Form No. 3360-955 Rev A TITAN® ZX5400 and ZX6000 Zero-Turn-Radius Riding Mower Model No. 74822—Serial No. 290000001 and Up Model No. 74823—Serial No. 290000001 and Up G009968 To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com.
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. G009950 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.
Contents Changing the Hydraulic System Filter and Oil.................................................................. 38 Mower Deck Maintenance ...................................... 40 Servicing the Cutting Blades ............................... 40 Mower Deck Leveling......................................... 42 Inspecting the Belts ............................................ 44 Replacing the Mower Belt ................................... 44 Removing the Mower .........................................
Safety • 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. Stop the engine and wait for all parts to come to a complete stop before cleaning the machine, removing the grass catcher or unclogging the discharge chute. • Operate the machine only in daylight or good artificial light. • Do not operate the machine while under the influence of alcohol or drugs.
• Avoid sudden starts when mowing uphill because the mower may tip backwards. • Be aware that loss of traction may occur going downhill. Weight transfer to the front wheels may cause drive wheels to slip and cause loss of braking and steering. • Always avoid sudden starting or stopping on a slope. If tires lose traction, disengage the blades and proceed slowly off the slope. • Use extreme care with grass catchers or other attachments. These can change the stability of the machine and cause loss of control.
Note: Determine the left and right sides of the machine from the normal operating position. • Never tamper with safety devices. Check their proper operation regularly. • Keep the machine free of grass, leaves, or other debris build-up. Clean up oil or fuel spillage fuel soaked debris. Allow the machine to cool before storing. • Stop and inspect the equipment if you strike an object. Repair, if necessary, before restarting. • Never make any adjustments or repairs with the engine running.
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. 115-9631 1. Power take-off (PTO), Blade control switch on some models 2. Blade control switch—On 99-8936 1. Machine speed 2. Fast 3. Slow 4. Neutral 5. Reverse 3. Blade control switch—Off 4. Choke 5. Fast 6. Continuous variable setting 7. Slow 114-1606 1. Entanglement hazard, belt—keep all guards in place.
110-6691 1. Thrown object hazard—keep bystanders a safe distance from the machine. 2. Thrown object hazard, mower—do not operate without the deflector, discharge cover, or grass collection system in place. 3. Cutting/dismemberment of hand or foot—stay away from moving parts. 112-9840 1. Read the Operator’s Manual. 3. Remove the ignition key and read the instructions before servicing or performing maintenance. 115-9644 1. Press the pedal and lift the height of cut lever to unlock the deck position. 2.
9-8965 1. Warning–read the Operator’s Manual. 2. Read the instructions before servicing or performing maintenance; apply parking brake, remove the ignition key and disconnect the spark plug wire. 3. Thrown object hazard—keep bystanders a safe distance from the machine, pick up debris before operating, keep the discharge deflector in place. 4. Loss of traction/control hazard, slopes–loss of traction/control on slope, disengage the blade control switch (PTO), proceed off the slope slowly. 5.
5-9628 1. Fuel 2. Full 3. Half 4. Empty 115-9629 1. Fuel 2. Full 3. Half 11 4.
Product Overview 2 1 10 3 4 5 9 6 8 G010001 7 Figure 3 1. Motion control levers 2. Operator seat 3. Parking brake 4. Fuel gauge 5. Footrest 6. Front caster wheel 7. Anti-scalp roller 8. Deflector 9. Foot pedal deck lift and height-of-cut 10. Control panel 1 2 6 5 3 4 G010009 Figure 4 1. Gas tank cap 2. Mower Deck 3. Washout port 4. Drive wheel 5. Engine guard 6.
Controls Become familiar with all the controls before you start the engine and operate the machine (Figure 5). G010016 1 2 1 4 3 G009918 Figure 5 1. Throttle and choke control 2. Hour meter 3. Ignition switch 4. Blade control switch (PTO) 5. Fuses G010077 Figure 6 1. Fuel gauge window Ignition Switch Motion Control Levers The ignition switch has three positions: Start, Run and Off. The key will turn to Start and move back to Run upon release.
