Form No. 3381-550 Rev C TITAN® ZX 4800, ZX 5400, or ZX 6000 Zero-Turn-Radius Riding Mower Model No. Model No. Model No. Model No. 74851—Serial No. 74852—Serial No. 74853—Serial No. 74855—Serial No. 314000001 and Up 314000001 and Up 314000001 and Up 314000001 and Up g024406 Register at www.Toro.com.
Introduction 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. 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.
Contents This manual identifies potential hazards and has safety messages identified by the safety alert symbol (Figure 2), which signals a hazard that may cause serious injury or death if you do not follow the recommended precautions. Introduction .................................................................. 2 Safety ........................................................................... 4 Safe Operating Practices........................................... 4 Toro Riding Mower Safety ............
Safety Inspecting the Belts ................................................43 Replacing the Mower Belt ........................................43 Removing the Mower..............................................44 Installing the Mower Deck.......................................45 Replacing the Grass Deflector ..................................46 Cleaning ...................................................................47 Washing the Underside of the Mower ........................47 Waste Disposal........
Operation • Be certain that the seat belt can be released quickly in • Lightning can cause severe injury or death. If lightning • • • • • • • • • • • • • • • • • • • • is seen or thunder is heard in the area, do not operate the machine; seek shelter. Never run an engine in an enclosed area. Only operate in good light, keeping away from holes and hidden hazards. Be sure all drives are in neutral and parking brake is engaged before starting engine. Only start engine from the operator's position.
• Stopping distance increases with the weight of the towed • Shut off fuel while storing or transporting. Do not store load. Travel slowly and allow extra distance to stop. fuel near flames or drain indoors. • Park the machine on level ground. Set the parking brake. • Make wide turns to keep the attachment clear of the Never allow untrained personnel to service the machine. machine. • Use jack stands to support components when required.
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. 114-1606 1. Entanglement hazard, belt—keep all guards in place. 99-8936 1. Machine speed 4. Neutral 2. Fast 3. Slow 5. Reverse 115-9625 1. Parking brake—disengaged 2. Parking brake—engaged 109-7076 115-9632 1. Power take-off (PTO), Blade control switch on some models 2.
Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 6. Keep bystanders a safe distance from the battery. 2. No fire, open flame, or smoking. 7. Wear eye protection; explosive gases can cause blindness and other injuries 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. 5. Read the Operator's Manual. 130-0654 1. Transport—lock 10.
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. 130-0765 1. Read the Operator's Manual. 3. Remove the key from the ignition and read the Operator's Manual before permorning maintenance. 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 130-6928 1. Thrown object hazard—keep bystanders away from the machine. 2.
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 130-6921 1. Warning—read the Operator's Manual; do not operate the machine unless you are trained; wear hearing protection. 3. Thrown object hazard—keep bystanders away from the machine. 5.
Product Overview 3 2 4 5 6 1 10 g024328 9 8 7 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 12 10.
Controls Fuel Gauge Become familiar with all the controls before you start the engine and operate the machine (Figure 5). The fuel window located below the operator position can be used to verify the level of gasoline in the tank (Figure 7). 1 2 Motion Control Levers 3 The motion control levers are speed sensitive controls of independent wheel motors.
Using the Rollover Protection System (ROPS) Operation Note: Determine the left and right sides of the machine from the normal operating position. WARNING To avoid injury or death from rollover: keep the roll bar installed and use the seat belt. Think Safety First Please carefully read all of the safety instructions and decals in the safety section. Knowing this information could help you, your family, pets, or bystanders avoid injury.
Adding Fuel DANGER • For best results, use only clean, fresh (less than 30 days 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. • Always place gasoline containers on the ground away from your vehicle before filling.
Fuel Gauge 1 2 Use the fuel window below the operator to verify the level of gasoline before filling the tank (Figure 7). 1 1 3 4 G020318 Figure 7 1. Fuel gauge window G020304 Figure 8 Filling the Fuel Tank Make sure the engine is shut off and the motion controls are in the park position. 3. Install the fuel tank cap securely and tighten until it “clicks.” Wipe up any gasoline that may have spilled. Important: Do not overfill fuel tank. Fill the fuel tank to the bottom of the filler neck.
Operating the Parking Brake 1. Pull up on the choke knob to engage the choke before using the ignition switch (Figure 12). Always set the parking brake when you stop the machine or leave it unattended. 2. Push down on the choke to disengage the choke after the engine has started (Figure 12). Setting the Parking Brake 1 2 1 G020305 Figure 9 Releasing the Parking Brake 1 2 2 G008959 Figure 12 1. On 2. Off Operating the Ignition Switch G020306 1.
Starting and Stopping the Engine the Choke control and let the engine run for a few seconds. Then push down the Choke control. Repeat as required. Starting the Engine Note: If the fuel system was depleted of fuel—add fuel to the machine and use additional starting cycles when starting the engine. 1. Sit down on the seat (Figure 14). 2. Move the motion controls outward to the neutral lock position (Figure 14). Stopping the Engine 3. Set the parking brake (Figure 10); refer to Setting the Parking Brake.
