Form No. 3352-172 Rev - TimeCutter® ZX440 Riding Mower Model No. 74406—Serial No. 250000001 and Up Register your product at www.Toro.
This spark ignition system complies with Canadian ICES-002 Engine Maintenance.................................. 22 Servicing the Engine Oil .................... 22 Servicing the Air Cleaner ................... 24 Cleaning the Cooling System.............. 25 Fuel System Maintenance .......................... 25 Replacing the Fuel Filter .................... 25 Draining the Fuel Tank ...................... 26 Electrical System Maintenance................... 26 Spark Plug .....................................
Figure 1 1. Model and serial number plate 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. Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention.
Safety ◊ being driven too fast; Safe Operation Practices for Ride-on (riding) Rotary Lawnmower Machines ◊ the type of machine is unsuitable for its task; ◊ inadequate braking; ◊ lack of awareness of the effect of ground conditions, especially slopes; 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.
• Do not operate the engine in a confined space where dangerous carbon monoxide fumes can collect. • Mow only in daylight or in good artificial light. • Before attempting to start the engine, disengage all blade attachment clutches and shift into neutral. • Do not use on slopes of more than 12-1/2 degrees. • Remember there is no such thing as a safe slope. Travel on grass slopes requires particular care.
information that you must know that is not included in the CEN standard. • Engine exhaust contains carbon monoxide, which is an odorless, deadly poison that can kill you. Do not run engine indoors or in an enclosed area. • Keep hands, feet, hair and loose clothing away from attachment discharge area, underside of mower and any moving parts while engine is running. • Do not touch equipment or attachment parts which may be hot from operation. Allow to cool before attempting to maintain, adjust, or service.
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. 93-7009 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. 99-3943 1. Engine 93-7316 1. 2. 3. Thrown object hazard—keep bystanders a safe distance from the machine.
9-8939 3. 1. Read the Operator’s Manual. 2. Height of cut Remove the ignition key and read the instructions before servicing or performing maintenance. 104-8062 1. Height of cut 104-8009 1. 2. 3. 4. 5. 6. Throttle 7. 8. Choke Continuous variable setting 9. 10. Slow On 11. Off Headlights Engine—stop Engine—run Engine—start Ignition 104-8063 1. 104-8061 1. To ride the machine, pull the lever out. 2. Do not tow the machine. 3. To push the machine, push the lever in.
Battery Symbols Some or all of these symbols are on your battery 107-2474 1. 2. Read the instructions before 3. servicing or performing maintenance. 4. Check the tire pressure every 25 operating hours. Grease every 25 operating hours. Engine 1. Explosion hazard 6. 2. No re, open ame, or smoking. 7. 3. Caustic liquid/chemical burn hazard Wear eye protection 8. 4. 5. Read the Operator’s Manual. 9. 10. Keep bystanders a safe distance from the battery.
Product Overview Figure 3 1. Seat 2. Control panel 3. Motion control levers 4. 5. 6. Height of cut lever Parking brake Mower deck 7. Anti-scalp wheel 8. Front castor wheel 9. Footrest 10. Discharge chute 11. Gas tank 12. Rear drive wheel Controls Become familiar with all of the controls (Figure 4 and Figure 5) before you start the engine and operate the machine. Figure 5 1. 2. Figure 4 1. Ignition switch 2. Throttle/Choke 3. 4.
Operation Note: Determine the left and right sides of the machine from the normal operating position. Think Safety First Please carefully read all of the safety instructions and decals in the safety section. Knowing this information could help you, your family, pets or bystanders avoid injury. Mowing on wet grass or steep slopes can cause sliding and loss of control. Figure 6 Wheels dropping over edges can cause rollovers, which may result in serious injury, death or drowning. 1. 2.
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. Gasoline is harmful or fatal if swallowed. Long-term exposure to vapors can cause serious injury and illness. • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any gasoline that spills. • Keep face away from nozzle and gas tank or conditioner opening. • Avoid prolonged breathing of vapors.
Checking the Oil Level in Engine Maintenance, page 22. Using the Parking Brake Always set the parking brake when you stop the machine or leave it unattended. Figure 8 1. PTO-On 2. PTO-Off Setting the Parking Brake 1. Move the motion control levers (Figure 5) out to the neutral lock position. 4. Move the throttle lever to Choke before starting a cold engine. Note: A warm or hot engine may require choking. After the engine starts, move the throttle lever to Fast. 2.
