Form No. 3352-224 TimeCutter® Z380 and Z420 Riding Mowers Model No. 74402—Serial No. 250000001 and Up Model No. 74403—Serial No. 250000001 and Up Register your product at www.Toro.
This spark ignition system complies with Canadian ICES-002 Servicing the Spark Plug......................... 26 Servicing the Battery.............................. 27 Servicing the Fuses................................ 28 Drive System Maintenance ............................ 29 Checking the Tire Pressure ..................... 29 Mower Maintenance ..................................... 29 Servicing the Cutting Blades ................... 29 Leveling the Mower from Side-to-Side ...........................
Write the product model and serial numbers in the space below: Model No. Serial No. This manual identifies potential hazards and has safety messages identified by the safety alert symbol (Figure 2 ), which signals a hazard that may cause serious injury or death if you do not follow the recommended precautions. Figure 2 1. Safety alert symbol. This manual uses two other words to highlight information.
Safety ◊ incorrect hitching and load distribution. Safe Operation Practices for Ride-on (riding) Rotary Lawnmower Machines Preparation • While mowing, always wear substantial footwear This machine meets or exceeds European Standards in effect at the time of production. However, improper use or maintenance by the operator or owner can result in injury.
• • • • • • • • • • • • Never store the equipment with fuel in the tank – stay alert for humps and hollows and other hidden hazards; Use care when pulling loads. – Use only approved drawbar hitch points. – Limit loads to those you can safely control. – Do not turn sharply. Use care when reversing. Watch out for traffic when crossing or near roadways. Stop the blades rotating before crossing surfaces other than grass.
Sound Pressure for Model 74403 • Use a walk behind mower and/or a hand trimmer near drop-offs, ditches, steep banks, or water. • Reduce speed and use extreme caution on slopes. This unit has a maximum sound pressure level at the operator’s ear of 87 dBA, based on measurements of identical machines per Directive 98/37/EC. • Remove or mark obstacles such as rocks, tree limbs, etc. from mowing area. Tall grass can hide obstacles.
Slope Chart 7
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 lost. 93-6677 1. 2. Warning—don’t operate the mower with the deector up or removed; keep the deector in place. Cutting/dismemberment hazard of hand or foot, mower blade—stay away from moving parts. 93-7009 1. 2. Warning—don’t operate the mower with the deector up or removed; keep the deector in place.
106-2223 106-8742 1. Parking brake 106-2224 1. 2. 3. 4. 5. 6. Throttle 7. 8. Choke Fast 9. Continuous variable setting10. 11. Slow Power take-off (PTO) 106-8743 Headlights Engine—stop Engine—run Engine—start Ignition 1. Height of cut Battery Symbols Some or all of these symbols are on your battery 108-6109 1. To push the machine, move tow levers forward and then out to lock them into position. 1. Explosion hazard 6. 2. No re, open ame, or smoking. 7. 3.
7-2514 1. 2. 3. 4. 5. 6. 7. Warning—read the instructions before servicing or performing maintenance; move the levers out to set the parking brake and remove the ignition key before leaving the machine. Warning—read the Operator’s Manual. Thrown object hazard, mower—keep the deector in place. Tipping hazard, slopes greater than 12.5 degrees—do not drive the machine on a slope greater than 12.5 degrees.
Product Overview Figure 3 1. Seat 2. Control levers 3. Height of cut lever 4. 5. 6. Mower deck Engine hood Control panel 7. Front caster wheel 8. Footrest 9. Rear drive wheel 10. Gas tank cap Controls Become familiar with all of the controls Figure 4 and Figure 5 before you start the engine and operate the machine. Figure 4 1. 2. 11 Ignition switch Throttle/Choke 3.
Figure 5 1. Motion control lever 2. Height-of-cut lever Parking Brake The parking brake is automatically set when the motion control levers are in the brake position . Always position the motion control levers into the brake position when you stop the machine or leave it unattended.
Operation Recommended Gasoline Note: Determine the left and right sides of the machine from the normal operating position. Use UNLEADED Regular Gasoline suitable for automotive use (87 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available. Think Safety First Important: Never use methanol, gasoline containing methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged. Do not mix oil with gasoline.
• Cleans the engine while it runs • Eliminates gum-like varnish buildup in the fuel In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property. system, which causes hard starting Important: Do not use fuel additives containing methanol or ethanol. Add the correct amount of gas stabilizer/conditioner to the gas. • Fill the fuel tank outdoors, in an open area, when the engine is cold.
Operating the Power Take Off (PTO) Note: A warm or hot engine may not require choking. 4. Turn the ignition key to Start to energize the starter. When the engine starts, release the key. The power take off (PTO) switch engages and disengages power to the electric clutch. Important: Do not engage the starter for more than 10 seconds at a time. If the engine fails to start, allow a 60 second cool-down period between attempts. Failure to follow these instructions can burn out the starter motor.
operate as described below, have an Authorized Service Dealer repair the safety system immediately. 1. While sitting on the seat, with the control levers in brake position, and move the PTO to On. Try starting the engine; the engine should not crank. 2. While sitting on the seat, move the PTO to Off. Move either motion control lever to the center, unlocked position. Try starting the engine; the engine should not crank. Repeat with the other motion control lever. Figure 11 3.
