 31

Note: Change the engine-oil filter more frequently when operating conditions are extremely dusty or sandy.

Note: Dispose of the used oil at a recycling center.

1. Park the machine on a level surface to ensure that the oil drains completely.

2. Disengage the PTO and ensure that the parking brake is engaged.

3. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

4. Drain the engine oil.

   

   Figure 32

5. Change the engine-oil filter (Figure 33).

   Note: Ensure that the oil-filter gasket touches the engine and then turn the filter an extra 3/4 turn.

   

   Figure 33

6. 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 34).

   

   Figure 34

1. Disengage the PTO and ensure that the parking brake is engaged.

2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

   

   Figure 35

   Note: Due to the deep recess around the spark plug, blowing out the cavity with compressed air is the most effective method for cleaning. The spark plug is most accessible when the blower housing is removed for cleaning.

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.

Set the gap to 0.76 mm (0.03 inch).

Figure 36

Tighten the spark plug(s) to 25 to 30 N∙m (18.5 to 22.1 ft-lb).

Figure 37

1. Park the machine on a level surface and disengage the blade-control switch.

2. Ensure that the parking brake is engaged, shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3. Raise the seat to access the battery.

4. Disconnect the negative (black) ground cable from the battery post (Figure 39).

   Note: Retain all fasteners.

   Warning

   Incorrect battery-cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury.

   • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable.

   • Always connect the positive (red) battery cable before connecting the negative (black) cable.

5. Slide the rubber cover up the positive (red) cable.

6. Disconnect the positive (red) cable from the battery post (Figure 39).

   Note: Retain all fasteners.

7. Remove the battery hold-down (Figure 39), and lift the battery from the battery tray.

   

   Figure 39

   1. Battery
   2. Positive (+) battery post
   3. Bolt, washer, and nut
   4. Terminal boot
   5. Negative (–) battery post
   6. Wing nut, washer, and bolt
   7. Battery hold-down

1. Remove the battery from the chassis; refer to Removing the Battery.

2. Charge the battery for a minimum of 1 hour at 6 to 10 A.

   Note: Do not overcharge the battery.

3. When the battery is fully charged, unplug the charger from the electrical outlet, then disconnect the charger leads from the battery posts (Figure 40).

   

   Figure 40

   1. Positive (+) battery post
   2. Negative (–) battery post
   3. Red (+) charger lead
   4. Black (–) charger lead

1. Position the battery in the tray (Figure 39).

2. Using the fasteners previously removed, install the positive (red) battery cable to the positive (+) battery terminal.

3. Using the fasteners previously removed, install the negative battery cable to the negative (-) battery terminal.

4. Slide the red terminal boot onto the positive (red) battery post.

5. Secure the battery with the hold-down (Figure 39).

6. Lower the seat.

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 disconnect the spark-plug wires from the spark plugs.

1. Inspect the cutting edges (Figure 44).

2. If the edges are not sharp or have nicks, remove and sharpen the blade; refer to Sharpening the Blades.

3. Inspect the blades, especially in the curved area.

4. If you notice any cracks, wear, or a slot forming in this area, immediately install a new blade (Figure 44).

   

   Figure 44

   1. Cutting edge
   2. Curved area
   3. Wear/slot forming
   4. Crack

Note: The machine must be on a level surface for the following procedure.

1. Raise the mower deck to the highest height-of-cut position.

2. While wearing thickly padded gloves, or other adequate hand protection, slowly rotate the blade to be measure into a position that allows effective measurement of the distance between the cutting edge and the level surface the machine is on (Figure 45).

   

   Figure 45

   1. Deck
   2. Spindle housing
   3. Blade

3. Measure from the tip of the blade to the flat surface (Figure 46).

   

   Figure 46

   1. Blade (in position for measuring)
   2. Level surface
   3. Measured distance between blade and the surface (A)

4. Rotate the same blade 180 degrees so that the opposing cutting edge is now in the same position (Figure 47).

   

   Figure 47

   1. Blade (side previously measured)
   2. Measurement (position used previously)
   3. Opposing side of blade being moved into measurement position

5. Measure from the tip of the blade to the flat surface (Figure 48).

   Note: The variance should be no more than 3 mm (1/8 inch).