The Safety Interlock System Stopping the Engine 1. Move the throttle lever to Slow (Figure 9). 2. Move the PTO to Off (Figure 8). If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. 3. Turn the ignition key to Off (Figure 10). 4. Pull the wire off of the spark plug(s) to prevent the possibility of someone accidentally starting the machine before transporting or storing the machine. • Do not tamper with the interlock switches.
the parking brake, engage the PTO, and rise slightly from the seat; the engine should stop. 4. While sitting on the seat, engage the parking brake, move the PTO to Off, and lock the motion control levers in neutral. Start the engine. While the engine is running, center the motion controls and move (forward or reverse); the engine should stop. Figure 12 Driving Forward or Backward 1. 2. The throttle control regulates the engine speed as measured in rpm (revolutions per minute).
Adjusting the Anti-Scalp Rollers Important: Do not engage the parking brake while the machine is moving. Damage to the drive system may occur. Whenever you change the height-of-cut it is recommended to adjust the height of the anti-scalp rollers. 1. Disengage the PTO and move the control levers to the neutral locked position and apply the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. A.
Pushing the Machine by Hand Important: Always push the machine by hand. Never tow the machine because damage may occur. To Push the Machine 1. Disengage the PTO and move the control levers to the neutral locked position and apply the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Pull the two bypass levers up and push them until the washer on the rod passes through the slot.
Installing the Recycler® Bafe 2. Remove the knobs from the top of the mower deck securing the right side baffle (Figure 18). 3. Lift the baffle and slide it out of the interlock with the left side baffle (Figure 18). Install the right side baffle to convert from side discharge mode to mulching. 1. Thoroughly clean the mower. 2. Remove the bolts and nuts in the holes needed for the baffle (Figure 18). 3. Install the bolts (5/16 x 5/8 inch) and locknuts (5/16 inch) in the right side baffle. 4.
height-of-cut so low as to totally surround the mower by uncut grass. Always try to have one side of the mower free from uncut grass, which allows air to be drawn into the mower. moisture, raise the cutting height higher than usual and cut the grass at this setting. Then cut the grass again using the lower, normal setting. When Stopping Cutting a Lawn for the First Time If the machine’s forward motion must be stopped while mowing, a clump of grass clippings may drop onto your lawn.
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 8 operating hours • Change the engine oil. Before each use or daily • • • • • Check the safety system. Check the engine oil level (more often in dirty or dusty conditions). Clean the air intake screen. Check the cutting blades. Clean the mower housing.
3. Clean the grease fittings with a rag. Make sure to scrape any paint off of the front of the fitting(s). Oil Type: Detergent oil (API service SC, SD, SE, SF, SG, or SH) Crankcase Capacity: with filter, 51 ounce (1.5 l) 4. Connect a grease gun to the fitting. Pump grease into the fittings until grease begins to ooze out of the bearings. Viscosity: See the table below. 5. Wipe up any excess grease.
Note: Dispose of the used oil at a certified recycling center. Figure 22 1. Oil dipstick 2. Filler tube 3. Metal end, dipstick Figure 23 5. 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. 1. Oil drain 10. Clean around the oil dipstick and unscrew the cap (Figure 23). 11.
Figure 24 1. Oil lter 2. Figure 25 1. 2. 3. Adapter 4. Install the replacement oil filter to the adapter. Turn the oil filter clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 3/4 turn (Figure 24). 5. Fill the crankcase with the proper type of new oil; refer to Changing and Draining the Oil. Cover Foam element Paper element 4. 5. 6. Wing nut Air cleaner base Latches Cleaning the Foam and Paper Elements 1. Foam Element A.
Important: Never clean the paper element with pressurized air or liquids, such as solvent, gas, or kerosene. Replace the paper element if it is damaged or cannot be cleaned thoroughly. Figure 28 1. 2. Air intake screen Fan housing 3. 4. Cylinder cover Cylinder cover Figure 27 1. Paper element 2. Rubber seal Cleaning the Cooling System Fuel System Maintenance Clean the air intake screen from grass and debris before each use.
Note: Now is the best time to install a new fuel filter because the fuel tank is empty. Electrical System Maintenance Spark Plug Check the spark plug(s) after every 200 operating hours. Make sure 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(s) and a gapping tool/feeler gauge to check and adjust the air gap. Install a new spark plug(s) if necessary. Figure 29 1. 2.
Checking the Spark Plug Removing the Battery 1. Look at the center of the spark plug(s) (Figure 31). 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. Battery terminals or metal tools could short against metal tractor components causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. Important: Never clean the spark plug(s).
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 33). Do not allow the electrolyte to fall below the Lower line (Figure 33). Figure 32 1. 2. 3. 4. Battery Terminal boot Positive battery cable Negative battery cable 5. 6. 7. Figure 33 Battery hold-down Bolt and washer Nut 1. 2. Vent caps Upper line 3. Lower line 3.