Important: Make sure that the spacers stay in place when loosening the knobs to move the seat. Loss of the spacers can result in damage to the seat. Children or bystanders may be injured if they move or attempt to operate the mower while it is unattended. 2. Move the seat to the desired position and tighten the knobs. Always remove the ignition key and move the motion control levers to the brake position when leaving the machine unattended, even if just for a few minutes.
Figure 15 Figure 14 1. 2. Control lever Bolt 3. Control arm shaft 3. Repeat the adjustment for the opposite control lever. 1. Bypass levers 3. 2. Lever position for pushing the machine Lever position for operating the machine To Operate the Machine Pushing the Machine by Hand Move the bypass levers to the inside and pull them rearward, to the end the slot (Figure 15 ). Note: The machine will not drive unless the bypass levers are disengaged. Important: Always push the machine by hand.
Mow at Correct Intervals Normally, mow every four days. But remember, grass grows at different rates at different times. So to maintain the same cutting height, which is a good practice, 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 two days later at a lower height setting.
Safe Towing Practices Tow only with a machine that has a hitch designed for towing. Do not attach towed equipment except at the hitch point. This product has a limited towing capacity for small attachments, such as leaf sweepers, rollers up to 500 lbs (227 kg) or carts up to 5 cubic feet. These types of attachments should be limited to flat ground. Never allow children or others in or on towed equipment. On slopes, the weight of towed equipment may cause a loss of traction and control.
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 rst use • Change the engine oil. Before each use or daily • • • • Test the safety interlock system. Check the engine oil level. Check the cutting blades. Clean the mower housing. Every 25 hours • Grease all lubrication points.
Figure 17 1. Engine hood 2. Knob Figure 19 2. To install the hood, put the hooks into the slots and slide forward (Figure 18 ). 1. Front caster tire 3. Tighten the knobs in the engine hood (Figure 17 ). Figure 20 4. Connect a grease gun to each fitting (Figure 19 and Figure 20 ). Pump grease into the fittings until grease begins to ooze out of the bearings. Figure 18 1. Engine hood 2. 5. Wipe up any excess grease.
Cleaning the Foam Element 2. Move the motion control levers to the brake position, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 1. Wash the foam element in liquid soap and warm water. When the element is clean, rinse it thoroughly. 3. Clean around the air cleaner to prevent dirt from getting into the engine and causing damage. Pull up on the air cleaner cover handle and rotate it toward the engine (Figure 21 ). Remove the air cleaner cover.
Figure 25 1. Figure 23 Oil dipstick 2. Metal end 4. Screw the oil dipstick fully onto the fill hole. Unscrew the dipstick, pull it out, and look at the metal end. If the oil level is low, slowly pour only enough oil into the fill hole to raise the level to, but not over, the Full mark on the dipstick. Checking the Oil Level Important: Do not overfill the crankcase with oil because the engine may be damaged. 1. Park the machine on a level surface, disengage the PTO, stop the engine, and remove the key.
10. Clean around the oil dipstick and unscrew the cap (Figure 24 ). Fuel System Maintenance 11. Slowly pour approximately 80% of the specified oil into the filler tube (Figure 24 ). Draining the Fuel Tank 9. Change the oil filter, if necessary (Figure 27 ). 12. Check the oil level; refer to Checking the Oil Level in Engine Maintenance, page 22. 13. Slowly add additional oil to bring it to the full mark. In certain conditions, gasoline is extremely flammable and highly explosive.
Electrical System Maintenance Note: Now is the best time to install a new fuel filter because the fuel tank is empty. 7. Install the fuel line onto the fuel filter. Slide the hose clamp close to the fuel filter to secure the fuel line (Figure 28 ). Servicing the Spark Plug Replace the spark plug after every 100 operating hours. Make sure that the air gap between the center and side electrodes is correct before installing the spark plug.
3. Tip the seat forward to see the battery. 4. Disconnect the negative (black) ground cable from the battery post (Figure 32 ). Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. Figure 31 1. Center electrode insulator 2. Side electrode 3. • Always disconnect the negative (black) Air gap (not to scale) battery cable before disconnecting the positive (red) cable.
1. Tip the seat forward to see the battery. 2. Look at the side of the battery. The electrolyte must be up to the Upper line (Figure 32 ). Do not allow the electrolyte to fall below the Lower line (Figure 32 ). 1. Remove the battery from the chassis; refer to Removing the Battery. 2. Check the electrolyte level; refer to Checking the Electrolyte Level. 3. Make sure that the vent caps are installed in the battery. Charge the battery for 1 hour at 25 to 30 amps or 6 hours at 4-6 amps.