Attachments/Accessories Operation A selection of Toro approved attachments and accessories are available for use with the machine to enhance and expand its capabilities. Contact your Authorized Service Dealer or Distributor or go to www.Toro.com for a list of all approved attachments and accessories. 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.
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. • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any gasoline that spills. • Never fill the fuel tank inside an enclosed trailer. • Do not fill the fuel tank completely full. Add gasoline to the fuel tank until the level is 1/4 to 1/2 inch (6 to 13 mm) below the bottom of the filler neck.
Important: Do not use fuel additives containing methanol or ethanol. 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. Add the correct amount of gas stabilizer/conditioner to the gas. Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline.
Filling the Fuel Tank Setting the Parking Brake Note: Do not fill the fuel tank completely full, this will allow gasoline to expand. 1 2 1. Shut the engine off and set the parking brake. 2. Clean around the fuel tank cap. 3. Fill the fuel tank to the bottom of the filler neckFigure 9. G010078 Figure 10 Releasing the Parking Brake G010016 1 1 2 3 2 G010079 Figure 11 Operating the Throttle 4 The throttle control can be moved between Fast and Slow positions (Figure 12).
3. Set the parking brake (Figure 15); refer to Setting the Parking Brake. G010288 4. Move the blade control switch (PTO) to the Off position (Figure 15). 5. Move the throttle lever to Choke before starting a cold engine. Note: A warm or hot engine may not require choking. Figure 13 1 2 3 4 Move the throttle lever back to disengage the choke after the engine has started. Operating the Ignition Switch 1. Turn the ignition key to the Start position (Figure 14). When the engines starts, release the key.
Operating the Mower Blade Control Switch (PTO) ST The blade control switch (PTO) starts and stops the mower blades and any powered attachments. RT A N RU P ST O Engaging the Blade Control Switch (PTO) G008947 Figure 16 1. Off 2. Run Note: Engaging the blade control switch (PTO) with the throttle position at half or less will cause excessive wear to the drive belts. 3.
Understanding the Safety Interlock System Machine can spin very rapidly. Operator may lose control of machine and cause personal injury or damage to machine. The safety interlock system is designed to prevent the engine from starting unless: • The parking brake is engaged. • Use caution when making turns. • The blades are disengaged. • Slow the machine down before making sharp turns. • The motion control levers are in the neutral lock position.
Stopping the Machine To stop the machine, move the traction control levers to neutral and move to locked position, disengage the blade control switch (PTO), and turn the ignition key to off. Set the parking brake when you leave the machine; refer to Setting the Parking Brake. Remember to remove the key from the ignition switch. Children or bystanders may be injured if they move or attempt to operate the tractor while it is unattended.
1 G010016 5 4 3 2 G010236 Figure 24 1. Deck lift pedal 2. Cut height pin 4. Lock position. lowest height-of-cut (use only for deck removal) 5. Lock position. transport position 3. Height-of-cut positions Using the Lock Positions G010219 The deck can be locked in the highest height-of-cut or transport position or the lowest height-of-cut position. 1. Push on the deck lift pedal with your foot and raise the mower deck to the transport position (also the 4.
Changing the Seat Ride Suspension 4 The number of seat springs can be changed to maximize rider comfort. More springs should be used with heavier operators and on rough terrain. Fewer springs should be used with lighter operators and when mowing smooth, well established lawns. Always keep the number of springs on the left and right side the same when adding and removing springs. G010233 3 1 2 Figure 25 1. Anti-scalp roller 2. Bolt 4 3. Flange Nut 4.
1 Pushing the Machine by Hand 2 Important: Always push the machine by hand. Never tow the machine because damage may occur. 3 4 To Push the Machine 1. Park the machine on a level surface and disengage the blade control switch. 2. Move the motion control levers outward to neutral lock position, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Locate the bypass levers at the rear of the machine, on the left and right side of the frame.
