Form No. 3438-269 Rev A Titan® ZX4800, ZX5400, or ZX6000 Riding Mower Model No. Model No. Model No. Model No. Register at www.Toro.com. Original Instructions (EN) 75301—Serial No. 400000000 and Up 75301TA—Serial No. 400000000 and Up 75302—Serial No. 400000000 and Up 75303—Serial No.
Introduction Gross or Net Torque: The gross or net torque of this engine was laboratory rated by the engine manufacturer in accordance with the Society of Automotive Engineers (SAE) J1940 or J2723. As configured to meet safety, emission, and operating requirements, the actual engine torque on this class of mower will be significantly lower. Please refer to the engine manufacturer’s information included with the machine.
information and Note emphasizes general information worthy of special attention. Contents The safety-alert symbol (Figure 2) appears both in this manual and on the machine to identify important safety messages that you must follow to avoid accidents. This symbol will appear with the word Danger, Warning, or Caution. Safety ....................................................................... 4 General Safety ................................................... 4 Slope Indicator .........................
Safety Replacing the Mower Belt ................................. 37 Mower Maintenance............................................. 38 Blade Safety ..................................................... 38 Servicing the Cutting Blades ............................. 38 Leveling the Mower Deck.................................. 41 Removing the Mower Deck............................... 43 Installing the Mower Deck................................. 43 Replacing the Grass Deflector ..........................
Slope Indicator g011841 Figure 4 You may copy this page for personal use. 1. The maximum slope you can operate the machine on is 15 degrees. Use the slope chart to determine the degree of slope of hills before operating. Do not operate this machine on a slope greater than 15 degrees. Fold along the appropriate line to match the recommended slope. 2. Align this edge with a vertical surface, a tree, building, fence pole, etc. 3.
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 missing. decaloemmarkt Manufacturer's Mark 1. This mark indicates that the blade is identified as a part from the original machine manufacturer. decal117-1194 117-1194 decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery. 1. Explosion hazard 6. Keep bystanders away from the battery. 2.
decal130-0731 130-0731 1. Warning—thrown object hazard; keep the deflector shield in place. 2. Cutting hazard of hand or foot, mower blade—keep away from moving parts. decal132-0872 132-0872 1. Thrown object hazard—keep bystanders away from the machine. 3. Severing hazard of hand or foot—keep away from moving parts. 2. Thrown object hazard, raised baffle—do not operate the machine with an open deck; use a bagger or a baffle. 4.
decal136-5596 136-5596 1. Check the tire pressure every 25 operating hours. 4. Check the tire pressure every 25 operating hours. 2. Engine oil 5. Read the Operator's Manual before performing maintenance. 3. Check the tire pressure every 25 operating hours. decal139-3550 139-3550 1. Height of cut decal138-2456 138-2456 1. Read the Operator’s Manual. 2. Park the machine on a level surface when filling the fuel tank. 3. Do not overfill the fuel tank. decal139-7473 139-7473 1. Fast 4.
decal140-3451 140-3451 Note: This machine complies with the industry standard stability test in the static lateral and longitudinal tests with the maximum recommended slope indicated on the decal. Review the instructions for operating the machine on slopes in the Operator’s Manual as well as the conditions in which you would operate the machine to determine whether you can operate the machine in the conditions on that day and at that site.
Product Overview g297253 Figure 5 4. Controls 7. Mower deck 2. Height-of-cut pin 5. Engine 8. Anti-scalp roller 3. Motion-control lever 6. Fuel cap 9. Caster wheel 1. Deck-lift pedal 10 10.
Controls Choke Control Become familiar with all the controls before you start the engine and operate the machine. Use the choke control to start a cold engine (Figure 6). Hour Meter Control Panel The hour meter records the number of hours the engine has operated. It operates when the engine is running. Use these times for scheduling regular maintenance (Figure 6). Motion-Control Levers Use the motion-control levers to drive the machine forward, reverse, and turn either direction (Figure 5).
Height-of-Cut Pin Operation The height-of-cut pin works with the foot pedal to lock the deck in a specific cutting height. Adjust the height of cut only when the machine is not moving (Figure 5). Note: Determine the left and right sides of the machine from the normal operating position. Attachments/Accessories Before Operation A selection of Toro approved attachments and accessories is available for use with the machine to enhance and expand its capabilities.