• Main F1-30 amp, blade-type • Charge Circuit F2-25 amp, blade-type • Optional Headlight Kit-10 amp, blade type 1. Raise the seat to gain access to the fuse holder (Figure 35 ). 2. To replace a fuse, pull out on the fuse to remove it (Figure 35 ). Figure 36 1. Valve stem Mower Maintenance Servicing the Cutting Blades The Toro bullhorn logo (Figure 37 ) is a registered trademark of the Toro Company. It identifies the component it appears on as a genuine Toro part.
Before Inspecting or Servicing the Blades 2. Rotate the opposite ends of the blades forward. 3. Measure from a level surface to the cutting edge of the blades at the same position as in step 1. The difference between the dimensions obtained in steps 1 and 2 must not exceed 1/8 inch (3 mm). If this dimension exceeds 1/8 inch (3 mm), the blade is bent and must be replaced. Refer to Removing the Blades and Installing the Blades.
5. Carefully rotate the blade(s) side to side (Figure 48 ). Measure between the outside cutting edges and the flat surface (Figure 48 ). If both measurements are not within 3/16 inch (5 mm), an adjustment is required; continue with this procedure. Figure 41 1. Sharpen at original angle 2. Check the balance of the blade by putting it on a blade balancer (Figure 42 ). If the blade stays in a horizontal position, the blade is balanced and can be used.
Figure 45 1. 2. Hairpin cotter and washer Leveling bracket-38 inch model shown 3. 4. Figure 46 Front hole Rear hole 1. 2. 8. Check the front-to-rear blade slope; refer to Adjusting the Front-to-Rear Blade Slope. Leveling bracket-38 inch model shown Adjusting block 3. Adjusting rod 4. Hairpin cotter and washer 8. Repeat steps 5 through 7 for the opposite side of the mower. Adjusting the Front-to-Rear Blade Slope 9.
13. After adjusting both adjustment nuts evenly, check the front-to-rear slope again. Continue adjusting the nuts until the front blade tip is 1/16-5/16 inch (1.6-7.9 mm) lower than the rear blade tip (Figure 48 ). Note: After adjusting the adjustment nuts, make sure there is no slack in either support rod (Figure 49 ). Tighten either one to remove the slack (Figure 48 ). Figure 49 1. Hairpin cotter and clevis pin 2. Support rod 5.
Check the belts for cracks, frayed edges, burn marks, or any other damage. Replace damaged belts. The spring is under tension when installed and can cause personal injury. Replacing the Mower Belt Be careful when removing the spring. Squealing when the belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks, and cracks are signs of a worn mower belt. Replace the mower belt if any of these conditions are evident. 6.
2. Remove the nut (3/8 inch) from the rod under the mower (Figure 52 ). 2. Move the motion control levers to the brake position, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Slide the rod out of the short stand-off, internal lock washer, spring, and grass deflector (Figure 52 ). Remove the damaged or worn grass deflector. 3. Attach the hose coupling to the end of the mower washout fitting, and turn the water on high (Figure 53 ). 4.
A broken or missing washout fitting could expose you and others to thrown objects or blade contact. Contact with blade or thrown debris can cause injury or death. • Replace broken or missing washout fitting immediately, before using mower again. • Plug any hole(s) in mower with bolts and locknuts. • Never put your hands or feet under the mower or through openings in the mower.
Storage Dispose of fuel properly. Recycle as per local codes. Important: Do not store stabilizer/conditioned gasoline over 90 days. Cleaning and Storage 1. Disengage the PTO, set the parking brake, stop the engine, and remove the key. 11. Remove the spark plug(s) and check its condition; refer to Servicing the Spark Plug in Engine Maintenance, page 22. With the spark plug(s) removed from the engine, pour two tablespoons of engine oil into the spark plug hole.
Troubleshooting Problem The engine overheats. The starter does not crank The engine will not start, starts hard, or fails to keep running. Possible Cause Corrective Action 1. The engine load is excessive. 1. Reduce ground speed. 2. The oil level in the crankcase is low. 3. The cooling ns and air passages under the engine blower housing are plugged. 4. The air cleaner is dirty. 2. Add oil to the crankcase. 3. Remove the obstruction from the cooling ns and air passages. 5.
Problem The engine loses power. Possible Cause 1. The engine load is excessive. 1. Reduce ground speed. 2. The air cleaner is dirty. 2. Clean the air cleaner element. 3. Add oil to the crankcase. 3. The oil level in the crankcase is low. 4. The cooling ns and air passages under the engine blower housing are plugged. 5. The spark plug(s) is pitted, fouled, or the gap is incorrect. 6. The vent in the fuel cap is closed. 7. There is dirt in the fuel lter. 8.
Problem Uneven cutting height. Possible Cause 1. The blade(s) is not sharp. 1. Sharpen the blade(s). 2. A cutting blade(s) is/are bent. 3. The mower is not level. 2. Install a new cutting blade(s). 3. Level the mower from side-to-side and front-to-rear. 4. Adjust the anti-scalp wheel height. 5. Clean the underside of the mower. 6. Adjust the tire pressure. 4. An anti-scalp wheel is not set correctly. 5. The underside of the mower is dirty. 6. The tire pressure is incorrect. 7. A blade spindle is bent.
Schematics Electrical Diagram (Rev.