   

   Figure 48

   1. Opposite blade edge (in position for measuring)
   2. Level surface
   3. Second measured distance between blade and surface (B)

   1. 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 and Installing the Blades.

      Note: If a bent blade is replaced with a new blade, and the dimension obtained continues to exceed 3 mm (1/8 inch), the blade spindle could be bent. Contact an Authorized Toro Dealer for service.

   2. If the variance is within constraints, move to the next blade.

6. Repeat this procedure on each blade.

The blades must be replaced if a solid object is hit, if the blade is out of balance, or if the blade is bent. For best performance and continued safety conformance of the machine, use genuine Toro replacement blades. Replacement blades made by other manufacturers may result in non-conformance with safety standards.

1. Hold the blade end using a rag or thickly padded glove.

2. Remove the blade bolt, curved washer, and blade from the spindle shaft (Figure 49).

   

   Figure 49

   1. Sail area of the blade
   2. Blade
   3. Curved washer
   4. Blade bolt

1. Use a file to sharpen the cutting edge at both ends of the blade (Figure 50).

   Note: Maintain the original angle.

   Note: The blade retains its balance if the same amount of material is removed from both cutting edges.

   

   Figure 50

   1. Sharpen at original angle.

2. Check the balance of the blade by putting it on a blade balancer (Figure 51).

   Note: If the blade stays in a horizontal position, the blade is balanced and can be used.

   Note: If the blade is not balanced, file some metal off the end of the sail area only (Figure 50).

   

   Figure 51

   1. Blade
   2. Balancer

3. Repeat this procedure until the blade is balanced.

1. Install the blade onto the spindle shaft (Figure 49).

   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 49).

3. Torque the blade bolt to 47 to 88 N∙m (35 to 65 ft-lb).

1. Park the machine on a level surface and disengage the blade-control switch.

2. Ensure that the parking brake is engaged, shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3. Set the height-of-cut lever to middle position.

4. Carefully rotate the blades so that they are all side to side (Figure 52).

   

   Figure 52

   1. Blades side to side
   2. Sail area of blade
   3. Outside cutting edges
   4. Measure from the tip of the blade to the flat surface here

5. Measure between the outside cutting edges and the flat surface (Figure 52). If both measurements are not within 5 mm (3/16 inch), an adjustment is required; continue with this procedure.

6. Move to the left side of the machine.

7. Loosen the side locknut.

8. Raise or lower the left side of the mower deck by rotating the rear nut. (Figure 53).

   Note: Rotate the rear nut clockwise to raise the mower deck; rotate the rear nut counter-clockwise to lower the mower deck.

   

   Figure 53

   1. Hanger bracket
   2. Side locknut
   3. Rear locknut

9. Check the side-to-side adjustments again. Repeat this procedure until the measurements are correct.

10. Continue leveling the deck by checking the front-to-rear blade slope; refer to 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 using the following instructions:

1. Park the machine on a level surface and disengage the blade-control switch.

2. Ensure that the parking brake is engaged., shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3. Set the height-of-cut lever to middle position.

   Note: Check and adjust the side-to-side blade level if you have not checked the setting; refer to Leveling from Side to Side.

4. Carefully rotate the blades so they are facing front to rear (Figure 54).

   

   Figure 54

   1. Blades front to rear
   2. Measure from the tip of the blade to the flat surface here

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 54).

   Note: If the front blade tip is not 1.6 to 7.9 mm (1/16 to 5/16 inch) lower than the rear blade tip, adjust the front locknut.

6. To adjust the front-to-rear blade slope, rotate the adjustment nut in the front of the mower (Figure 55).

   

   Figure 55

   1. Adjusting rod
   2. Adjusting block
   3. Locknut

7. To raise the front of the mower, tighten the adjustment nut.

8. To lower the front of the mower, loosen the adjustment nut.

9. 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 (Figure 54).

10. When the front-to-rear blade slope is correct check the side-to-side level of the mower again, refer to Leveling from Side to Side.