Form No. 3354-630 Rev A TimeCutter® ZX440 and ZX525 Riding Mowers Model No. 74406—Serial No. 260000001 and Up Model No. 74407—Serial No. 260000001 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.
Adjusting the Motion Control Levers ............................... 18 Pushing the Machine by Hand............ 18 Converting to Side Discharge............. 19 Operating Tips .................................. 21 Maintenance...................................................... 23 Recommended Maintenance Schedule(s) ............................... 23 Lubrication................................................ 23 How to Grease .................................. 23 Where to Add Grease ........................
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. • 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.
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. 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 110-1868 1. Thrown object hazard, mower—keep the deector in place. 2.
9-8939 3. 1. Read the Operator’s Manual. 2. Height of cut Remove the ignition key and read the instructions before servicing or performing maintenance. 104-8062 1. Height of cut 104-8009 1. 2. 3. 4. 5. 6. Throttle 7. 8. Choke Continuous variable setting 9. 10. Slow On 11. Off Headlights Engine—stop Engine—run Engine—start Ignition 104-8063 1. Height of cut 104-8061 1. To ride the machine, pull the lever out. 2. Do not tow the machine. 3. To push the machine, push the lever in. 106-5517 1.
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.
• 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. The safety interlock system also is designed to stop the engine when the traction controls are moved with the parking brake on or if you rise from the seat when the blades are engaged. • Use caution when making turns. • Slow the machine down before making sharp turns.
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.
Adjusting the Motion Control Levers The motion control levers can be adjusted higher or lower for maximum operator comfort. 1. Remove the 2 screws and curved washers holding the control lever to the control arm shaft (Figure 16). 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.
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. Operating the mower without the front baffle in place, can expose you and others to blade contact and thrown debris.
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 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.
pour only enough oil into the fill hole to raise the level to, but not over, the Full mark on the dipstick. 11. Slowly pour approximately 80% of the specified oil into the filler cap (Figure 25). Refer to Servicing the Engine Oil, in Engine Maintenance, page 24. 12. Check the oil level; refer to Checking the Oil Level. 13. Slowly add additional oil to bring it to the full mark. Important: Do not overfill the crankcase with oil because the engine may be damaged. Changing and Draining the Oil 1.
Note: Service the air cleaner more frequently (every few hours) if operating conditions are extremely dusty or sandy. C. Soak the element in new engine oil. (Figure 28). Squeeze the element to remove excess oil. Important: Replace the foam element if it is torn or worn. Removing the Foam and Paper Elements 1. Disengage the blade control switch and move the control levers to the neutral locked position and apply the parking brake. 2.
2. Place the air cleaner assembly onto the air cleaner base and install the wing nut (Figure 27). 3. Install the air cleaner cover and secure the latches (Figure 27). installing the spark plug. Use a spark plug wrench for removing and installing the spark plug(s) and a gapping tool/feeler gauge to check and adjust the air gap. Install a new spark plug(s) if necessary. Cleaning the Cooling System Air Gap: 0.030 inch (0.76 mm) Clean the air intake screen from grass and debris before each use.
3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 4. Close the fuel shut-off valve located under the front of the fuel tank. 5. Loosen the hose clamp at the fuel filter and slide it up the fuel line away from the fuel filter (Figure 33). Figure 32 1. Center electrode insulator 2. Side electrode 3. 6. Pull the fuel line off of the fuel filter (Figure 33). Air gap (not to scale) 7. Open the fuel shut-off valve.
2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Tip the seat forward to see the battery. 4. Disconnect the negative (black) ground cable from the battery post (Figure 34). Incorrect battery cable routing could damage the tractor and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. Figure 33 1. Fuel lter 2. Hose clamp 3.
Adding Water to the Battery 2. Install the positive (red) battery cable to the positive (+) battery terminal. 3. Install the negative battery cable to the negative (-) battery terminal. 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. 4. Secure the cables with 2 bolts (1/4 x 3/4 inch), washers (1/4 inch), and nuts (1/4 inch) (Figure 34). 1.
Figure 36 1. Positive battery post 2. Negative battery post 3. 4. Red (+) charger lead Black (-) charger lead 5. Install the battery in the tractor and connect the battery cables; refer to Installing the Battery. Figure 37 Note: Do not run the tractor with the battery disconnected, electrical damage may occur. Servicing the Fuses 1. Main–30 amp 2. Charge circuit–25 amp 3.
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 39 1. Cutting edge 2. Curved area Check the cutter blades daily for sharpness, and for any wear or damage. File down any nicks and sharpen the blades as necessary.
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. the same amount of material is removed from both cutting edges. Figure 43 A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders. 1. • Always replace bent or damaged blade with a new blade. Sharpen at original angle 2.
Adjusting the Front-to-Rear Blade Slope 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 45). Measure between the outside cutting edges and the flat surface (Figure 45). If both measurements are not within 3/16 inch (4.75 mm), an adjustment is required; refer to steps 5 and 6.
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. 13. When the front-to-rear blade slope is correct, tighten the jam nuts (Figure 47 and Figure 49). 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. 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 52). Figure 51 1. Hairpin cotter and clevis pin 2. Rear trunion rod 3. Hairpin cotter and washer 4. Leveling bracket 8. Slide the mower rearward to remove the mower belt from the engine pulley. 9. Slide the mower out from underneath the tractor.
Installing the Mower 1. Park the machine on a level surface. 2. Disengage the blade control switch and move the control levers to the neutral locked position and apply the parking brake. 3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 4. Slide the mower under the tractor. Figure 54 5. Lower the height-of-cut lever to the lowest position. 1. 2. 3. 6.
2. Disengage the blade control switch and move the control levers to the neutral locked position and apply the parking brake. A broken or missing washout fitting could expose you and others to thrown objects or blade contact. Contact with blade or thrown debris contact will cause injury or death. 3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 4.
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.
