Form No. 3394-232 Rev B TITAN® ZX 4800 and ZX 5400 Zero-Turn-Radius Riding Mower Model No. 74846—Serial No. 315000001 and Up Model No. 74848—Serial No. 315000001 and Up Register at www.Toro.com.
This machine is a ride-on, rotary-blade lawnmower intended to be used by homeowners in residential applications. It is primarily designed for cutting grass on well-maintained lawns. It is not designed for cutting brush, mowing grass and other growth alongside highways, or for agricultural uses. This product complies with all relevant European directives, for details please see the separate product specific Declaration of Conformity (DOC) sheet.
WARNING Removing standard original equipment parts and accessories may alter the warranty, traction, and safety of the machine. Failure to use original Toro parts could cause serious injury or death. Making unauthorized changes to the engine, fuel or venting system, may violate EPA and CARB regulations. Replace all parts including, but not limited to, tires, belts, blades, and fuel system components with original Toro parts.
Contents Servicing the Battery......................................... 43 Servicing the Fuses .......................................... 44 Drive System Maintenance .................................. 45 Checking the Tire Pressure............................... 45 Hydraulic System Maintenance ........................... 45 Checking the Hydraulic Oil Level ...................... 45 Changing the Hydraulic System Filter and Oil .................................................................
Safety ◊ incorrect hitching and load distribution. Preparation The following instructions are from the EN standard EN ISO 5395:2013. • While mowing, always wear substantial, Safe Operation Practices for Ride-On (riding) Rotary Lawnmower Machines • • 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.
• Never store the equipment with fuel in the tank • Use care when pulling loads. • • • • • • • • • • • – Use only approved drawbar hitch points. – Limit loads to those you can safely control. – Do not turn sharply. Use care when reversing. Watch out for traffic when crossing or near roadways. Stop the blades rotating before crossing surfaces other than grass. When using any attachments, never direct discharge of material toward bystanders nor allow anyone near the machine while in operation.
Sound Pressure • Reduce speed and use extreme caution on slopes. • Remove or mark obstacles such as rocks, tree This unit has a sound pressure level at the operator’s ear of 92 dBA, which includes an Uncertainty Value (K) of 1 dBA. limbs, etc. from mowing area. Tall grass can hide obstacles. • Watch for ditches, holes, rocks dips, and rises that Sound power level was determined according to the procedures outlined in EN ISO 5395:2013.
Whole Body Vibration Measured vibration level = 0.45 m/s2 Uncertainty Value (K) = 0.22 m/s2 Measured values were determined according to the procedures outlined in EN ISO 5395:2013 (Riding & Stand-Ons).
Slope Indicator g011841 Figure 3 This page may be copied for personal use. 1. The maximum slope you can safely 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. Example of how to compare slope with folded edge.
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. decaloemmarkt Manufacturer's Mark 1. Indicates the blade is identified as a part from the original machine manufacturer. decal114-1606 decal99-8936 114-1606 99-8936 1. Machine speed 4. Neutral 2. Fast 3. Slow 5. Reverse 1. Entanglement hazard, belt—keep all guards in place.
decal115-9632 115-9632 1. Power take-off (PTO), Blade control switch on some models 2. Blade control switch—On 5. Fast 3. Blade control switch—Off 4. Choke 7. Slow 6. Continuous variable setting decal130-0654 130-0654 1. Transport—lock 3. Height-of-cut 2. Transport—unlock decal117-1194 117-1194 1. Engine decal130-0655 130-0655 1. Fuel tank 2. Full 11 3. Half 4.
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. decal130-0765 130-0765 1. Read the Operator's Manual. 3. Remove the key from the ignition and read the Operator's Manual before permorning maintenance. decal130-6927 130-6927 1. Warning—always use the ROPS and wear the seat belt when seated in the operator's position. 2. Height-of-cut selection decal130-6928 130-6928 1.
decal130-6996 130-6996 1. Read the Operator's 4. Check the hydraulic oil Manual for information on every 25 hours maintenance. 2. Check the engine oil every 5. Check the caster wheel 8 hours tire pressure every 25 hours 3. Check the drive wheel tire 6. Lubricate the caster wheel every 25 hours pressure every 25 hours decal131-4036 131-4036 1. The maximum drawbar pull is 36 kg (80 lb). 2. Read the Operator's Manual.
decal132-0871 132-0871 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 those conditions on that day and at that site.
Product Overview g024328 Figure 4 1. Drive wheel 2. Operator seat 4. Motion control levers 5. Parking brake 7. Front caster wheel 8. Anti-scalp roller 3. Roll over protection system (ROPS) 6. Footrest 9. Foot pedal deck lift and height-of-cut 15 10.