To Operate the Machine than six inches tall, you may want to cut the lawn twice to ensure an acceptable quality of cut. Move the bypass to the position for pushing the machine (Figure 30) to engage the wheel motors. Cut 1/3 of the Grass Blade Using the Side Discharge It is best to cut only about 1/3 of the grass blade. Cutting more than that is not recommended unless grass is sparse, or it is late fall when grass grows more slowly.
Keep the Underside of the Mower Clean Clean clippings and dirt from the underside of the mower after each use. If grass and dirt build up inside the mower, cutting quality will eventually become unsatisfactory. Blade Maintenance 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.
Maintenance Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 8 hours • Change the engine oil. After the first 50 hours • Change the hydraulic system filter and oil. Before each use or daily • • • • • • • Check the safety interlock system. Check the air cleaner for dirty, loose or damaged parts. Check the engine oil level. Check air intake and cooling areas, clean as necessary. Check the mower blades.
Figure 31 Located on the seat pan underside 1. Read the Operator’s Manual before performing any maintenance. 2. Check the engine oil every 8 hours 3. Check the drive wheel tire pressure every 25 hours 4. Check the hydraulic oil every 25 hours 5. Check the caster wheel tire pressure every 25 hours 6.
Premaintenance Procedures Lubrication Raising the Seat Service Interval: Every 25 hours—Grease all lubrication points. Greasing the Bearings Make sure the motion control levers are locked in the neutral lock position. Lift the seat forward. Grease Type: No. 2 General Purpose Lithium Base Grease The following components can be accessed by raising the seat: 1. Park the machine on a level surface and disengage the blade control switch. • Service decal 2.
Engine Maintenance 1 2 3 Contact with hot surfaces may cause personal injury. 5 Keep hands, feet, face, clothing and other body parts away the muffler and other hot surfaces. 4 6 Servicing the Air Cleaner G010338 Service Interval: Before each use or daily—Check the air cleaner for dirty, loose or damaged parts. Figure 34 1. Air cleaner cover 2. Air cleaner latch 3. Air cleaner 4. Air cleaner base 5. Foam element 6.
Checking the Engine Oil Level Replace the air cleaner element yearly, or every 100 hours. 1. Open the air cleaner cover door on the blower housing to access the air cleaner element (Figure 34). 2. Unhook the latch and remove the air cleaner(Figure 34). 3. Remove the foam element and inspect. Clean and replace as necessary. 4. Gently tap the paper element to dislodge dirt. Do not wash the paper element or use pressurized air, as this will damage the element. Replace a dirty, bent, or damaged element.
“ADD” or “L” mark or above the “FULL” or “F” mark on the dipstick. 8. Remove dipstick and check oil level. The level should be between the “Full or F” and “Add or L” marks. If low, add oil of the proper type up to the full mark. Reinstall oil fill cap/dipstick and screw tight. G009950 Changing the Engine Oil 1 2 3 4 5 6 Service Interval: After the first 8 hours Every 100 hours (more often under dusty, dirty conditions) Note: Dispose of the used oil at a recycling center. 1.
Note: Ensure the oil filter gasket touches the engine and then an extra 3/4 turn is completed. 3. Fill the crankcase with the proper type of new oil; refer to Changing the Oil. 5. 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. 6. Install the oil fill cap/dipstick. 7. Check the oil level; refer to Checking the Oil Level. Servicing the Spark Plug 8. Slowly add additional oil to bring it to the full mark.
Fuel System Maintenance 2 1 Replacing the Fuel Filter Service Interval: Every 500 hours/Yearly (whichever comes first) (more often under dusty, dirty conditions). G008794 Figure 39 1. Disengage the blade control switch (PTO), move the motion control levers to the neutral lock position, and set the parking brake. Installing the Spark Plug 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Tighten the spark plug to 18-22 ft-lb (25-29 N-m).
