Form No. 3354-742 Rev A TimeCutter® ZD380 and ZD420 Riding Mowers Model No. 74432—Serial No. 260000001 and Up Model No. 74433—Serial No. 260000001 and Up Register your product at www.Toro.
Introduction Figure 2 Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage. You are responsible for operating the product properly and safely. 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. You may contact Toro directly at www.Toro.
Maintenance...................................................... 27 Recommended Maintenance Schedule(s) ............................... 27 Premaintenance Procedures....................... 28 Accessing the Machine....................... 28 Lubrication................................................ 29 Greasing the Bearings ........................ 29 Engine Maintenance.................................. 29 Servicing the Air Cleaner ................... 29 Servicing the Engine Oil ....................
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 15 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.
This unit has an equivalent continuous A-weighted whole body vibration level of .195 m/s2, based on measurements of identical machines per EN 1032. Model 74433 This unit has an equivalent continuous A-weighted hand/arm vibration level of 4.66 m/s2, based on measurements of identical machines per EN 1033. This unit has an equivalent continuous A-weighted whole body vibration level of .14 m/s2, based on measurements of identical machines per EN 1032.
Slope Chart 8
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. 93-7010 1. Thrown object hazard—keep bystanders a safe distance from the machine. 2. Thrown object hazard, mower—keep the deector in place. 3. Cutting/dismemberment of hand or foot—stay away from moving parts. 106-2224 1. 2. 3. 4. 5. 6. Throttle 7. 8. Choke Fast 9. Continuous variable setting10. 11.
Battery Symbols Some or all of these symbols are on your battery 106-8742 1. Parking brake 1. Height of cut 108-8769 2. 6. 2. No re, open ame, or smoking. 7. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 8. 5. Read the Operator’s Manual. 106-8743 1. Collect position 1. Explosion hazard Recycler® position 108-8759 1. Belt routing 10 9. 10. Keep bystanders a safe distance from the battery.
0-6567 1. Warning—read the Operator’s Manual. 2. Warning—read the instructions before servicing or performing maintenance; move the motion control levers to the brake position, remove the ignition key and disconnect the spark plug wire. 3. Cutting/dismemberment hazard, mower blade; entanglement hazard, belt—do not open or remove safety shields while engine is running. 4.
Product Overview Figure 3 1. Motion control lever 2. Height-of-cut lever 3. Control panel 4. 5. 6. Collection bag DFS lever Operator’s position, seat 7. Mower deck 8. Recycle-on-demand lever 9. Rear drive wheel 10. 11. 12. Cup holder Footrest Front caster wheel 10. 11. Mower deck Collection bag presence sensor Figure 4 Collection bag removed 1. Motion control lever 2. Height of cut lever 4. 5. Collection sensors Rear access panel 7. Engine cover 8. Discharge chute 3. Gas tank cap 6.
Controls the same side forward or in reverse. Moving the control levers outward from the center position engages the parking brake and allows the operator to exit the machine (Figure 5). Become familiar with all of the controls in Figure 3, Figure 4, Figure 5 and Figure 6 before you start the engine and operate the machine. Parking Brake The parking brake is automatically set when the motion control levers are in the brake position.
Ignition Switch The ignition switch has three positions, Off, Run and Start. The key will turn to Start and move back to Run upon release. Turing the key to the Off position will stop the engine; however, always remove the key when leaving the machine to prevent the engine from accidentally starting (Figure 6). Throttle/Choke Control The throttle and choke is combined into one control lever. The throttle controls the engine speed and it has a continuous variable setting from Slow to Fast.
Operation Recommended Fuel 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, fuel containing methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged. Do not mix oil with fuel.
• Cleans the engine while it runs • Eliminates gum-like varnish buildup in the fuel system, which causes hard starting In certain conditions during fueling, static electricity can be released causing a spark which can ignite the fuel vapors. A fire or explosion from fuel can burn you and others and can damage property. Important: Do not use fuel additives containing methanol or ethanol. Add the correct amount of gas stabilizer/conditioner to the gas.
Figure 11 1. 2. Figure 9 1. Blade control switch—On 2. Off Run 3. 4. Start Ignition Stopping the Engine Blade control switch—Off 1. Move the throttle lever to Fast (Figure 10). 2. Disengage the blades by moving the blade control switch to Off (Figure 9). 3. Move the throttle lever to Choke before starting a cold engine (Figure 10). 3. Turn the ignition key to Off (Figure 11). Note: A warm or hot engine may not require choking. 4.
