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Toro TimeCutter ZX440, Operator'S Manual

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Toro TimeCutter ZX440 Operator'S Manual Download Page 2

This spark ignition system complies with Canadian
ICES-002

Contents

Introduction........................................................ 2
Safety .................................................................. 4

Safe Operation Practices for

Ride-on (riding)
Rotary Lawnmower
Machines............................. 4

Safe Operating Practices ...................... 4
Toro Riding Mower Safety ................... 5
Sound Pressure.................................... 6
Sound Power ....................................... 6
Vibration............................................. 6
Slope Chart ......................................... 7
Safety and Instructional Decals ............ 8

Product Overview ............................................. 11

Controls ............................................ 11

Operation.......................................................... 12

Think Safety First .............................. 12
Recommended Gasoline.................... 12
Checking the Engine Oil Level ........... 13
Using the Parking Brake..................... 14
Starting and Stopping the

Engine .............................. 14

Operating the Power Take Off

(PTO) ............................... 15

The Safety Interlock System............... 15
Driving Forward or Backward ............ 16
Stopping the Machine ........................ 16
Adjusting the Height of Cut ............... 17
Adjusting the Anti-Scalp

Rollers............................... 17

Positioning the Seat ........................... 17
Adjusting the Motion Control

Levers ............................... 18

Pushing the Machine by Hand ............ 18
Removing the Recycler®

Baffle ................................ 18

Installing the Recycler® Baffle ........... 19
Side Discharge................................... 19
Operating Tips .................................. 19

Maintenance...................................................... 21

Recommended Maintenance

Schedule(s) ............................... 21

Lubrication................................................ 21

How to Grease .................................. 21
Where to Add Grease ........................ 22

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 ......................................... 26
Servicing the Battery.......................... 27
Servicing the Fuses ............................ 29

Drive System Maintenance......................... 29

Checking the Tire Pressure................. 29

Mower Maintenance .................................. 30

Servicing the Cutting Blades............... 30
Leveling the Mower from

Side-to-Side....................... 32

Adjusting the Front-to-Rear Blade

Slope ................................. 32

Removing the Mower ........................ 33
Inspecting the Belts ........................... 34
Replacing the Mower Belt .................. 34
Installing the Mower .......................... 35
Replacing the Grass Deflector............ 35

Cleaning .................................................... 36

Washing the Underside of the

Mower............................... 36

Storage .............................................................. 37

Cleaning and Storage ......................... 37

Troubleshooting................................................ 38
Schematics ........................................................ 41

Introduction

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.

You may contact Toro directly at www.Toro.com
for product and accessory information, help
finding a dealer, or to register your product.

Whenever you need service, genuine Toro parts,
or additional information, contact an Authorized
Service Dealer or Toro Customer Service and have
the model and serial numbers of your product
ready. Figure 1 identifies the location of the model
and serial numbers on the product. Write the
numbers in the space provided.

© 2005—The Toro® Company

8111 Lyndale Avenue South

Bloomington, MN 55420

2

Contact us at www.Toro.com.

Printed in the USA.

All Rights Reserved

Summary of Contents for TimeCutter ZX440

Page 1: ...Form No 3352 172 Rev TimeCutter ZX440 Riding Mower Model No 74406 Serial No 250000001 and Up Register your product at www Toro com Original Instructions EN ...

Page 2: ... Draining the Fuel Tank 26 Electrical System Maintenance 26 Spark Plug 26 Servicing the Battery 27 Servicing the Fuses 29 Drive System Maintenance 29 Checking the Tire Pressure 29 Mower Maintenance 30 Servicing the Cutting Blades 30 Leveling the Mower from Side to Side 32 Adjusting the Front to Rear Blade Slope 32 Removing the Mower 33 Inspecting the Belts 34 Replacing the Mower Belt 34 Installing...

Page 3: ...lert 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 3 ...

Page 4: ...achines control of a ride on machine sliding on a slope will not be regained by the application of the brake The main reasons for loss of control are insufficient wheel grip being driven too fast inadequate braking the type of machine is unsuitable for its task lack of awareness of the effect of ground conditions especially slopes incorrect hitching and load distribution Preparation While mowing al...