Fuel Safety compartment to help prevent fires. Clean up oil or fuel spills. • Fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. Adding Fuel – To prevent a static charge from igniting the fuel, place the container and/or machine directly on the ground before filling, not in a vehicle or on an object. Recommended Fuel – Fill the fuel tank outdoors on level ground, in an open area, and when the engine is cold.
Using the Safety-Interlock System WARNING If the safety-interlock switches are disconnected or damaged, the machine could operate unexpectedly, causing personal injury. • Do not tamper with the interlock switches. • 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 blade-control switch (PTO) is disengaged.
4. 5. Adjusting the Motion-Control Levers Sit on the seat, engage the parking brake, move the blade-control switch (PTO) to the OFF position, and move the motion-control levers to NEUTRAL-LOCK position. Start the engine. While the engine is running, center either motion-control lever and move it forward or reverse; the engine should shut off. Repeat for other motion-control lever. Adjusting the Height You can adjust the motion-control levers higher or lower for maximum comfort (Figure 10).
During Operation During Operation Safety • General Safety • • • The owner/operator can prevent and is responsible • • • • • • • • • • • • for accidents that may cause personal injury or property damage. Use your full attention while operating the machine. Do not engage in any activity that causes distractions; otherwise, injury or property damage may occur. Do not operate the machine while ill, tired, or under the influence of alcohol or drugs.
• Before backing up or turning the machine, look • These can change the stability of the machine and cause a loss of control. Follow directions for counterweights. down and all around for small children. Do not carry children on the machine, even when the blades are not moving. Children could fall off and be seriously injured or prevent you from safely operating the machine.
Operating the Parking Brake Engaging the Blade-Control Switch (PTO) Always engage the parking brake when you stop the machine or leave it unattended. Engaging the Parking Brake Park the machine on a level surface. g008945 Figure 15 Note: Always engage the blades with the throttle in the FAST position (Figure 16). g188778 Figure 13 Disengaging the Parking Brake To disengage the parking brake, pull the lever out of the detent slot and toward you, then push it down (Figure 14).
Operating the Throttle Operating the Key Switch 1. You can move the throttle control between the FAST and SLOW positions (Figure 18). Turn the key to the START position (Figure 20). Note: When the engine starts, release the key. Always use the FAST position when engaging the PTO. Important: Do not engage the starter motor for more than 5 seconds at a time. If the engine fails to start, wait 10 seconds between attempts. Failure to follow these instructions can burn out the starter motor.
Starting the Engine Shutting Off the Engine Note: A warm or hot engine may not require choking. 1. Disengage the blades by moving the blade-control switch to the OFF position (Figure 21). 2. Engage the parking brake. 3. Move the throttle control to the FAST position. 4. Turn the key to the OFF position and remove the key. Important: Do not engage the starter for more than 5 seconds at a time. Engaging the starter motor for more than 5 seconds can damage the starter motor.
Driving the Machine The drive wheels turn independently, powered by hydraulic motors on each axle. You can turn 1 side in reverse while you turn the other forward, causing the machine to spin rather than turn. This greatly improves the machine maneuverability but may require some time for you to adapt to how it moves. 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.
Using the Side Discharge Adjusting the Height of Cut The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. The machine is equipped with a foot pedal deck-lift system. You can use the foot pedal to lift the deck briefly to avoid obstacles and to raise the deck. You can adjust the height of cut from 38 to 114 mm (1-1/2 to 4-1/2 inches) in 6 mm (1/4 inch) increments by moving the height-of-cut pin into different hole locations.
Adjusting the Anti-Scalp Rollers Operating Tips Using the Fast Throttle Setting Whenever you change the height of cut, adjust the height of the anti-scalp rollers. For best mowing and maximum air circulation, operate the engine at the FAST position. Air is required to thoroughly cut grass clippings, so do not set the height-of-cut so low as to totally surround the mower deck in uncut grass.
After Operation drop onto your lawn. To avoid this, move onto a previously cut area with the blades engaged or you can disengage the mower deck while moving forward. After Operation Safety Keeping the Underside of the Mower Deck Clean General Safety Clean clippings and dirt from the underside of the mower deck after each use. If grass and dirt build up inside the mower deck, cutting quality will eventually become unsatisfactory.
Transporting the Machine Use a heavy-duty trailer or truck to transport the machine. Use a full-width ramp. Ensure that the trailer or truck has all the necessary brakes, lighting, and marking as required by law. Please carefully read all the safety instructions. Knowing this information could help you or bystanders avoid injury. Refer to your local ordinances for trailer and tie-down requirements.
