Form No. 3357-831 Rev A TimeCutter® ZX440 Riding Mower Model No. 74603—Serial No. 270000001 and Up Register your product at www.Toro.
Warning and serial numbers on the product. Write the numbers in the space provided. CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Important: This engine is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate the engine on any forest-covered, brush-covered, or grass-covered land.
Contents Leveling the Mower from Side-to-Side....................... 31 Adjusting the Front-to-Rear Blade Slope ................................. 32 Removing the Mower ........................ 33 Inspecting the Belts ........................... 33 Replacing the Mower Belt .................. 33 Installing the Mower .......................... 34 Replacing the Grass Deflector............ 35 Cleaning .................................................... 35 Washing the Underside of the Mower......................
Safety • Do not operate the mower without either the entire grass catcher or the guard in place. • Be alert, slow down and use caution when making turns. Look behind and to the side before changing directions. • Never leave a running machine unattended. Always turn off blades, set parking brake, stop engine, and remove key before dismounting. • Turn off blades when not mowing.
• Always keep the wheel motors engaged when going down slopes. Do not move the motion control levers to the neutral position and coast downhill. • Reduce speed and use extreme caution on slopes. • Do not make sudden turns or rapid speed changes. • Remove or mark obstacles such as rocks, tree limbs, etc. from the mowing area. Tall grass can hide obstacles. • Avoid sudden starts when mowing uphill because the mower may tip backwards. • Be aware that loss of traction may occur going downhill.
Toro Riding Mower Safety place containers on the ground away from your vehicle before filling. The following list contains safety information specific to Toro products or other safety information that you must know that is not included in the ANSI standards. • Remove gas-powered equipment from the truck or trailer and refuel it on the ground. If this is not possible, then refuel such equipment with a portable container, rather than from a gasoline dispenser nozzle.
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. 114-1606 1. Entanglement hazard, belt—keep all guards in place. 93-7009 1. Warning—don’t operate the mower with the deector up or removed; keep the deector in place. 2. Cutting/dismemberment hazard of hand or foot, mower blade—stay away from moving parts. 99-3943 1. Engine 110-6691 1.
112-9840 1. Read the Operator’s Manual. 2. Height of cut 3. 99-8936 1. Machine speed 2. Fast 3. Slow 4. 5. Neutral Reverse Remove the ignition key and read the instructions before servicing or performing maintenance. 104-8009 1. 2. 3. 4. 5. 6. Throttle 7. 8. Choke Continuous variable setting 9. 10. Slow On 11. Off 104-8032 Headlights Engine—stop Engine—run Engine—start Ignition 1. Height of cut 104-8061 1. 2. 9 To ride the machine, pull the lever out. Do not tow the machine. 3.
Battery Symbols Some or all of these symbols are on your battery 107-2474 1. Read the instructions before 3. servicing or performing maintenance. 4. 2. 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 4. Wear eye protection 8. 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 Figure 4 1. Ignition switch 3. 2. Throttle/Choke 4. 1. 2.
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.
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. In certain conditions during fueling, static electricity can be released causing a spark which can ignite the gasoline vapors. A fire or explosion from gasoline can burn you and others and can damage property. • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any gasoline that spills.
• Cleans the engine while it runs • Eliminates gum-like varnish buildup in the fuel 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. Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline. To minimize the chance of varnish deposits in the fuel system, use fuel stabilizer at all times. Figure 7 1. Parking brake-On 2.
Operating the Blades 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. 6. After the engine starts, move the throttle lever to Fast (Figure 9). If the engine stalls or hesitates, move the throttle lever back to Choke for a few seconds. Then move the throttle lever to the desired setting. Repeat this as required.
Understanding the Safety Interlock System the throttle control in the Fast position for best performance. Always operate in the full throttle position. The safety interlock system is designed to prevent the engine from starting unless: • The parking brake is engaged. • The blades are disengaged. • The motion control levers are in the neutral locked position. The machine can spin very rapidly. The operator may lose control of the machine and cause personal injury or damage to the machine.
Backward 1. Move the levers to the center, unlocked position. 2. To go backward, slowly pull the motion control levers rearward (Figure 12). 4. Secure the clevis pin with the hairpin cotter (Figure 13). To go straight, apply equal pressure to both motion control levers (Figure 12). To turn, release the pressure on the motion control lever toward the direction you want to turn (Figure 12). To stop, push the motion control levers to neutral. Stopping the Machine Figure 13 1. 2.
1. Remove the 2 screws and curved washers holding the control lever to the control arm shaft (Figure 16). G000911 2. Move the control lever to the next set of holes. Secure the lever with the 2 screws and curved washers. The cupped side of the washer should be toward the control arm shaft (Figure 16). 3. Repeat the adjustment on the other control lever. Figure 14 1. Gage wheel 2. Stud 3. Washer 4. 5. Nut Wheel nut and washer. Do not remove. B.
Operating Tips Fast Throttle Setting For best mowing and maximum air circulation, operate the engine at Fast. Air is required to thoroughly cut grass clippings, so do not set the 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. Cutting a Lawn for the First Time Figure 17 1. Position for pushing the machine 2.
Long Grass If the grass is ever allowed to grow slightly longer than normal, or if it contains a high degree of 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 If the machine’s forward motion must be stopped 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.
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 Before each use or daily • • • • Check the safety system. Check the engine oil level (more often in dirty or dusty conditions). Check the cutting blades. Clean the mower housing. Every 25 hours • • • • • • Grease all lubrication points (more often in dusty, dirty conditions).