Page 5: ...emove the key Disengage drive to attachments stop the engine and disconnect the spark plug wire s or remove the ignition key before clearing blockages or unclogging chute before checking cleaning or working on the lawnmower after striking a foreign object Inspect the lawnmower for damage and make repairs before restarting and operating the equipment if the machine starts to vibrate abnormally chec...

Page 6: ...a hand trimmer near drop offs ditches steep banks or water Reduce speed and use extreme caution on slopes Remove or mark obstacles such as rocks tree limbs etc from mowing area Tall grass can hide obstacles Watch for ditches holes rocks dips and rises that change the operating angle as rough terrain could overturn the machine Avoid sudden starts when mowing uphill because the mower may tip backwar...

Page 7: ...Slope Chart 7 ...

Page 8: ...or foot mower blade stay away from moving parts 93 7316 1 Thrown object hazard keep bystanders a safe distance from the machine 2 Thrown object hazard mower keep the de ector in place 3 Cutting dismemberment of hand or foot stay away from moving parts 93 7317 1 Thrown object hazard keep bystanders a safe distance from the machine 2 Thrown object hazard mower keep the de ector in place 3 Cutting di...

Page 9: ...nce 2 Height of cut 104 8009 1 Throttle 7 Headlights 2 Choke 8 Engine stop 3 Continuous variable setting 9 Engine run 4 Slow 10 Engine start 5 On 11 Ignition 6 Off 104 8061 1 To ride the machine pull the lever out 3 To push the machine push the lever in 2 Do not tow the machine 104 8062 1 Height of cut 104 8063 1 Height of cut 9 ...

Page 10: ... 10 Contains lead do not discard Manufacturer s Mark 1 Indicates the blade is identi ed as a part from the original machine manufacturer 107 2482 1 Engage 5 Warning read the Operator s Manual 9 Crushing dismemberment hazard of bystanders do not carry passengers 2 Disengage 6 Thrown object hazard mower keep the de ector in place 10 Cutting dismemberment hazard of hand or foot mower blade stay away ...

Page 11: ... 3 Motion control levers 6 Mower deck 9 Footrest 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 4 1 Ignition switch 3 Power take off PTO 2 Throttle Choke 4 Headlights optional Figure 5 1 Motion control lever 3 Height of cut lever 2 Parking brake lever 11 ...

Page 12: ... control and possibility of rollover Do not mow near drop offs or near water Do not mow slopes greater than 12 5 degrees Reduce speed and use extreme caution on slopes Avoid sudden turns or rapid speed changes Figure 6 1 Safe Zone use the TimeCutter here 3 Water 2 Use walk behind mower and or hand trimmer near drop offs and water Recommended Gasoline Use UNLEADED Regular Gasoline suitable for auto...

Page 13: ...the rim of the fuel tank or container opening at all times until fueling is complete Gasoline is harmful or fatal if swallowed Long term exposure to vapors can cause serious injury and illness Avoid prolonged breathing of vapors Keep face away from nozzle and gas tank or conditioner opening Keep gas away from eyes and skin Using Stabilizer Conditioner Use a fuel stabilizer conditioner in the machi...

Page 14: ...ntrols to neutral locked position 2 Set the parking brake refer to Setting the Parking Brake above 3 Move the PTO power take off to Off Figure 8 Figure 8 1 PTO On 2 PTO Off 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 5 Turn the ignition key to Start to energize the starter Whe...

Page 15: ...tches Check the operation of the interlock switches daily and replace any damaged switches before operating the machine Understanding the Safety Interlock System The safety interlock system is designed to prevent the engine from starting unless The parking brake is engaged The PTO is disengaged The motion control levers are in the neutral locked position The safety interlock system also is designe...

Page 16: ...levers are moved with the parking brake engaged Figure 12 1 Motion control lever neutral lock position 3 Forward 2 Center unlock position 4 Backward To go straight apply equal pressure to both motion control levers Figure 12 To turn release pressure on the motion control lever toward the direction you want to turn Figure 12 The farther you move the traction control levers in either direction the f...