Electrical System Maintenance Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. Servicing the Battery Service Interval: Monthly • Always Disconnect the negative (black) battery cable before disconnecting the positive (red) cable. Warning • Always Reconnect the positive (red) battery cable before reconnecting the negative (black) cable.
5. Slide the red terminal boot off the positive (red) battery terminal and remove the positive (+)(red) battery cable (Figure 42). 6. Remove the clamp (Figure 42). 7. Remove the battery. Installing the Battery 1. Position battery in the tray with the terminal posts opposite from the hydraulic tank (Figure 42). 2. First, install the positive (red) battery cable to positive (+) battery terminal. Figure 43 3. Then install the negative battery cable and ground wire to the negative (-) battery terminal. 1.
Drive System Maintenance G010340 1 Checking the Tire Pressure 3 2 Service Interval: Every 25 hours—Check tire pressure. 25 30 Maintain the air pressure in the front and rear tires as specified. Uneven tire pressure can cause uneven cut. Check the pressure at the valve stem (Figure 45). Check the tires when they are cold to get the most accurate pressure reading. Rear Tires: 13 psi (90 kPa) Front Tires (caster wheels): 35 psi (241 kPa) G010241 Figure 44 1. 30 amp 2. 25 amp 3.
Hydraulic System Maintenance 2. Locate the filter and guards on each transaxle drive system (Figure 47). Remove three screws securing the filter guard and guard. 5 Oil Type: 20w-50 engine oil. G010254 Important: Use oil specified or equivalent. Other fluids could cause system damage. 1 Checking the Hydraulic Oil Level 2 Service Interval: Every 25 hours Check expansion reservoir and if necessary add 20W-50 engine oil to the FULL COLD line 3 1 3 4 Figure 47 Right side shown 2 1.
1 2 3 4 1 G010333 Figure 49 1. Jacking points 5 6 2. Start engine and move throttle control ahead to 1/2 throttle position. Disengage parking brake. A. Move the bypass levers into the pushing the machine position; refer to the Pushing the Machine by Hand section in Operation. With the bypass valves open and the engine running, slowly move the motion control levers in both forward and reverse (5 or 6 times). 3/4 G008748 B. Move the bypass levers into the operating the machine position.
Mower Deck 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 50 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.
3. Measure from the tip of the blade to the flat surface here. 1 1 G009680 3 2 G009680 3 Figure 54 Figure 52 1. Opposing blade edge, in position for measuring 2. Level surface 3. Second measured distance between blade and surface (B) 2 1. Blade, in position for measuring 2. Level surface 3. Measured distance between blade and surface (A) 4. Rotate the same blade 180 degrees so that the opposing cutting edge is now in the same position.
Figure 57 1. Blade 2. Balancer Installing the Blades 1 1. Install the blade onto the spindle shaft (Figure 55). 2 Important: The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting. 2. Install the spring disk and blade bolt. The spring disk cone must be installed toward the bolt head (Figure 55). Torque the blade bolt to 100-110 ft-lb (135-150 N-m). 3 4 G010341 Figure 55 1. Sail Area of Blade 2. Blade 3. Curved washer 4.
are not within 3/16 inch (5 mm), an adjustment is required; continue to the Leveling procedure. Figure 59 1. Blades front to rear 3. Measure from the tip of the blade to the flat surface here Figure 58 1. Blades side to side 2. Outside cutting edges 3. Measure from the tip of the blade to the flat surface here 2. Outside cutting edges Leveling the Mower Deck 1. Set anti-scalp rollers to top holes or remove completely for this procedure. 2. Set the height-of-cut lever to the 3 inch (76 mm) position.
then tighten the four leveling adjust locking nuts (Figure 61). 1 1 5. Recheck that blocks fit just snugly under the deck skirt. Make sure all attachment bolts are tight 6. Verify the deck is level by checking the side-to-side level and front-to-rear blade slope; repeat deck leveling procedure if necessary.