Engaging the Blade Control Switch (PTO) The Safety Interlock System WARNING To engage the mower blades perform the following: If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. 1. Set the throttle to the position at Fast position; refer to Operating the Throttle (page 17). 2. Pull up on the blade-control (PTO) switch. • Do not tamper with the interlock switches.
Driving Forward or Backward 3. To go forward, slowly push the motion control levers forward (Figure 19). 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. 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.
Stopping the Machine Adjusting the Height-of-Cut 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. The machine is equipped with a foot pedal deck lift system. The operator can use the foot pedal to lift the deck briefly to avoid obstacles or lock the deck in the highest height-of-cut or transport position.
4. Push on the deck lift pedal with your foot and pull the handle rearward to disengage the transport lock (Figure 21). Adjusting the Anti-Scalp Rollers 5. Lower the deck slowly until the lever makes contact with the pin. Whenever you change the height-of-cut, it is recommended to adjust the height of the anti-scalp rollers. 3 1. Disengage the blade control switch (PTO), move the motion control levers to the neutral lock position and set the parking brake. 4 2.
Positioning the Seat Adjusting the Tilt The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable. The motion control levers can be tilted forward or backward for maximum operator comfort. 1. Loosen the upper bolt holding the control lever to the control arm shaft. While sitting in the operator's position, raise the seat adjustment lever slightly and move the seat forward or backward to the desired position (Figure 24). 2.
Pushing the Machine by Hand Using the Side Discharge Important: Towing the machine will damage the drivetrain of the machine. Always push the machine by hand. The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. DANGER To Push the Machine 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.
Operating Tips 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 When Stopping For best mowing and maximum air circulation, operate the engine at the fast throttle 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 by uncut grass.
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.
Figure 27 Located on the seat pan underside 1. Read the Operator's Manual for information on maintenance. 4. Check the hydraulic oil every 25 hours 2. Check the engine oil every 8 hours 5. Check the caster wheel tire pressure every 25 hours 3. Check the drive wheel tire pressure every 25 hours 6. Lubricate the caster wheel every 25 hours Premaintenance Procedures Lubrication Raising the Seat Service Interval: Every 25 hours—Grease all lubrication points.
Engine Maintenance WARNING Contact with hot surfaces may cause personal injury. 1 Keep hands, feet, face, clothing and other body parts away the muffler and other hot surfaces. Servicing the Air Cleaner Note: Service the air cleaner more frequently (every few hours) if operating conditions are extremely dusty or sandy. G009949 Removing the Element Figure 28 1. Park the machine on a level surface and disengage the blade control (PTO). 1. Front caster tire 4.
Cleaning the Element 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. Service Interval: Every 100 hours—Service the paper element. (more often in dusty, dirty conditions) 1. Park the machine on a level surface, disengage the blade control switch, stop the engine, engage parking brake, and remove the key. Every 200 hours/Yearly (whichever comes first)—Replace the paper element.
Changing the Engine Oil 4. 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 33). Service Interval: After the first 8 hours—Change the engine oil. Every 100 hours—Change the engine oil. (more often in dusty, dirty conditions) 1 2 3 4 5 6 Note: Dispose of the used oil at a recycling center. 1.
Changing the Engine Oil Filter Servicing the Spark Plug Service Interval: Every 200 hours—Change the oil filter. (more often in dusty, dirty conditions) Service Interval: Every 100 hours—Check the spark plug(s). 1. Drain the oil from the engine; refer to Changing the Engine Oil (page 30). Make sure the air gap between the center and side electrodes is correct before installing the spark plug.
Installing the Spark Plug Fuel System Maintenance Tighten the spark plug(s) to 22 N-m (16 ft-lb). 1 2 DANGER 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. 3 • Perform any fuel related maintenance when the engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills.
1 2 3 G008963 Figure 39 1. Fuel filter 2. Hose clamp 3. Fuel line 1 2 g020178 Figure 40 6. Remove the filter from the fuel lines. 1. Emissions filter 7. Install a new filter with the flow direction arrow coming from the fuel tank and pointing to the engine. Move the hose clamps close to the filter (Figure 38) to secure it in place.
Electrical System Maintenance 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. Servicing the Battery 3. Remove the wing nut securing the battery clamp (Figure 41).
Charging the Battery 2 WARNING Charging the battery produces gasses that can explode. 1 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 the 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: 20w-50 engine 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 45).
Removing Hydraulic System Filters 1 2 3 4 5 6 1. Stop engine, wait for all moving parts to stop, and allow engine to cool. 2. Remove the key and engage the parking brake. 3. Locate the filter and guards on each transaxle drive system (Figure 47). 5 G010254 1 2 3 4 Figure 47 Right side shown 3/4 G0201 18 1. Transaxle drive 2. Oil filter 4. Screws 5. Vent plug Figure 48 3. Filter guard 7. Locate and remove the vent plug on each transmission 8.