Where to Add Grease Lubricate the grease fittings as shown on the Check Service Reference Aid decal (Figure 18) located beneath the seat and the mower (Figure 19). Figure 20 Figure 18 Checking the Oil Level 1. Park the machine on a level surface, disengage the blade control switch, stop the engine, and remove the key. 2. Disengage the blade control switch and move the control levers to the neutral locked position and apply the parking brake. 3.
Important: Do not overfill the crankcase with oil because the engine may be damaged. Changing the Oil Filter Replace the oil filter every 200 hours or every other oil change. Changing and Draining the Oil 1. Start the engine and let it run until warm. This warms the oil so that it drains better. 2. Park the machine so that the drain side is slightly lower than the opposite side to ensure that the oil drains completely. 3.
3. Clean around the air cleaner to prevent dirt from getting into the engine and causing damage. Unscrew the knob and remove the air cleaner cover (Figure 24). Figure 25 1. Foam element 2. Oil 2. Paper Element A. Lightly tap the element on a flat surface to remove dust and dirt (Figure 26). B. Inspect the element for tears, an oily film, and damage to the rubber seal. Important: Never clean the paper element with pressurized air or liquids, such as solvent, gas, or kerosene.
Spark Plug Important: Never clean the spark plug(s). Always replace the spark plug(s) when it has a black coating, worn electrodes, an oily film, or cracks. 2. Check the gap between the center and side electrodes (Figure 28). Bend the side electrode (Figure 28) if the gap is not correct. 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.
1. Park the machine on a level surface, to ensure that the fuel tank drains completely. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 2. Disengage the blade control switch and move the control levers to the neutral locked position and apply the parking brake. 3. Close the fuel shut-off valve located under the front of the fuel tank. 3.
Removing the Battery 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. • When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the tractor. • Do not allow metal tools to short between the battery terminals and metal parts of the tractor. Figure 30 1. 2. 3. 4. 1.
Charging the Battery 2. Look at the side of the battery. The electrolyte must be up to the Upper line (Figure 31). Do not allow the electrolyte to fall below the Lower line (Figure 31). 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). 1. Remove the battery from the chassis; refer to Removing the Battery. 2. Check the electrolyte level; refer to Checking the Electrolyte Level. 3.
1. Raise the seat to gain access to the fuse holder (Figure 33). 2. To replace a fuse, pull out on the fuse to remove it (Figure 33). Figure 34 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. Figure 33 1. Main–30 amp 3. 2.
sharpen the blades; refer to Sharpening the Blades. 4. Rotate the opposite ends of the blades forward. 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. 2. Inspect the blades, especially the curved area (Figure 35).
original angle. The blade retains its balance if the same amount of material is removed from both cutting edges. 2. Check the air pressure of all four tires. If needed, adjust to the recommended inflation; refer to Tire Press. 3. Set the height-of-cut at 3 inch (76 mm). 4. Carefully rotate the blade(s) from side to side (Figure 41). Measure between the outside cutting edges and the flat surface (Figure 41). If both measurements are not within 3/16 inch (4.
Adjusting the Front-to-Rear Blade Slope the flat surface. If the front blade tip is not 1/16-5/16 inch (1.6-7.9 mm) lower than the rear blade tip, adjust the front trunion rods. Check the front-to-rear blade level any time you install the mower. If the front of the mower is more than 5/16 inch (7.9 mm) lower than the rear of the mower, adjust the blade level using the following instructions: 1. Position the mower on a flat surface. 2.
13. When the front-to-rear blade slope is correct, tighten the jam nuts (Figure 43 and Figure 45). 14. Recheck the side-to-side level of the mower; refer to Leveling the Mower from Side-to-Side. 15. Check the height of the anti-scalp rollers; refer to Adjusting the Anti-Scalp Rollers. Removing the Mower 1. Park the machine on a level surface. Figure 47 2. Disengage the blade control switch and move the control levers to the neutral locked position and apply the parking brake. 1. 2.
The spring is under tension when installed and can cause personal injury. Do not remove the spring from the spring eye bolt. 5. Route the new belt through the idler arm and around the idler pulley (Figure 48). Figure 49 Top View 1. Mower belt 2. Idler arm 3. Outside pulley Figure 48 Outer nut Idler pulley Idler arm Spring eye bolt 5. 6. 7. Spring Idler pulley Installing the Mower Top View 1. 2. 3. 4. 4. 5. 1. Park the machine on a level surface. Spring 1/8 inch (3 mm) Mower belt 2.
Replacing the Grass Deector 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 bolt with the second hole 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. 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.
Figure 51 1. Washout tting 2. Coupling 3. Hose 5. Lower the mower to the lowest height-of-cut. 6. Sit on the seat and start the engine. Engage the blade control switch and let the mower run for one to three minutes. 7. Disengage the blade control switch, stop the engine, and remove the ignition key. Wait for all moving parts to stop. 8. Turn the water off and remove the coupling from the washout fitting. Note: If the mower is not clean after one washing, soak it and let it stand for 30 minutes.
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 blade control switch, set the parking brake, stop the engine, and remove the key. 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 switch (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.
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.
Evaporative Emission Control Warranty Statement California Evaporative Emission Control Warranty Statement Your Warranty Rights and Obligations Introduction The California Air Resources Board and The Toro® Company are pleased to explain the evaporative emission control system’s warranty on your 2006 model year equipment. In California, new equipment that use small off-road engines must be designed, built, and equipped to meet the State’s stringent anti-smog standards.
Consumer The Toro Total Coverage Guarantee TimeCutter ZX (Model A Three-Year Full Warranty (Limited Warranty for Commercial Use) 74603 only) Conditions and Products Covered The Toro Company and its afliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair any Toro Product used for normal residential purposes* if defective in materials or workmanship.