Forward Operating the Blades 1. Move the levers to the center, unlocked position. The blade control switch, represented by a power take-off (PTO) symbol, engages and disengages power to the mower blades. This switch controls power to any attachments that draw power from the engine, including the mower deck and cutting blades. 2. To go forward, slowly push the motion control levers forward (Figure 12). Engaging the Blades 1.
control lever to the center, unlocked position. Try starting the engine; the engine should not crank. Repeat with the other motion control lever. Children or bystanders may be injured if they move or attempt to operate the mower while it is unattended. 3. While sitting on the seat, move the blade control switch to Off, and lock the motion control levers in neutral. Start the engine.
Changing Operation Modes Operation in the Collection Mode The recycle-on-demand lever allows the operator to alternate functions between Recycler® and collection modes from the seated, operating position. Use the recycle-on-demand lever to change modes. As the bagger fills, extra weight is added to the back of the machine. If you stop and start suddenly on hills, you may lose steering control or the machine may tip. 1.
Emptying the Collection System Collection Bag Once the collection bag fills with enough grass to cover one or both of the sensors and break the infrared beam a beeping alarm will sound to alert the operator. The alarm shuts off once the blade control switch is turned Off. If one or both sensors are unplugged the mower blades will not engage. The collection bag is retained in the engine cover by seating the lever side pin into a holed bracket in the right hand side of the engine cover.
Removing the Collection Chute As you are bagging, a small amount of grass clippings normally blow out the front of the mower. An excessive amount of clippings blowing out and no audible alarm signalling a full bag may indicate a plugged chute. The collection chute can be removed to be cleaned and safely cleared of any obstructions. Use the following procedure to remove it: 1. Make sure the collection bag is empty. 2. Park the machine on a level surface and disengage the blade control switch. 3.
6. Return to the machine. Inspect the internal engine compartment and clear any clippings or debris dislodged during chute removal. Debris built up in the engine compartment, if not removed, could be ignited by a hot engine. A fire in the engine compartment could can burn you and others and can damage property. • Before using and while the engine is cool, check for debris in the engine compartment. • Keep the machine free of grass, leaves, or other debris build-up.
Operation in the Recycler® Mode Air is required to cut and recut grass clippings in the mower housing, so do not set the height-of-cut too low or completely surround the housing by uncut grass. Always try to have one side of the mower deck free from uncut grass; allowing air to be drawn into the mower deck. When making an initial cut through the center of an uncut area, operate the machine slower and back up if the mower starts to clog.
Pushing the Machine by Hand Adjusting the Footrest The footrest can be adjusted forward or backward for maximum operator comfort. Important: Always push the machine by hand. Never tow the machine because damage may occur. Lift up the footrest and place the rods in the same hole positions (Figure 23). To Push the Machine 1. Park the machine on a level surface and disengage the blade control switch. 2.
Mowing Direction 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 cutter blades daily 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. Alternate mowing direction to keep the grass standing straight.
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 5 operating hours • Change the engine oil. Before each use or daily • • • • • Test the safety interlock system. Check the engine oil level. Check the cutting blades. Wipe clean the collection sensors. Clean the mower housing. Every 25 hours • Grease all lubrication points.
Premaintenance Procedures front retaining clasp and lift the engine hood off the frame (Figure 25). Accessing the Machine Some internal components can be accessed by simply raising the seat. Use the following procedures to access to the internal components as needed when performing the maintenance procedures described in this manual. Removing the Engine Hood Remove the engine hood to gain access to the engine compartment. To remove the engine hood the collection bag must be emptied and removed first. 1.
forcing the hood down. Push down gently to seat the retaining pin. Figure 28 Figure 27 1. Engine hood 2. Frame 3. 1. Front caster tire Frame mating with slot in the hood. 2. Install the collection bag; refer to Operation, page 15. Figure 29 Lubrication 4. Connect a grease gun to each fitting (Figure 28 and Figure 29). Pump grease into the fittings until grease begins to ooze out of the bearings. 5. Wipe up any excess grease. Greasing the Bearings Grease the front caster pivots and wheels (Figure 28).
Cleaning the Foam Element 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. Remove the engine hood. 4. 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 30). Remove the air cleaner cover. 2. Dry the element by squeezing it in a clean cloth.
Figure 34 1. Figure 32 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 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 1. Park the machine on a level surface, disengage the blade control switch, stop the engine, and remove the key.