Controls control switch (PTO) is engaged. Use these times for scheduling regular maintenance (Figure 5). Become familiar with all the controls before you start the engine and operate the machine (Figure 5). Fuel Gauge The fuel window located below the operator position can be used to verify the level of gasoline in the tank (Figure 6). g017722 Figure 5 g020264 1. Throttle control 4. Ignition switch 2. Choke 5. Blade control switch (PTO) Figure 6 1. Fuel gauge window 3.
Attachments/Accessories Operation A selection of Toro approved attachments and accessories is 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.
Add the correct amount of gas stabilizer/conditioner to the gas. WARNING Gasoline is harmful or fatal if swallowed. Long-term exposure to vapors can cause serious injury and illness. Note: A fuel stabilizer/conditioner is most effective • Avoid prolonged breathing of vapors. when mixed with fresh gasoline. To minimize the chance of varnish deposits in the fuel system, use fuel stabilizer at all times. • Keep face away from nozzle and gas tank or conditioner opening.
DANGER Mowing on wet grass or steep slopes can cause sliding and loss of control. Wheels dropping over edges can cause rollovers, which may result in serious injury, death or drowning. A loss of traction is a loss of steering control. To avoid loss of control and possibility of rollover: • Do not mow near drop-offs or near water. • Do not mow slopes greater than 15 degrees. • Reduce speed and use extreme caution on slopes. • When mowing slopes, gradually work from lower to higher areas on the incline.
Understanding the Safety Interlock System CAUTION This machine produces sound levels in excess of 85 dBA at the operators ear and can cause hearing loss through extended periods of exposure. The safety interlock system is designed to prevent the engine from starting unless: • The parking brake is engaged. Wear hearing protection when operating this machine. • The blades are disengaged. • The motion control levers are in the neutral lock position.
Breaking in a New Machine New engines take time to develop full power. Mower decks and drive systems have higher friction when new, placing additional load on the engine. Allow 40 to 50 hours of break-in time for new machines to develop full power and best performance. g008946 Operating the Parking Brake Figure 13 Operating the Choke Always set the parking brake when you stop the machine or leave it unattended. Use the choke to start a cold engine. 1.
g008947 Figure 15 2. Turn the ignition key to stop to stop the engine. Starting and Stopping the Engine Starting the Engine Note: A warm or hot engine may not require choking (Figure 16). Important: Do not engage starter for more than 5 seconds at a time. If the engine fails to start allow a 15 second cool-down period between attempts. Failure to follow these instructions can burn out the starter motor.
Operating the Mower Blade Control Switch (PTO) The blade control switch (PTO) starts and stops the mower blades and any powered attachments. Engaging the Blade Control Switch (PTO) Engage the blade control switch (PTO) with the throttle position at Fast. Note: Engaging the blade control switch (PTO) with the throttle position at half or less will cause excessive wear to the drive belts.
performance. Always operate in the full throttle position when mowing. CAUTION Machine can spin very rapidly. Operator may lose control of machine and cause personal injury or damage to machine. • Use caution when making turns. • Slow the machine down before making sharp turns. Using the Motion Control Levers g008952 Figure 21 Driving Backward Note: Always use caution when backing up and turning. 1. Move the levers to the center, unlocked position. 2.
Using the Foot Pedal Deck Lift System Stopping the Machine WARNING • Press the pedal down to raise the deck; continue to press the pedal until the deck is locked in the transport position (Figure 23). Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. • Push on the deck lift pedal with your foot and pull the transport lock handle rearward to disengage the transport lock (Figure 23).
Adjusting the Anti-Scalp Rollers Whenever you change the height-of-cut, it is recommended to adjust the height of the anti-scalp rollers. 1. Disengage the blade control switch (PTO), move the motion control levers to the neutral lock position and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the flange nut, anti-scalp roller and bolt from the bracket (Figure 25).
Positioning the Seat The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable. 1. Loosen the upper bolt holding the control lever to the control arm shaft. 2. Loosen the lower bolt just enough to pivot the control lever fore or aft. Tighten both bolts to secure the control in the new position. 3. Repeat the adjustment for the opposite control lever. Pushing the Machine by Hand Important: Always push the machine by hand.
Converting the 48 inch Mower to Side Discharge The mower deck and mower blades shipped with this machine were designed for optimum mulching and side discharge performance. Install the fasteners into the same holes in the deck they were originally removed from. This ensure no holes are left open when the deck is operated. DANGER g012841 Open holes in the mower expose you and others to thrown debris. Debris thrown out of holes in the mower can cause injury. Figure 29 1.
