Form No. 3354-642 Rev A TimeCutter® ZX525 Riding Mower Model No. 74806—Serial No. 260000001 and Up Register your product at www.Toro.
Warning 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. Other states or federal areas may have similar laws. Figure 1 1.
Contents 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......................
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.
• Reduce speed and use extreme caution on slopes. • Do not make sudden turns or rapid speed changes. • Use a walk behind mower and/or a hand trimmer near drop-offs, ditches, steep banks or water. • 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.
• Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until the fueling is complete. Do not use a nozzle lock-open device. • 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. • If fuel is spilled on clothing, change clothing immediately. • Stop the engine, disconnect spark plug wire(s) and remove key before performing any service, repairs, maintenance or adjustments.
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. 93-1122 1-633354 1. Fast 2. Slow 3. 4. Neutral Reverse 92-7108 98-3798 92-7109 99-3943 1.
104-8032 104-3641 1. 1. Height of cut Height of cut 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. 104-8009 1. 2. 3. 4. 5. 6. Throttle 7. 8. Choke Continuous variable setting 9. 10. Slow On 11.
Battery Symbols Some or all of these symbols are on your battery 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. 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. Contains lead; do not discard.
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.
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 After the rst 8 operating hours • Change the engine oil. Before each use or daily • • • • • Check the safety system. Clean the air intake screen. Check the engine oil level (more often in dirty or dusty conditions). 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). Paper Element: Clean after every 100 operating hours. Replace after every 200 operating hours or yearly, whichever comes first. 4. Connect a grease gun to the fitting. Pump grease into the fittings until grease begins to ooze out of the bearings. Note: Service the air cleaner more frequently (every few hours) if operating conditions are extremely dusty or sandy. 5. Wipe up any excess grease.
C. Soak the element in new engine oil. (Figure 21). Squeeze the element to remove excess oil. 1. Disengage the blade control switch and move the control levers to the neutral locked position and apply the parking brake. Important: Replace the foam element if it is torn or worn. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the air intake screen, cylinder covers, and fan housing. 4. Clean debris and grass from the parts. 5.
Important: Do not overfill the crankcase with oil because the engine may be damaged. Changing and Draining the Oil 1. Start the engine and let it run until warm. This warms the oil so 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. Disengage the blade control switch and set the parking brake. Figure 24 4.
Figure 27 Figure 26 1. 1. Oil drain Oil lter 2. Adapter 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 27). 10. Clean around the oil dipstick and unscrew the cap (Figure 26). 11. Slowly pour approximately 80% of the specified oil into the filler cap (Figure 26). Refer to Servicing the Engine Oil, in Engine Maintenance, page 22. 5.
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 28 1. Spark plug wire installed 2. • Drain gasoline from the fuel tank when the engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills. Spark plug Checking the Spark Plug 1. Look at the center of the spark plug(s) (Figure 29).
2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. part baking soda. Apply a light coating of grease to the battery terminals to prevent corrosion. Voltage: 12 v 3. Close the fuel shut-off valve located under the front of the fuel tank. Removing the Battery 4. Squeeze the ends of the hose clamps together and slide them away from the filter (Figure 30). 5. Remove the filter from the fuel lines.
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 32). Do not allow the electrolyte to fall below the Lower line (Figure 32). Figure 31 1. 2. 3. 4. Battery Terminal boot Positive battery cable Negative battery cable 5. 6. 7. Figure 32 Battery hold-down Bolt and washer Nut 1. Vent caps 2. Upper line 3. Lower line 3.
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 34). 2. To replace a fuse, pull out on the fuse to remove it (Figure 34). 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 36). If you notice any damage, wear, or a slot forming in this area (item 3 in Figure 36), immediately install a new blade. Figure 35 1. Valve stem Mower Maintenance Figure 36 Servicing the Cutting Blades 1. Cutting edge 2. Curved area Maintain sharp blades throughout the cutting season because sharp blades cut cleanly without tearing or shredding the grass blades.
Figure 38 4. Rotate the opposite ends of the blades forward. Figure 39 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. 1. 2. 3. Sail area of blade Blade Curved washer 4. 5.
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 39). Torque the blade bolt to 35-65 ft-lb (47-88 N⋅m). a different hole and install the washer and hairpin cotter. (Figure 43). A front hole lowers the blade height and a rear hole raises its height. Adjust both sides as required.
7. Then secure the yoke with the clevis pin and cotter pin. Repeat this procedure on the opposite side of the mower. Figure 46 1. 2. Figure 44 1. Rear trunion rod 2. Clevis pin and cotter pin 3. 4. Front trunion rod yoke Hairpin cotter 3. Jam nut 11. Rotate the yokes on the rods to change the adjustment (Figure 46). 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). Jam nut Yoke 8.
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 Figure 47 1. Hairpin cotter and clevis pin 2. 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. Remove the belt covers over the outside spindles. 4.
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 50 Top View 1. Mower belt 2. Idler arm 3. Outside pulley 4. 5. Spring Idler pulley 1.
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 bolts with the second holes 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. 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. Figure 52 Cleaning 1. Washout tting 2.
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 (PTO), 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 (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. 6.
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 A Three-Year Full Warranty (Limited Warranty for Commercial Use) ZX 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.
