Form No. 3361-783 Rev A TimeCutter® ZD420T Riding Mowers Model No. 74437—Serial No. 290000001 and Up Register at www.Toro.com.
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.
Safety Servicing the Engine Oil ..................................... 28 Servicing the Spark Plug ..................................... 29 Fuel System Maintenance ....................................... 31 Draining the Fuel Tank....................................... 31 Replacing the Fuel Filter ..................................... 31 Electrical System Maintenance................................ 32 Servicing the Battery........................................... 32 Servicing the Fuses ....................
– stay alert for humps and hollows and other hidden hazards; ◊ lack of awareness of the effect of ground conditions, especially slopes; ◊ incorrect hitching and load distribution. • Use care when pulling loads. – Use only approved drawbar hitch points. Preparation – Limit loads to those you can safely control. • While mowing, always wear substantial footwear and long trousers. Do not operate the equipment when barefoot or wearing open sandals.
Maintenance and Storage • Do not mow slopes when grass is wet. Slippery conditions reduce traction and could cause sliding and loss of control. • Keep all nuts, bolts and screws tight to be sure the equipment is in safe working condition. • Never store the equipment with fuel in the tank inside a building where fumes can reach an open flame or spark. • Allow the engine to cool before storing in any enclosure.
Slope Chart 6
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 deflector in place. 3. Cutting/dismemberment of hand or foot—stay away from moving parts. 106-2224 1. 2. 3. 4. Throttle Choke Fast Continuous variable setting 5. Slow 6.
Battery Symbols Some or all of these symbols are on your battery 106-8742 1. Explosion hazard 1. Parking brake 2. No fire, open flame, or smoking. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 106-8743 5. Read the Operator’s Manual. 1. Height of cut 108-8769 1. Collect position 2. Recycler® position 108-8759 1. Belt routing 8 6. Keep bystanders a safe distance from the battery. 7. Wear eye protection; explosive gases can cause blindness and other injuries 8.
110-6567 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 7. Mower deck 8. Recycle-on-demand lever 9. Rear drive wheel 4. Collection bag 5. DFS lever 6. Operator’s position, seat 10. Cup holder 11. Footrest 12. Front caster wheel G005884z Figure 4 Collection bag removed 1. Motion control lever 2. Height of cut lever 4. Collection sensors 5. Rear access panel 7. Mower deck 8. Engine cover 3. Gas tank cap 6. Rear drive wheel 9. Discharge chute 10 10. Rear frame 11.
Controls 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. Always position the motion control levers into the brake position when you stop the machine or leave it unattended (Figure 5).
Throttle/Choke Control Operation 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. Engage the choke by moving the lever past the Fast setting until it stops (Figure 6). 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.
Recommended Fuel Use Unleaded Regular Gasoline suitable for automotive use (87 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available. 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. Note: A warm or hot engine may not require choking. Add the correct amount of gas stabilizer/conditioner to the gas. 4. Turn the ignition key to Start to energize the starter. When the engine starts, release the key. Note: A fuel stabilizer/conditioner is most effective when mixed with fresh fuel. To minimize the chance of varnish deposits in the fuel system, use fuel stabilizer at all times.
Driving Forward or Backward Backward 1. Move the levers to the center, unlocked position. 2. To go backward, slowly pull the motion control levers rearward (Figure 12). The throttle control regulates the engine speed as measured in rpm (revolutions per minute). Place the throttle control in the Fast position for best performance. Always operate in the full throttle position. To go straight, apply equal pressure to both motion control levers (Figure 12).
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.
1. Park the machine on a level surface, disengage the blade control switch and move the motion control levers to the brake position. The collection mode uses air flow created by the cutting blades to direct clippings up, through an internal chute and deposit them in the collection bag. Shorter, dry clippings require less force to be moved up the chute and into the collection bag. 2. Move the throttle to Slow. 3.
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.
To Push the Machine 1. Park the machine on a level surface and disengage the blade control switch. 2. Move the motion control levers outward to engage the parking brake, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Move the two bypass levers to the inside and push them in until the washer on the rod passes through the slot (Figure 22). Figure 23 1. Footrest 2. Rod 4. Push the levers outward to lock them in place Figure 22. 5.
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. 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 (0.14 m3).
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 first 8 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 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. G005900 Figure 25 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.
Lubrication 3 Greasing the Bearings 1 Service Interval: Every 25 hours Grease the front caster pivots and wheels (Figure 29). 1. Park the machine on a level surface and disengage the blade control switch. G010222 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. 2 Figure 27 1. Rear access panel 2. Fastener 3. Frame 3. Clean the grease fittings (Figure 29 and Figure 30) with a rag.
Engine Maintenance Cleaning the Foam and Paper Elements 1. Foam Element Servicing the Air Cleaner A. Wash the foam element in liquid soap and warm water. When the element is clean, rinse it thoroughly. Service Interval: Every 25 hours—Service the foam air cleaner. (more often in dusty, dirty conditions) B. Dry the element by squeezing it in a clean cloth (do not wring). Allow the element to air dry. Every 50 hours—Service the paper air cleaner. (more often in dusty, dirty conditions) C.