Converting the 54 inch Mower to Side Discharge Install the fasteners into the same holes in the deck they were originally removed from. This ensure no holes are left open when the deck is operated. DANGER Open holes in the mower expose you and others to thrown debris. Debris thrown out of holes in the mower can cause injury. • Never operate the mower without hardware mounted in all holes in the mower. g012805 • Install hardware in mounting holes when the baffle is removed. Figure 31 1.
g011149 Figure 33 1. Locknut (5/16 inch) 3. Left baffle 2. Carriage bolt (5/16 x 3/4 inch) 4. Install fasteners here g010712 Figure 34 7. Remove the left baffle from the mower deck as shown in Figure 33. 8. Locate the two bolts in loose parts and use the existing locknuts. Install these fasteners into the holes shown in Figure 33 on the mower deck to prevent flying debris. Install the bolt up, through the underside of the deck and use an existing locknut to secure from the topside. 1.
17. Install the mower as described in the Installing the Mower procedure in the Maintenance section for more information. 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 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.
Transporting the Machine Loading the Machine Use a heavy-duty trailer or truck to transport the machine. Ensure that the trailer or truck has all necessary brakes, lighting, and marking as required by law. Please carefully read all the safety instructions. Knowing this information could help you, your family, pets, or bystanders avoid injury. Use extreme caution when loading or unloading machines onto a trailer or a truck. Use a full-width ramp that is wider than the machine for this procedure.
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. • Ensure that the ROPS is in the up position and use the seat belt when loading or unloading the machine. Ensure that the ROPS will clear the top of an enclosed trailer. • Use only a full-width ramp; do not use individual ramps for each side of the machine.
Long Grass Operating Tips 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. Fast Throttle Setting For best mowing and maximum air circulation, operate the engine at the fast throttle position.
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 engine oil level. Clean the air intake screen. Check the mower blades. Inspect the grass deflector for damage After each use • Clean the mower housing. Every 25 hours • Grease all lubrication points.
decal115-9630 Figure 40 Located on the seat pan underside 1. Read the Operator's Manual before performing any maintenance. 2. Check the engine oil every 8 hours 4. Check the hydraulic oil every 25 hours 5. Check the caster wheel tire pressure every 25 hours 3. Check the drive wheel tire pressure every 25 hours 6.
Pre-Maintenance 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: • Service decal 1. Park the machine on a level surface and disengage the blade control switch. 2.
Engine Maintenance Cleaning the Element Service Interval: Every 100 hours—Service the paper element (more often in dusty, dirty conditions). WARNING Contact with hot surfaces may cause personal injury. Every 200 hours/Yearly (whichever comes first)—Replace the paper element (more often in dusty, dirty conditions). Keep hands, feet, face, clothing and other body parts away the muffler and other hot surfaces. Servicing the Air Cleaner 1.
WARNING Contact with hot surfaces may cause personal injury. Keep hands, feet, face, clothing and other body parts away the muffler and other hot surfaces. Important: Do not overfill the crankcase with oil because damage to the engine may result. Do not run engine with oil below the low mark because the engine may be damaged. 1. Park the machine on a level surface, disengage the blade control switch, stop the engine, engage parking brake, and remove the key. 2.
Changing the Engine Oil Service Interval: After the first 8 hours—Change the engine oil. Every 100 hours—Change the engine oil (more often in dusty, dirty conditions). Note: Dispose of the used oil at a recycling center. 1. Park the machine so that the drain side is slightly lower than the opposite side to ensure the oil drains completely. 2. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 3.
2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. g027478 Figure 49 Note: Due to the deep recess around the spark plug, blowing out the cavity with compressed air is usually the most effective method for cleaning. The spark plug is most accessible when the blower housing is removed for cleaning. Checking the Spark Plug Important: Never clean the spark plug(s).
Fuel System Maintenance Replacing the Fuel Filter Service Interval: Every 100 hours/Yearly (whichever comes first) (more often under dusty, dirty conditions). g027661 Figure 51 1. Disengage the blade control switch (PTO), move the motion control levers to the neutral lock position, and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
Electrical System Maintenance 3. Remove the wing nut securing the battery clamp (Figure 53). Servicing the Battery Service Interval: Monthly DANGER Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns. Do not drink electrolyte and avoid contact with skin, eyes or clothing. Wear safety glasses to shield your eyes and rubber gloves to protect your hands.
Charging the Battery WARNING Charging the battery produces gasses that can explode. Never smoke near the battery and keep sparks and flames away from battery. Important: Always keep the battery fully charged. This is especially important to prevent battery damage when the temperature is below 32°F (0°C). 1. Charge battery for 10 to 15 minutes at 25 to 30 amps or 30 minutes at 10 amps. 2.
Drive System Maintenance Hydraulic System Maintenance Hydraulic System Oil Specification Checking the Tire Pressure Oil Type: Toro HYPR-OIL® 500 or 20w-50 motor oil. Service Interval: Every 25 hours—Check tire pressure. System Capacity: approximately 4.495 liter (152 oz) with a filter change. 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 57).