5. Remove the floor pan to access the idler pulley; refer to the Removing the Floor Pan procedure in Premaintenance. 1 2 6. Using a spring removal tool, (Toro part no. 92-5771), remove the idler spring from the deck post to remove tension on the idler pulley (Figure 64). 2 3 1 3 4 G010343 Figure 65 1. Position the belt cover, ensure the tabs seat 2. Pivot the belt cover down G009806 5 Figure 64 1. Spring removal tool (Toro part no. 92-5771) 2. Idler spring 3. Deck post 3.
1 60 inch Mower Decks 2 1. Remove the hair pin cotter and washer securing the long, link bar to the frame and deck; remove the link bar (Figure 68). 2 3 3 1 G01031 1 Figure 66 G010309 Figure 68 2. Remove the hardware from the front deck hangers on both sides of the deck (Figure 67). 1. Hair pin cotter 2. Washer 3. Carefully lift the deck off the rear hanger bolts and lower the front of the mower deck to the ground (Figure 67). 3. Link bar 2.
Installing the Mower Installing 54 inch Mower Decks 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. 1. Park the machine on a level surface and disengage the blade control switch. 2. Move the motion control levers outward to the neutral lock position, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3.
Cleaning before the bend and going over the rod as it returns from the bend. 4. Lift the long end of the spring and place it into the notch on the deflector assembly bracket (Figure 71). Washing the Underside of the Mower 2 Service Interval: Before each use or daily—Clean the mower housing. Wash the underside of the mower after each use to prevent grass buildup for improved mulch action and clipping dispersal. 1 3 1. Park the machine on a level surface and disengage the blade control switch. 2.
1 A broken or missing washout fitting could expose you and others to thrown objects or blade contact. Contact with blade or thrown debris can cause injury or death. • Replace broken or missing washout fitting immediately, before using mower again. 3 4 • Never put your hands or feet under the mower or through openings in the mower. 6 Waste Disposal 5 Engine oil, batteries, hydraulic oil, and engine coolant are pollutants to the environment.
Storage B. Run the engine to distribute conditioned fuel through the fuel system (5 minutes). Cleaning and Storage C. Stop the engine, allow it to cool, and drain the fuel tank; refer to Servicing the Fuel Tank in the Maintenance Section. 1. Disengage the blade control switch (PTO), set the parking brake, and turn the ignition key to Off. Remove the key. 2. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine and hydraulic system.
Troubleshooting Problem Starter does not crank Engine will not start, starts hard, or fails to keep running Possible Cause 1. Blade control switch (PTO) is engaged. 1. Move blade control switch (PTO) to disengaged. 2. Parking brake is not on. 3. Drive levers are not in neutral lock position. 4. Operator is not seated. 5. Battery is dead. 6. Electrical connections are corroded or loose. 7. Fuse is blown. 8. Relay or switch is defective. 2. Set the parking brake. 3.
Problem Machine does not drive. Abnormal vibration. Uneven cutting height. Possible Cause 1. By pass valves is not closed tight. 1. Tighten the by pass valves. 2. 3. 4. 5. 2. 3. 4. 5. Pump belt is worn, loose or broken. Pump belt is off a pulley. Broken or missing idler spring. Hydraulic oil level is low or too hot. Change the belt. Change the belt. Replace the spring. Add hydraulic oil to reservoirs or let it cool down. 1. Cutting blade(s) is/are bent or unbalanced. 1.
Schematics G010474 Wire Diagram (Rev.
Notes: 54
Notes: 55
TITAN Mowers The Toro Total Coverage Guarantee A Three-Year Limited Warranty Conditions and Products Covered The Toro® Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair any Toro Product, if defective in materials or workmanship for the period listed below. Instructions for Obtaining Warranty Service If you think that your Toro Product contains a defect in materials or workmanship, follow this procedure: 1.