1. If using a trailer, connect it to the towing vehicle and connect the safety chains. 2. If applicable, connect the trailer brakes and lights. 3. Lower the ramp, ensuring that the angle between the ramp and the ground does not exceed 15 degrees (Figure 28). 4. Back the machine up the ramp (Figure 29). g027995 Figure 29 1. Back the machine up the ramp. 2. Drive the machine forward down the ramp. 5. Shut off the engine, remove the key, and engage the parking brake. 6.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Maintenance Safety • If you leave the key in the switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the switch before you perform any maintenance. • Before you leave the operator’s position, do the following: – Park the machine on a level surface. – Disengage the drives. – Engage the parking brake. – Shut off the engine and remove the key.
Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 5 hours • Change the engine oil and filter. Before each use or daily Every 25 hours • • • • • Check the safety-interlock system. Check the engine-oil level. Clean the air intake screen. Inspect the blades. Inspect the grass deflector for damage. • Check tire pressure. • Check the belts for wear or cracks.
Engine Maintenance Note: Avoid knocking the filter into the side of the body. Engine Safety Inspecting the Filter • Keep your hands, feet, face, clothing, and other Inspect the filter for damage by looking into the filter while shining a bright light on the outside of the filter. If the filter is dirty, bent, or damaged, replace it. body parts away from the muffler and other hot surfaces. Allow engine components to cool before performing maintenance.
Servicing the Engine Oil Engine-Oil Specifications Oil Type: Detergent oil (API service SF, SG, SH, SJ, or SL) Crankcase Capacity: 2.4 L (81 fl oz) with oil filter Viscosity: See the table below. g029683 Figure 32 Checking the Engine-Oil Level Service Interval: Before each use or daily Note: Check the oil when the engine is cold. Important: If you overfill or underfill the engine crankcase with oil and run the engine, you may damage the engine. 1. 2.
5. Change the engine-oil filter (Figure 35). Note: Ensure that the oil-filter gasket touches the engine and then turn the filter an extra 3/4 turn. g027799 g027477 Figure 35 6. g029570 Figure 34 31 Slowly pour approximately 80% of the specified oil into the filler tube and slowly add the additional oil to bring it to the Full mark (Figure 36).
g027478 Figure 37 Checking the Spark Plug Important: Do not clean the spark plug(s). Always replace the spark plug(s) when it has a black coating, worn electrodes, an oily film, or cracks. If you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means the air cleaner is dirty. g235264 Figure 36 7. Set the gap to 0.75 mm (0.03 inch). Dispose of the used oil at a recycling center.
Cleaning the Cooling System 1. Fuel System Maintenance Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the air filter canister from the engine, but do not disconnect the hose. DANGER In certain conditions, fuel is extremely flammable and highly explosive.
Electrical System Maintenance Electrical System Safety • Disconnect the battery before repairing the g027939 machine. Disconnect the negative terminal first and the positive last. Connect the positive terminal first and the negative last. • Charge the battery in an open, well-ventilated area, away from sparks and flames. Unplug the charger before connecting or disconnecting the battery. Wear protective clothing and use insulated tools.
Charging the Battery Service Interval: Before storage—Charge the battery and disconnect the battery cables. 1. Remove the battery from the chassis; refer to Removing the Battery (page 34). 2. Charge the battery for a minimum of 1 hour at 6 to 10 A. Note: Do not overcharge the battery. 3. g297596 Figure 43 1. Battery cover 4. 2. Fasteners When the battery is fully charged, unplug the charger from the electrical outlet, then disconnect the charger leads from the battery posts (Figure 45).
Servicing the Fuses Drive System Maintenance 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. Checking the Tire Pressure Fuse type: • Main—F1 (15 A, blade-type) Service Interval: Every 25 hours—Check tire pressure. • Charge Circuit—F2 (25 A, blade-type) Maintain the air pressure in the front and rear tires as specified. Uneven tire pressure can cause uneven cut.
Belt Maintenance WARNING The spring is under tension when installed and can cause personal injury. Inspecting the Belts Be careful when removing the belt. Service Interval: Every 25 hours—Check the belts for wear or cracks. Replace the belt if it is worn. The signs of a worn belt include squealing while the belt is rotating; the blades slipping while cutting grass; and frayed edges, burn marks, and cracks on the belt.