1. Carefully slide the foam element onto the paper air cleaner element (Figure 31). 2. Place the air cleaner assembly onto the air cleaner base and install the wing nut (Figure 31). 3. Install the air cleaner cover and secure the latches (Figure 31). Servicing the Engine Oil Oil Type: Detergent oil (API service SF, SG, SH, or SJ) 1 G005765 Crankcase Capacity: with filter, 51 ounces (1.5 l) 2 3 Figure 35 Viscosity: See the table below. 1. Oil dipstick 2. Filler tube 3. Dipstick end 6.
Changing the Oil Filter Service Interval: Every 200 hours—Change the oil filter. (more often in dusty, dirty conditions) Components will be hot if the machine has been running. If you touch hot components you may be burned. 1. Drain the oil from the engine; refer to Changing and Draining the Oil. Allow the machine to cool before performing maintenance or touching components under the hood. 2. Remove the old filter (Figure 37). 3.
Removing the Spark Plug 1. Disengage the blade control switch 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. Remove the engine hood and engine duct to access the engine components. Figure 39 1. Center electrode insulator 2. Side electrode 4. Pull the wires off of the spark plugs (Figure 38).
Fuel System Maintenance 5. Loosen the hose clamp at the fuel filter and slide it up the fuel line away from the fuel filter (Figure 41). Draining the Fuel Tank Service Interval: Before storage In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. • Drain fuel from the fuel tank when the engine is cold. Do this outdoors in an open area. Wipe up any fuel that spills. Figure 41 1. Hose clamp 2.
6. Install a new filter with the flow direction arrow coming from the fuel tank and pointing to the engine and move the hose clamps close to the filter (Figure 41). Electrical System Maintenance 7. Open the fuel shut-off valve. Servicing the Battery Check the electrolyte level in the battery every 25 hours. Always keep the battery clean and fully charged. Use a paper towel to clean the battery case.
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 43). Do not allow the electrolyte to fall below the Lower line (Figure 43). Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable.
Servicing the Fuses 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). 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. 1. Remove the battery from the chassis; refer to Removing the Battery. Fuse: 2. Check the electrolyte level; refer to Checking the Electrolyte Level.
Drive System Maintenance Mower Maintenance Checking the Tire Pressure 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. Servicing the Cutting Blades Service Interval: Every 25 hours Maintain the air pressure in the front and rear tires as specified. Uneven tire pressure can cause uneven cut.
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. Figure 47 1. Cutting edge 2. Curved area • Never file or create sharp notches in the edges or surfaces of blade. 3. Wear/slot forming Removing the Blades Checking for Bent Blades The blades must be replaced if a solid object is hit, if the blade is out of balance, or the blade is bent.
5. Carefully rotate the blade(s) side to side (Figure 52). Measure between the outside cutting edges and the flat surface (Figure 52). If both measurements are not within 3/16 inch (5 mm), an adjustment is required; continue with this procedure. Figure 50 1. Sharpen at original angle 2. Check the balance of the blade by putting it on a blade balancer (Figure 51). If the blade stays in a horizontal position, the blade is balanced and can be used.
Adjusting the Front-to-Rear Blade Slope 10. Measure from the tip of the front blade to the flat surface and the tip of the rear blade to the flat surface (Figure 55). 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 locknuts. 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.
5. Remove the hairpin cotter and washer from the adjusting rod (Figure 58) on each side of the mower. 6. Remove the hairpin cotter and washer at the mower leveling brackets (Figure 58) on each side of the mower. Note which hole the leveling bracket is mounted in for future installation. Slide the brackets off of the mounting pin. Figure 56 1. Locknut and adjusting nut 2. Front tire 3. Adjustment nut 4. Lock nut 14.
3. Set the height-of-cut at A [1-1/2 inch (38 mm)]. 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. 4. Remove the belt covers over the outside spindles. 5. Loosen fastener securing the belt guide to the rear pulley (Figure 59). 3. Lift the front of the machine and support it with stands. 6. Pull the idler arm in the direction shown in Figure 59 and roll the belt off of the pulleys. 4.
Cleaning Cleaning the Collection Sensors Service Interval: Before each use or daily 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 60 1. Washout fitting 2.
Storage Dispose of fuel properly. Recycle as per local codes. Important: Do not store stabilizer/conditioned fuel over 30 days. Cleaning and Storage 11. Remove the spark plug(s) and check its condition; refer to Servicing the Spark Plug in the Engine Maintenance section. With the spark plug(s) removed from the engine, pour two tablespoons of engine oil into the spark plug hole. Use the starter to crank the engine and distribute the oil inside the cylinder. Install the spark plug(s).
Troubleshooting Problem The engine overheats. Possible Cause 1. The engine load is excessive. 1. Reduce ground speed. 2. The oil level in the crankcase is low. 3. The cooling fins 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 fins and air passages. 5. Dirt, water, or stale fuel is in fuel system.
Problem There is abnormal vibration. Reduced bagging performance. Frequent clogging of chute system. Possible Cause 1. The engine mounting bolts are loose. 1. Tighten the engine mounting bolts. 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. 2. Tighten the appropriate pulley. 1. Low engine speed. 1.
Schematics G005894 Electrical Diagram (Rev.
Notes: 46
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The Toro Warranty Conditions and Products Covered Instructions for Obtaining Warranty Service The Toro® Company and its afliate, Toro Warranty Company, pursuant to an agreement between them, jointly promises to the original purchaser* to repair any Toro Product used for normal residential purposes* if defective in materials or workmanship.