Installing the Hydraulic System Filters Service Interval: After the first 50 hours Every 400 hours 1. Apply a thin coat of oil on the surface of the rubber seal of each filter (Figure 48). 2. Turn the filter clockwise until rubber seal contacts the filter adapter then tighten the filter an additional 3/4 to 1 full turn (Figure 48). 3. Repeat step 2 for the other filter. 1 4. Align the filter guards over each filter; refer to step 4 of Removing Hydraulic System Filters (page 37). Figure 49 1.
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 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 level surface. 1 1 G014973 3 G014973 2 3 Figure 54 2 1. Opposing blade edge, in position for measuring Figure 52 2. Level surface 3. Second measured distance between blade and surface (B) 1. Blade, in position for measuring 2. Level surface 3. Measured distance between blade and surface (A) WARNING 4. Rotate the same blade 180 degrees so that the opposing cutting edge is now in the same position.
B. Repeat this procedure until the blade is balanced. Figure 57 1. Blade 1 2. Balancer Installing the Blades 2 3 1. Install the blade onto the spindle shaft (Figure 55). 4 Important: The curved part of the blade must point upward toward the inside of the mower to ensure proper cutting. G010341 Figure 55 1. Sail Area of Blade 2. Blade 2. Install the spring disk and blade bolt (Figure 55). 3. Curved washer 4. Blade Bolt Note: The spring disk cone must be installed toward the bolt head 3.
Note: If both measurements are not within 5 mm (3/16 inch), 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 2. Outside cutting edges 1. Blades side to side 3. Measure from the tip of the blade to the flat surface here 2. Outside cutting edges Leveling the Mower Deck 1.
signs of a worn mower belt. Replace the mower belt if any of these conditions is evident. 1. Disengage the blade control switch (PTO), move the motion control levers to the neutral locked 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. Lower the mower to the 76 mm (3 inch) height-of-cut position. 4. Lift the floor pan to gain access to the belt and idler pulley. 5. Remove the belt covers (Figure 62).
A 2 B A 1 B 2 1 3 C 4 D C 3 5 G020312 Figure 63 G020313 1. Spring removal tool (Toro part no. 92-5771) 4. Idler arm 2. Idler spring 5. Mower belt Figure 64 1. Position the belt cover and 3. Tighten the screws ensure that the tabs seat. 2. Pivot the belt cover down 3. Deck post 7. Lower the mower to the lowest height-of-cut. Removing the Mower 8. Place the height-of-cut pin in the lock position for lowest height-of-cut.
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 65). 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, set the parking brake and wait for all moving parts to stop before leaving the operating position. 3. Slide the mower under the machine. 4.
Replacing the Grass Deflector the shorter spring end is coming from under the rod before the bend and going over the rod as it returns from the bend. Service Interval: Before each use or daily—Inspect the grass deflector for damage 5. Lift the loop end of the spring and place it into the notch on the deflector assembly bracket (Figure 68). WARNING 2 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.
Cleaning 5. Sit on the seat and start the engine. Engage the blade control switch and let the mower run for 1 to 3 minutes. Washing the Underside of the Mower 6. Disengage the blade control switch, stop the engine, and remove the ignition key. Wait for all moving parts to stop. 7. Turn the water off and remove the coupling from the washout fitting. Service Interval: After each use—Clean the mower housing.
Storage C. Stop the engine, allow it to cool, and drain the fuel tank. Cleaning and Storage D. Restart the engine and run it until it stops. E. Dispose of fuel properly. Recycle the fuel according to local codes. 1. Disengage the blade control switch (PTO), set the parking brake, and turn the ignition key to Off. Remove the key. Important: Do not store stabilizer/conditioned fuel over 90 days. 2.
Troubleshooting Problem The starter does not crank. The engine will not start, starts hard, or fails to keep running. Possible Cause 1. The blade control switch (PTO) is engaged. 1. Move the blade control switch (PTO) to disengaged. 2. The parking brake is not on. 3. The drive levers are not in neutral lock position. 4. The operator is not seated. 5. The battery is dead. 6. The electrical connections are corroded or loose. 7. The fuse is blown. 8. The relay or switch is defective. 2.
Problem The machine does not drive. The machines vibrates abnormally. The machine cuts grass at an uneven cutting height. Possible Cause 1. The by pass valves are not closed tight. 1. Tighten the by pass valves. 2. The pump belt is worn, loose or broken. 3. The pump belt is off a pulley. 4. There is a broken or missing idler spring. 5. The hydraulic oil level is low or too hot. 2. Change the belt. 3. Change the belt. 4. Replace the spring. 1. The cutting blade(s) is/are bent or unbalanced. 1.
Schematics Wire Diagram (Rev.
The Toro Total Coverage Warranty TimeCutter and TITAN Mowers Limited Warranty (see warranty periods below) Conditions and Products Covered the Yellow Pages of your telephone directory (look under “Lawn Mowers”) or access our web site at www.Toro.com. You may also call the numbers listed in item #3 to use the 24-hour Toro Dealer locator system.