Removing Hydraulic System Filters Important: When the hydraulic oil filter is removed, all of the hydraulic oil in each transaxle will drain out. Use a container that will handle 4.495 liters (152 oz) or larger. 1. Stop engine, wait for all moving parts to stop, and allow engine to cool. Remove the key and engage the parking brake. 2. Locate the filter and guards on each transaxle drive system (Figure 59). Remove three screws securing the filter guard and guard.
Important: Failure to perform the Bleeding reaches the FULL COLD line on the expansion reservoir if necessary. the Hydraulic System procedure after changing hydraulic filters and oil can result in irreparable damage to the transaxle drive system. Bleeding the Hydraulic System 1. Raise the rear of machine up and support with jack stands (or equivalent support) just high enough to allow drive wheels to turn freely. g010333 Figure 61 1. Jacking points 2. 3. Enter the operator's 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. g006530 Figure 62 Check the cutter blades daily for sharpness, and for any wear or damage. File down any nicks and sharpen the blades as necessary.
g014973 g014973 Figure 64 Figure 66 1. Blade, in position for measuring 1. Opposing blade edge, in position for measuring 2. Level surface 3. Measured distance between blade and 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. WARNING A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders.
g000277 Figure 69 1. Blade 2. Balancer Installing the Blades 1. Install the blade onto the spindle shaft (Figure 67). Important: The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting. 2. g010341 Figure 67 1. Sail Area of Blade 2. Blade 3. Curved washer 4. Blade Bolt Sharpening the Blades WARNING When sharpening blade, pieces of blade could be thrown and cause serious injury. Wear proper eye protection when sharpening blade. 1.
Mower Deck Leveling Checking the Front-to-Rear Blade Slope Check to ensure 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 using the following instructions: 1. Park the machine on a level surface and disengage the blade control switch. 2.
Inspecting the Belts Service Interval: Every 50 hours Check the belts for 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 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.
Removing the Mower Park the machine on a level surface and disengage the blade control switch. Move the motion control levers outward to the neutral position, engage parking brake, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Lower the mower to the lowest height-of-cut. Select one of the following procedures depending on the mower deck size installed to complete the removal. Preparing to Remove the Mower Deck g009806 Figure 74 1.
Installing the Mower Deck Removing the Mower Deck 1. Remove the hair pin cotter and washer securing the long, link pin to the frame and deck; remove the link bar (Figure 75). g024314 Figure 75 1. Link pin 3. Hair pin cotter 1. Park the machine on a level surface and disengage the blade control switch. 2.
deflector (Figure 77). Remove the damaged or worn discharge deflector. g024316 Figure 78 g028042 Figure 77 1. Deflector 4. Spring 2. Deck brackets 5. Spring installed over the rod 6. Cotter pin 3. Rod 1. Rod and spring assembly partially installed 3. Rod, short end, moved behind mower bracket 2. Loop end of the spring installed into the notch in the deflector bracket 4. Short end, retained by mower bracket. 6. 3. 4. 5.
Cleaning Washing the Underside of the Mower Service Interval: After each use—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. 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.
Storage WARNING 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. Cleaning and Storage • Replace broken or missing washout fitting immediately, before using mower again. 1. Disengage the blade control switch (PTO), set the parking brake, and turn the ignition key to Off. Remove the key. 2.
B. Run the engine to distribute conditioned fuel through the fuel system (5 minutes). C. Stop the engine, allow it to cool, and drain the fuel tank. D. Restart the engine and run it until it stops. E. Dispose of fuel properly. Recycle the fuel according to local codes. Important: Do not store stabilizer/conditioned fuel over 90 days. 13. Check and tighten all bolts, nuts, and screws. Repair or replace any part that is damaged. 14. Paint all scratched or bare metal surfaces.
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 g028048 Wire Diagram (Rev.
Notes:
International Distributor List Distributor: Country: Phone Number: Distributor: Phone Number: 57 1 236 4079 Colombia Japan 81 3 3252 2285 Czech Republic 420 255 704 220 420 255 704 Slovakia 220 Argentina 54 11 4 821 9999 Russia 7 495 411 61 20 Ecuador 593 4 239 6970 Finland 358 987 00733 Agrolanc Kft Balama Prima Engineering Equip. B-Ray Corporation Hungary Hong Kong Korea 36 27 539 640 852 2155 2163 82 32 551 2076 Maquiver S.A. Maruyama Mfg. Co. Inc. Mountfield a.s.
Residential Products The Toro Warranty and The Toro GTS Starting Guarantee Conditions and Products Covered Owner Responsibilities The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair for the original purchaser1the Toro Product listed below if defective in materials or workmanship or if the Toro GTS (Guaranteed to Start) engine will not start on the first or second pull, provided the routine maintenance required in the Operator's Manua