Page 17: ...irpin cotter 2 Clevis pin 5 Lower the height of cut lever onto the clevis pin Adjusting the Anti Scalp Rollers 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 l...

Page 18: ...e 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 Push the levers down to lock them in place Figu...

Page 19: ... 8 inch and locknuts 5 16 inch in the right side baffle 4 Place the right side baffle inside the cutting chamber so the extended lug interlocks with the left side baffle Figure 18 5 Secure the baffle with the curved washers and knobs removed previously Figure 18 Side Discharge The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf Without the grass deflector...

Page 20: ...t then mow again two days later at a lower height setting Cutting Speed To improve cut quality use a slower ground speed Avoid Cutting Too Low If the cutting width of the mower is wider than the mower you previously used raise the cutting height to ensure that uneven turf is not cut too short Long Grass If the grass is ever allowed to grow slightly longer than normal or if it contains a high degre...

Page 21: ...y dirty conditions Replace the fuel lter Every 300 hours Clean the engine shrouds and cooling ns more often in dusty dirty conditions Before storage Perform all maintenance procedures listed above before storage Drain the fuel tank Charge the battery and disconnect the battery cables Paint any chipped surfaces If you leave the key in the ignition switch someone could accidently start the engine an...

Page 22: ...Servicing the Engine Oil Change the oil after the first 8 operating hours and every 100 operating hours thereafter Oil Type Detergent oil API service SC SD SE SF SG or SH Crankcase Capacity with filter 51 ounce 1 5 l Viscosity See the table below Figure 21 Checking the Oil Level 1 Park the machine on a level surface disengage the PTO stop the engine and remove the key 2 Disengage the PTO and move th...

Page 23: ...l drain valve Figure 23 6 Place a pan below the oil drain hose Use either a flat screw driver 3 8 inch 10 mm wrench to open valve Figure 23 7 Rotate valve end counterclockwise to open valve Figure 23 8 When oil has drained completely rotate valve end clockwise to close the valve Figure 23 9 Remove the drain hose Note Dispose of the used oil at a certified recycling center Figure 23 1 Oil drain 10 Cl...

Page 24: ...g parts to stop before leaving the operating position 3 Clean around the air cleaner to prevent dirt from getting into the engine and causing damage Unlatch the two side latches and remove the air cleaner cover Figure 25 4 Carefully remove the foam element from the paper element Figure 25 5 Unscrew the wing nut and remove the paper element Figure 25 Figure 25 1 Cover 4 Wing nut 2 Foam element 5 Ai...

Page 25: ...and grass from the parts 5 Install the air intake screen cylinder covers and fan housing Figure 28 1 Air intake screen 3 Cylinder cover 2 Fan housing 4 Cylinder cover Fuel System Maintenance Replacing the Fuel Filter Replace the fuel filter after every 200 operating hours or yearly whichever occurs first Never install a dirty filter if it is removed from the fuel line 1 Disengage the PTO and move the...

Page 26: ... the fuel line off of the fuel filter Figure 29 7 Open the fuel shut off valve Allow gasoline to drain into a gas can or drain pan 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 insta...

Page 27: ...event corrosion Voltage 12 v 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 an...

Page 28: ... must be up to the Upper line Figure 33 Do not allow the electrolyte to fall below the Lower line Figure 33 Figure 33 1 Vent caps 3 Lower line 2 Upper line 3 If the electrolyte is low add the required amount of distilled water refer to Adding Water to the Battery 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 wat...

Page 29: ...ttery Note Do not run the tractor with the battery disconnected electrical damage may occur Servicing the Fuses Service Interval Specification The electrical system is protected by fuses It requires no maintenance however if a fuse blows check the component circuit for a malfunction or short Fuse Main F1 30 amp blade type Charge Circuit F2 25 amp blade type Optional Headlight Kit 10 amp blade type ...

