Form No. 3433-585 Rev A Titan® ZX4800, ZX5400, and ZX6000 Riding Mower Model No. 75301—Serial No. 400000000 and Up Model No. 75302—Serial No. 400000000 and Up Model No. 75303—Serial No. 400000000 and Up Register at www.Toro.com.
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. 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.
Contents Belt Maintenance ................................................ 39 Inspecting the Belts .......................................... 39 Replacing the Mower Belt ................................. 39 Mower Maintenance............................................. 40 Blade Safety ..................................................... 40 Servicing the Cutting Blades ............................. 40 Leveling the Mower Deck.................................. 43 Removing the Mower Deck......................
Safety to explain this material to them; other languages may be available on our website. • Only allow trained, responsible, and physically This machine has been designed in accordance with ANSI standard B71.1-2017. capable operators that are familiar with the safe operation, operator controls, and safety signs and instructions to operate the machine. Never let children or untrained people operate or service the equipment. Local regulations may restrict the age of the operator.
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.
Pre-Start Fuel Safety Fill fuel tank on level ground. See Fuel Recommendations in the Specifications section for additional gasoline information. Use extreme care when handling fuel. Do Not add oil to gasoline. In certain conditions gasoline is extremely flammable and vapors are explosive. DANGER Do Not overfill fuel tank. Fill the fuel tank to the bottom of the filler neck. The empty space in the tank allows gasoline to expand.
flame or any enclosed area where open pilot lights or heat appliances are present. DANGER In certain conditions during fueling, static electricity can be released causing a spark which can ignite gasoline vapors. A fire or explosion from gasoline can burn you and others and cause property damage. Adding Fuel • Always place gasoline containers on the ground away from your vehicle before filling.
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 • Be sure all drives are in neutral and parking brake • During Operation Safety • General Safety The operator must use their full attention when operating the machine. Do Not engage in any activity that causes distractions; otherwise, injury or property damage may occur. • WARNING Operating engine parts, especially the muffler, become extremely hot. Severe burns can occur on contact and debris, such as leaves, grass, brush, etc. can catch fire.
• • distance (twice the width of the machine) between the machine and any hazard. Use a walk behind machine or a hand trimmer to mow the grass in these areas. – Whenever you leave the mower. Do Not leave a running machine unattended. Stop engine, wait for all moving parts to stop: – Before refueling. – Before dumping the grass catcher. – Before making height adjustments. Tragic accidents can occur if the operator is not alert to the presence of children.
Towing Safety Operating the Parking Brake • Do not attach towed equipment except at the hitch point. Always engage the parking brake when you stop the machine or leave it unattended. • Do not use the machine as a towing vehicle unless it has a hitch installed. • Do not exceed the weight limits for towed Engaging the Parking Brake equipment and towing on slopes. The towed weight must not exceed the weight of the machine and operator. Park the machine on a level surface.
Engaging the Blade-Control Operating the Throttle You can move the throttle control between FAST and Switch (PTO) SLOW positions (Figure 17). Always use the FAST position when engaging the PTO. g008945 Figure 14 Note: Always engage the blades with the throttle in the FAST position (Figure 15). g295539 Figure 17 Operating the Choke Use the choke to start a cold engine. 1. Pull up the choke knob to engage the choke before using the key switch (Figure 18). Note: Ensure that you fully engage the choke.
Operating the Key Switch 1. Starting the Engine Turn the key to the START position (Figure 19). Note: A warm or hot engine may not require choking. Note: When the engine starts, release the key. Important: Do not engage the starter for more Important: Do not engage the starter motor than 5 seconds at a time. Engaging the starter motor for more than 5 seconds can damage the starter motor. If the engine fails to start, wait 10 seconds before operating the engine starter again.
Driving the Machine Shutting Off the Engine 1. Disengage the blades by moving the blade-control switch to the OFF position (Figure 16). 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. 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.
Using the Side Discharge The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. DANGER Without a grass deflector, discharge cover, or a 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 deck because the grass deflector routes material down toward the turf.
Adjusting the Height of Cut Adjusting the Anti-Scalp Rollers 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. Whenever you change the height of cut, adjust the height of the anti-scalp rollers. 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.
Operating Tips 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. Using the Fast Throttle Setting 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 WARNING Driving on the street or roadway without turn signals, lights, reflective markings, or a slow moving vehicle emblem is dangerous and can lead to accidents causing personal injury. After Operation Safety General Safety • Park machine on level ground, disengage drives, • • Do not drive machine on a public street or roadway. set parking brake, stop engine, remove key or disconnect spark plug wire.
WARNING Loading a machine onto a trailer or truck increases the possibility of tip-over and could cause serious injury or death. • Use extreme caution when operating a machine on a ramp. • Use only a full-width ramp; do not use individual ramps for each side of the machine. • Do not exceed a 15-degree angle between the ramp and the ground or between the ramp and the trailer or truck. • Ensure the length of ramp is at least four times (4X) as long as the height of the trailer or truck bed to the ground.
3. Locate the bypass levers on the frame on both sides of the engine. 4. Move the bypass levers forward through the key hole and down to lock them in place (Figure 29). Note: Do this for each lever. 5. Disengage the parking brake. g298692 Figure 29 1. Bypass-lever locations 3. Lever position for pushing the machine 2. Lever position for operating the machine 6. When finished, engage the parking brake.
Maintenance WARNING Removal or modification of original equipment, parts and/or accessories may alter the warranty, controllability, and safety of the machine. Unauthorized modifications to the original equipment or failure to use original Toro parts could lead to serious injury or death. Unauthorized changes to the machine, engine, fuel or venting system, may violate applicable safety standards such as: ANSI, OSHA and NFPA and/or government regulations such as EPA and CARB.
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 • Shut off the engine before checking the oil or 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. adding oil to the crankcase. • Keep your hands, feet, face, clothing, and other body parts away the muffler and other hot surfaces.
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 31 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 34). Note: Ensure that the oil-filter gasket touches the engine and then turn the filter an extra 3/4 turn. g027799 g027477 Figure 34 6. g029570 Figure 33 33 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 35).
g027478 Figure 36 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 35 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 36). 2. Charge the battery for a minimum of 1 hour at 6 to 10 A. Note: Do not overcharge the battery. 3. g297596 Figure 42 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 44).
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 A worn or damaged blade can break, and a piece of the blade could be thrown toward you or bystanders, resulting in serious personal injury or death. Trying to repair a damaged blade may result in discontinued safety certification of the product. g006530 Figure 50 • 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.
g014973 g014973 Figure 52 Figure 54 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 53). 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 55). g000553 Figure 57 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 55).
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 24). 2. Set the height-of-cut lever to the 76 mm (3 inch) position; refer to Adjusting the Height of Cut (page 24). 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 61). 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 39). 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 66. 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 66 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 • Let the engine cool before storing the machine. • Do not store the machine or fuel near flames or Engine oil, batteries, hydraulic fluid, and engine coolant are pollutants to the environment. Dispose of these according to your state and local regulations. drain the fuel indoors. Cleaning and Storage 1. Disengage the blade-control switch (PTO), and engage the parking brake. 2.
Storing the Battery Note: A fuel stabilizer/conditioner is most effective when mixed with fresh fuel and used at all times. B. Run the engine to distribute conditioned fuel through the fuel system (5 minutes). C. Shut off the engine, allow it to cool, and drain the fuel tank using a pump type syphon or operate the engine until it shuts off. D. Fully charge the battery. 2. Let the battery rest for 24 hours, then check the battery voltage. Note: If the battery voltage is below 12.
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.