Mower Maintenance Blade Safety • Inspect the blades periodically for wear or damage. • Use care when checking the blades. Wrap the blades or wear gloves, and use caution when servicing the blades. Only replace or sharpen the blades; never straighten or weld them. g006530 Figure 51 • On multi-bladed machines, take care as rotating one blade can cause other blades to rotate. 1. Cutting edge 3. Wear/slot forming 2. Curved area 4.
g014973 g014973 Figure 53 Figure 55 1. Blade (in position for measuring) 1. Opposite blade edge (in position for measuring) 2. Level surface 3. Measured distance between blade and the surface (A) 2. Level surface 3. Second measured distance between blade and surface (B) 4. Rotate the same blade 180 degrees so that the opposing cutting edge is now in the same position (Figure 54). A.
Removing the Blades Replace the blades if they hit a solid object, or if the blade is out of balance or bent. 1. Hold the blade end using a rag or thickly padded glove. 2. Remove the blade bolt, curved washer, and blade from the spindle shaft (Figure 56). g000553 Figure 58 1. Blade 3. 2. Balancer Repeat this procedure until the blade is balanced. Installing the Blades 1. Install the blade onto the spindle shaft (Figure 56).
Leveling the Mower Deck Checking the Front-to-Rear Blade Slope Check to ensure that the mower deck is level any time you install the mower or when you see an uneven cut on your lawn. Check the front-to-rear blade level any time you install the mower. If the front of the mower is more than 7.9 mm (5/16 inch) lower than the rear of the mower, adjust the blade level.
Leveling the Mower Deck 1. Set the anti-scalp rollers to the top holes or remove them completely for this procedure; refer to Adjusting the Anti-Scalp Rollers (page 23). 2. Set the height-of-cut lever to the 76 mm (3 inch) position; refer to Adjusting the Height of Cut (page 22). 3. Place 2 blocks, each having a thickness of 6.6 cm (2-5/8 inches), under each side of the front edge of the deck but not under the anti-scalp roller brackets (Figure 62). 4. Place 2 blocks, each having a thickness of 7.
Removing the Mower Deck 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and disconnect the spark-plug wires from the spark plugs. 3. Lower the mower to the 76 mm (3 inches) height-of-cut position. 4. Remove the mower belt from the engine pulley; refer to Replacing the Mower Belt (page 37). 5.
Replacing the Grass Deflector 3. Position the new discharge deflector with the bracket ends between the welded brackets on the deck as shown in Figure 67. Service Interval: Before each use or daily—Inspect the grass deflector for damage. 4. Install the spring onto the straight end of the rod. 5. Position the spring on the rod as shown in Figure 67 so that the shorter spring end comes from under the rod before the bend and going over the rod as it returns from the bend. 6.
Cleaning Storage Disposing of Waste Storage Safety • Shut off the engine, remove the key, and wait Engine oil, batteries, hydraulic fluid, and engine coolant are pollutants to the environment. Dispose of these according to your state and local regulations. for all moving parts to stop before you leave the operator’s position. Allow the machine to cool before adjusting, servicing, cleaning, or storing it.
A. Storing the Battery Add fuel stabilizer/conditioner to fresh fuel in the tank. Follow mixing instructions from the fuel stabilizer manufacturer. Do not use an alcohol-based stabilizer (ethanol or methanol). B. Run the engine to distribute conditioned fuel through the fuel system for 5 minutes. C. Shut off the engine, allow it to cool, and drain the fuel tank. D. Start the engine and run it until it shuts off. E. Dispose of fuel properly. Recycle the fuel according to local codes. 1.
Troubleshooting Problem Possible Cause The fuel tank is showing signs of collapsing or the machine is frequently showing signs of running out of fuel. 1. The air-cleaner paper element clogged. The engine overheats. 1. The engine load is excessive. 1. Reduce the 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.
Problem The machine does not drive. The machine vibrates abnormally. The cutting height is uneven. The blades do not rotate. Possible Cause Corrective Action 1. The bypass valves are open. 1. Close the tow valves. 2. The traction belts are worn, loose, or broken. 3. The traction belts are off the pulleys. 4. The transmission has failed. 2. Contact an Authorized Service Dealer. 1. The cutting blade(s) is/are bent or unbalanced. 1. Install new cutting blade(s). 2. The blade mounting bolt is loose.
Schematics g297640 Electrical Diagram (Rev.
Notes:
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