Page 30: ...or damaged blade Before Inspecting or Servicing the Blades Park the machine on a level surface disengage the PTO and set the parking brake Stop the engine remove the key and disconnect the spark plug wire s from the spark plug s Inspecting the Blades 1 Inspect the cutting edges Figure 37 If the edges are not sharp or have nicks remove and sharpen the blades refer to Sharpening the Blades 2 Inspect...

Page 31: ...chine use genuine Toro replacement blades Replacement blades made by other manufacturers may result in non conformance with safety standards Hold the blade end using a rag or thickly padded glove Remove the blade bolt curved washer stifener and blade from the spindle shaft Figure 40 Figure 40 1 Sail area of blade 4 Blade bolt 2 Blade 5 Stifener 3 Curved washer Sharpening the Blades 1 Use a file to ...

Page 32: ...leveling bracket s in a different hole and install the washer and hairpin cotter Figure 44 A front hole lowers the blade height and a rear hole raises its height Adjust both sides as required Figure 44 1 Hairpin cotter and washer 3 Front hole 2 Leveling bracket 4 Rear hole 6 Check the front to rear blade slope refer to Adjusting the Front to Rear Blade Slope Adjusting the Front to Rear Blade Slope...

Page 33: ...re 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 12 After adjusting both trunion rod yokes evenly secure the yokes with the hairpin cotters Check the front to rear level again Continue adjusting the yokes until the front blade tip is 1 16 5 16 inch 1 6 7 9 mm lower than the rear blade tip Figure 46 13 When t...

Page 34: ...ed belts 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 1 Stop the engine set the parking brake remove the key and disconnect the spark plug wire s from the spark plug s 2 Set the height of cut at 1 1 2 inch 38 mm 3 Re...

Page 35: ... the tractor with the clevis pins and hairpin cotters Figure 48 9 Install the mower belt onto the engine pulley refer to Replacing the Mower Belt Replacing the Grass De ector 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 yo...

Page 36: ...mower washout fitting and turn the water on high Figure 53 Note Spread petroleum jelly on the washout fitting O ring to make the coupling slide on easier and protect the O ring Figure 53 1 Washout tting 3 Hose 2 Coupling 5 Lower the mower to the lowest height of cut 6 Sit on the seat and start the engine Engage the PTO and let the mower run for one to three minutes 7 Disengage the PTO stop the engin...

Page 37: ... when mixed with fresh gasoline and used at all times A Run the engine to distribute the conditioned fuel through the fuel system 5 minutes B Stop the engine allow it to cool and drain the fuel tank refer to Draining the Fuel Tank Fuel System Maintenance page 25 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 p...

Page 38: ...nt The engine overheats 5 Dirt water or stale fuel is in fuel system 5 Contact an Authorized Service Dealer 1 The blade control PTO is engaged 1 Move the PTO to Disengaged 2 The parking brake is not on 2 Move the motion control levers to the brake position 3 The operator is not seated 3 Sit on the seat 4 The battery is dead 4 Charge the battery 5 The electrical connections are corroded or loose 5 ...

Page 39: ...low 10 Add oil to the crankcase 1 The engine load is excessive 1 Reduce ground speed 2 The air cleaner is dirty 2 Clean the air cleaner element 3 The oil level in the crankcase is low 3 Add oil to the crankcase 4 The cooling ns and air passages under the engine blower housing are plugged 4 Remove the obstruction from the cooling ns and air passages 5 The spark plug s is pitted fouled or the gap is...

Page 40: ... the blade s 2 A cutting blade s is are bent 2 Install a new cutting blade s 3 The mower is not level 3 Level the mower from side to side and front to rear 4 An anti scalp wheel is not set correctly 4 Adjust the anti scalp wheel height 5 The underside of the mower is dirty 5 Clean the underside of the mower 6 The tire pressure is incorrect 6 Adjust the tire pressure Uneven cutting height 7 A blade...

Page 41: ...Schematics Electrical Schematic Rev A 41 ...

Page 42: ...Notes ...

Page 43: ...Notes ...

Page 44: ......

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