Form No. 3357-837 Rev A TimeCutter® ZX440 and ZX525 Riding Mowers Model No. 74406—Serial No. 270000001 and Up Model No. 74407—Serial No. 270000001 and Up Register your product at www.Toro.
For models with stated engine horsepower, the gross horsepower of the engine was laboratory rated by the engine manufacturer in accordance with SAE J1940. As configured to meet safety, emission, and operating requirements, the actual engine horsepower on this class of lawn mower will be significantly lower. 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.
Converting to Side Discharge............. 20 Operating Tips .................................. 22 Maintenance...................................................... 24 Recommended Maintenance Schedule(s) ............................... 24 Lubrication................................................ 24 How to Grease .................................. 24 Where to Add Grease ........................ 25 Engine Maintenance.................................. 25 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 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. • Watch for ditches, holes, rocks dips, and rises that change the operating angle, as rough terrain could overturn the machine. • 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. • Avoid sudden starts when mowing uphill because the mower may tip backwards. • Be aware that loss of traction may occur going downhill.
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. 93-7316 Service Deector 1.
104-8009 1. 2. 3. 4. 5. 6. 99-3943 1. Engine Throttle 7. 8. Choke Continuous variable setting 9. 10. Slow On 11. Off Headlights Engine—stop Engine—run Engine—start Ignition 104-8061 1. 2. To ride the machine, pull the lever out. Do not tow the machine. 3. To push the machine, push the lever in. 99-8936 1. Machine speed 2. Fast 3. Slow 4. 5. Neutral Reverse 104-8062 1. 112-9840 1. Read the Operator’s Manual. 2. Height of cut 3.
Battery Symbols Some or all of these symbols are on your battery 104-8063 1. Explosion hazard 6. 2. No re, open ame, or smoking. 7. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 8. 1. Height of cut 5. Read the Operator’s Manual. 9. 10. Keep bystanders a safe distance from the battery. Wear eye protection; explosive gases can cause blindness and other injuries Battery acid can cause blindness or severe burns. Flush eyes immediately with water and get medical help fast.
107-2482 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Engage Disengage Parking brake Warning—set the parking brake and remove the ignition key before leaving the machine and read the instructions before servicing or performing maintenance. Warning—read the Operator’s Manual. Thrown object hazard, mower—keep the deector in place. Tipping hazard, slopes greater than 12.5 degrees—do not drive the machine on a slope greater than 12.5 degrees.
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. 11. 12. Discharge chute Gas tank 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. Motion control lever 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. 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. 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. Height-of-cut lever 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.
Without the grass deflector, discharge cover, or complete grass catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris. Contact with rotating mower blade(s) and thrown debris will cause injury or death. • Never remove the grass deflector from the mower because the grass deflector routes material down toward the turf. If the grass deflector is ever damaged, replace it immediately. Figure 17 1. Position for pushing the machine 2.
2. Remove the carriage bolts and locknuts securing the front baffle to the deck (Figure 19). Remove the front baffle to gain access to the right side Recycler® baffle. Figure 19 Figure 18 1. Right side bafe 2. Bolt (5/16 x 1-1/4 inches) 3. Locknut (5/16 inch) 4. 5. 6. Knob Curved washer Left side bafe Note: Save the hardware for use when installing the baffle. Operating the mower without the front baffle in place, can expose you and others to blade contact and thrown debris.
3. Remove the bolts and nuts in the deck holes needed to secure the baffle to the deck (Figure 20). 4. Install the baffle by sliding it into the discharge opening (Figure 20). 5. Secure the baffle with the nuts and bolts (Figure 20) removed in Step 3. 6. Replace the front baffle and secure it to the deck (Figure 19) using the fasteners removed previously. Figure 20 1. Bafe left side 2. Bolt, 5/16 x 5/8 inch 3.
Blade Maintenance grass is sparse, or it is late fall when grass grows more slowly. Maintain a sharp blade throughout the cutting season because a sharp blade cuts 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. Check the cutter blades daily for sharpness, and for any wear or damage. File down any nicks and sharpen the blades as necessary.
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 SF, SG , SH or SJ) Crankcase Capacity: with filter, 51 ounces (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 24 1. Oil dipstick 2. Filler tube 3. Metal end, dipstick Figure 25 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 25). 11.
Figure 26 1. Oil lter 2. Adapter Figure 27 1. 2. 3. 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 26). 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 Servicing the Air Cleaner 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. 4. Clean debris and grass from the parts. 5. Install the air intake screen, cylinder covers, and fan housing. Figure 29 1. Paper element 2. Rubber seal Installing the Foam and Paper Elements Figure 30 1. Air intake screen 2.
Fuel System Maintenance Draining the Fuel Tank 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. Figure 31 1. Spark plug wire installed 2. Spark plug • Drain gasoline from the fuel tank when the engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills. Checking the Spark Plug 1. Look at the center of the spark plug(s) (Figure 32).
Removing the Battery 2. 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. 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. 4. Squeeze the ends of the hose clamps together and slide them away from the filter (Figure 33).
2. Look at the side of the battery. The electrolyte must be up to the Upper line (Figure 35). Do not allow the electrolyte to fall below the Lower line (Figure 35). Figure 34 1. 2. 3. 4. Battery Terminal boot Positive battery cable Negative battery cable 5. 6. 7. Figure 35 Battery hold-down Bolt and washer Nut 1. 2. Vent caps Upper line 3. Lower line 3. If the electrolyte is low, add the required amount of distilled water; refer to Adding Water to the Battery. Installing the Battery 1.
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 37). 2. To replace a fuse, pull out on the fuse to remove it (Figure 37). 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 39). If you notice any damage, wear, or a slot forming in this area (item 3 in Figure 39), immediately install a new blade. Figure 38 1. Valve stem Mower Maintenance Figure 39 Servicing the Cutting Blades 1. 2. Cutting edge Curved area 3. Wear/slot forming Maintain sharp blades throughout the cutting season because sharp blades cut cleanly without tearing or shredding the grass blades.
Figure 41 Figure 42 4. Rotate the opposite ends of the blades forward. 1. Sail area of blade 2. Blade 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. 4. 5. 3.
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 42). Torque the blade bolt to 35-65 ft-lb (47-88 N⋅m). hairpin cotter. (Figure 46). 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.
Figure 49 Figure 47 1. Rear trunion rod 2. Clevis pin and cotter pin 3. 4. 1. Front trunion rod yoke 2. Hairpin cotter Jam nut Yoke 3. Jam nut 11. Rotate the yokes on the rods to change the adjustment (Figure 49). 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). 8. Set the height-of-cut at 3 inch (76 mm) and carefully rotate the blades so they are facing front to rear (Figure 48). 9.
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). Figure 50 1. Hairpin cotter and clevis pin 2. Front trunion 2. Set the height-of-cut at 1-1/2 inch (38 mm). 3. Remove the belt covers over the outside spindles. 6.
Replacing the Grass Deector 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. Figure 53 Top View 1. Mower belt 2. Idler arm 3. Outside pulley 4. 5. Spring Idler pulley 1.
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. 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. Then repeat the process. Cleaning 9. Run the mower again for one to three minutes to remove excess water.
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.
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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.