3. Apply a thin coat of clean oil to the rubber gasket on the replacement filter (Figure 36). Figure 36 1. Oil lter 2. Gasket 3. 4. Adapter 4. Install the replacement oil filter to the filter adapter. Turn the oil filter clockwise until the rubber gasket contacts the filter adapter; then tighten the filter an additional 1/2 to 3/4 turn (Figure 36). Figure 35 1. Oil drain valve 2. Oil drain tube 3. Oil pan Rear, ldrive wheel 5.
2. Tighten the spark plug to 30 ft-lb (41 N⋅m). 3. Push the wire onto the spark plug (Figure 37). 4. Close the access panel and tighten the fasteners to secure it shut. Important: Always make sure the panel is replaced and secured with the fasteners before operating the machine. Operating the machine with the access panel open would allow clippings and other debris entering the engine compartment possibly damaging the machine. Figure 37 4. Remove the spark plug and metal washer.
Replacing the Fuel Filter Replace the fuel filter after every 100 operating hours or yearly, whichever occurs first. Never install a dirty filter if it is removed from the fuel line. 1. Park the machine on a level surface and disengage the blade control switch. 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. Close the fuel shut-off valve located under the front of the fuel tank.
Removing the Battery Battery terminals or metal tools could short against metal machine components causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. • When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine. • Do not allow metal tools to short between the battery terminals and metal parts of the machine. Figure 41 1. 2. 3. Battery Terminal boot Positive battery cable 4. 5. 6.
the Battery in Electrical System Maintenance, page 34. disconnect the charger leads from the battery posts (Figure 43). Adding Water to the Battery The best time to add distilled water to the battery is just before you operate the machine. This lets the water mix thoroughly with the electrolyte solution. 1. Remove the battery from the machine; refer to Removing the Battery in Electrical System Maintenance, page 34.
1. Raise the seat to gain access to the fuse holder (Figure 44). 2. To replace a fuse, pull out on the fuse to remove it (Figure 44). Figure 45 1. Valve stem Mower Maintenance Servicing the Cutting Blades Maintain sharp blades throughout the cutting season because sharp blades cut 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.
sharpen the blades; refer to Sharpening the Blades. 1/8 inch (3 mm), the blade is bent and must be replaced. Refer to Removing the Blades and Installing the Blades. 2. Inspect the blades, especially the curved area (Figure 46). If you notice any damage, wear, or a slot forming in this area (item 3 in Figure 46), immediately install a new blade. A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders. • Always replace bent or damaged blade with a new blade.
Sharpening the Blades 1. Park the machine on a level surface and disengage the blade control switch. 1. Use a file to sharpen the cutting edge at both ends of the blade (Figure 49). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges. 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.
Figure 52 1. Hairpin cotter and washer 2. Leveling bracket 3. 4. Figure 53 Front hole Rear hole 1. Leveling bracket 2. Adjusting block 8. Check the front-to-rear blade slope; refer to Adjusting the Front-to-Rear Blade Slope. 3. 4. Adjusting rod 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.
12. To raise the front of the mower, tighten the adjustment nuts. To lower the front of the mower, loosen the adjustment nuts. 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 55). Note: After adjusting the adjustment nuts, make sure there is no slack in either support rod (Figure 56). Tighten either one to remove the slack (Figure 55). Figure 56 1.
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 moving the idler arm. 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. 7.
Cleaning Cleaning the Collection Sensors The collection sensors do not require any scheduled maintenance, however; in the event that the collection bag alarm goes off and the bag is less than full, gently wipe off the faces of the sensors with a soft cloth. The cloth can be damp with water. Important: Do not use solvents or chemicals of any kind to clean the face of the sensors. Figure 59 1. 2.
Storage Stop the engine, allow it to cool, and drain the fuel tank; refer to Draining the Fuel Tank in Fuel System Maintenance, page 33. Cleaning and Storage Restart the engine and run it until it stops. 1. Disengage the blade control switch, set the parking brake, stop the engine, and remove the key. 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. 2.
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 switch is engaged. 2. The motion control levers are not in the brake position. 3. The operator is not seated. 4. The battery is dead. 5.
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. 1. Low engine speed. 1. Always operate the collection mode at Fast throttle. 2.
Problem Possible Cause Corrective Action Collection sensor alarm sounding. 1. Collection bag is full. 1. Empty the collection bag. 2. Debris is covering sensor. 2. Remove collection bag and clean sensors with soft cloth. Uneven cutting height. 1. The blade(s) is not sharp. 1. Sharpen the blade(s). 2. A cutting blade(s) is/are 2. Install a new cutting blade(s). bent. 3. The mower is not level. 3. Level the mower from side-to-side and front-to-rear. 4. An anti-scalp wheel is 4.
Schematics Electrical Diagram (Rev.