Charging the Battery • Charge Circuit F2–25 amp, blade-type Important: Always keep the battery fully charged (1.260 specific gravity). This is especially important to prevent battery damage when the temperature is below 32°F (0°C). • 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). 1. Remove the battery from the chassis; refer to Removing the Battery. 2.
sharpen the blades; refer to Sharpening the Blades. 2. Inspect the blades, especially the curved area (Figure 37). If you notice any damage, wear, or a slot forming in this area (item 3 in Figure 37), immediately install a new blade. Figure 36 1. Valve stem Mower Maintenance Figure 37 Servicing the Cutting Blades 1. 2. Maintain sharp blades throughout the cutting season because sharp blades cut cleanly without tearing or shredding the grass blades.
Figure 39 Figure 40 4. Rotate the opposite ends of the blades forward. 1. 2. 3. 5. Measure from a level surface to the cutting edge of the blades at the same position as in step 3 above. The difference between the dimensions obtained in steps 3 and 4 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. Sail area of blade Blade Curved washer 4. 5.
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 blade bolt (Figure 40). Torque the blade bolt to 35-65 ft-lb (47-88 N·m). hairpin cotter. (Figure 44). A front hole lowers the blade height and a rear hole raises its height. Adjust both sides as required. Leveling the Mower from Side-to-Side The mower blades must be level from side to side.
7. Then secure the yoke with the clevis pin and cotter pin. Repeat this procedure on the opposite side of the mower. Figure 47 1. 2. Figure 45 1. Rear trunion rod 2. Clevis pin and cotter pin 3. 4. Front trunion rod yoke Hairpin cotter 3. Jam nut 11. Rotate the yokes on the rods to change the adjustment (Figure 47). To raise the front of the mower, tighten the yokes (shorten the rods). To lower the front of the mower, loosen the yokes (lengthen the rods). Jam nut Yoke 8.
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. Replacing the Mower Belt Figure 48 1. Hairpin cotter and clevis pin 2. 1. Stop the engine, set the parking brake, remove the key, and disconnect the spark plug wire(s) from the spark plug(s). Front trunion 6.
Replacing the Grass Deector Note: Check to ensure that the length of exposed thread on the spring eye bolt is 1/8 in. (3 mm) (Figure 50). 7. Install the belt covers over the outside spindles. An uncovered discharge opening could allow the lawn mower to throw objects in the operator’s or bystander’s direction and result in serious injury. Also, contact with the blade could occur. Never operate the lawn mower unless you install a cover plate, a mulch plate, or a grass chute and catcher. 1.
Note: It may be helpful to press down near the end of the bolt with a 9/16 inch open end wrench to align the bolts with the second holes on the mower bracket and grass deflector. 5. Lift the grass deflector and check that it is spring loaded and pivots freely to the full down position. Important: The grass deflector must be spring loaded in the down position. Lift the deflector up to test that it snaps to the full down position. Cleaning Figure 53 1. 2.
Storage C. Restart the engine and run it until it stops. D. Choke or prime the engine. Start and run the engine until it will not start. Operate the primer, if equipped, several times to ensure no fuel remains in the primer system. Cleaning and Storage 1. Disengage the PTO, set the parking brake, stop the engine, and remove the key. E. Dispose of fuel properly. Recycle as per local codes. 2. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine.
Troubleshooting Problem The engine overheats. Possible Cause 1. The engine load is excessive. 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. 5. Dirt, water, or stale fuel is in fuel system. The starter does not crank 1. The blade control (PTO) is engaged. 2. The parking brake is not on. 3. The operator is not seated. 4. The battery is dead. 5. The electrical connections are corroded or loose. 6.
Problem Possible Cause Corrective Action The engine will not start, starts hard, or fails to keep running. 1. The fuel tank is empty. 1. Fill the fuel tank. 2. The fuel valve turned off. 2. Open the fuel valve. 3. The choke is not on. 3. Move the choke lever to On. 4. The air cleaner is dirty. 4. Clean or replace the air cleaner element. 5. The spark plug wire(s) is 5. Install the wire(s) on the loose or disconnected. spark plug. 6. Install a new, correctly 6. The spark plug(s) is gapped spark plug(s).
Problem Possible Cause Corrective Action There is abnormal vibration. 1. The engine mounting bolts are loose. 2. The engine pulley, idler pulley, or blade pulley is loose. 3. The engine pulley is damaged. 4. The cutting blade(s) is/are bent or unbalanced. 5. A blade mounting bolt is loose. 6. A blade spindle is bent. 1. Tighten the engine mounting bolts. 2. Tighten the appropriate pulley. 3. Contact an Authorized Service Dealer. 4. Install a new cutting blade(s). 5. Tighten the blade mounting bolt. 6.
Schematics Electrical Schematic (Rev.
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