Form No. 3394-243 Rev C TITAN® ZX4800, ZX5400, or ZX6000 Zero-Turn-Radius Riding Mower Model No. 74861—Serial No. 315000001 and Up Model No. 74862—Serial No. 315000001 and Up Model No. 74863—Serial No. 315000001 and Up Register at www.Toro.com.
Introduction 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-coverd, or grasss-covered land. Other states or federal areas may have similar laws. 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.
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. Safety ....................................................................... 4 Safe Operating Practices.................................... 4 Toro Riding Mower Safety................................... 6 Slope Indicator ...................................................
Safety Servicing the Cutting Blades ............................. 44 Mower Deck Leveling ....................................... 46 Inspecting the Belts .......................................... 48 Replacing the Mower Belt ................................. 48 Removing the Mower........................................ 49 Installing the Mower Deck................................. 50 Replacing the Grass Deflector .......................... 51 Cleaning .........................................................
Rollover Protection System (ROPS) - Use and Maintenance properly. Do not operate unless they are functioning properly. • Do not remove the ROPS. • The ROPS is an integral and effective safety Operation • Lightning can cause severe injury or death. If device. Keep the ROPS on the machine and use the seat belt when operating the machine. lightning is seen or thunder is heard in the area, do not operate the machine; seek shelter.
Maintenance and storage • Use only Toro approved attachments. Warranty may be voided if used with unapproved attachments. • Disengage drives, set parking brake, stop engine and remove key or disconnect spark-plug wire. Wait for all movement to stop before adjusting, cleaning or repairing. • If loading the machine onto a trailer or truck, use a single, full-width ramp only. The ramp angle should not exceed 15 degrees.
Slope Indicator r:\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. decal115-9625 115-9625 1. Parking brake—disengaged 2. Parking brake—engaged decal99-8936 99-8936 1. Machine speed 4. Neutral 2. Fast 3. Slow 5. Reverse decaloemmarkt Manufacturer's Mark decal115-9632 115-9632 1. Indicates the blade is identified as a part from the original machine manufacturer.
decalbatterysymbols 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.
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 g028215 Figure 4 1. Grass deflector 4. Operator seat 7. Footrest 10. Mower-deck lift pedal 2. Drive wheel 5. Motion control levers 8. Front caster wheel 11. 3. Roll over protection system (ROPS) 6. Parking brake 9.
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). Motion Control Levers The motion control levers are speed sensitive controls of independent wheel motors.
Operation DANGER 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. Note: Determine the left and right sides of the machine from the normal operating position. Adding Fuel • For best results, use only clean, fresh (less than • • • • • Always place gasoline containers on the ground away from your vehicle before filling.
Add the correct amount of gas stabilizer/conditioner to the gas. Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline. To minimize the chance of varnish deposits in the fuel system, use fuel stabilizer at all times. Fuel Gauge Use the fuel window below the operator to verify the level of gasoline before filling the tank (Figure 6). g027637 Figure 7 3. g020318 Figure 6 1.
Think Safety First 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. 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. Wear hearing protection when operating this machine. DANGER Mowing on wet grass or steep slopes can cause sliding and loss of control.
Breaking in a New Machine operate as described below, have an Authorized Service Dealer repair the safety system immediately. 1. While sitting on the seat, engage the parking brake and move the blade control switch to On. Try starting the engine; the engine should not crank. 2. While sitting on the seat, engage the parking brake and move the blade control switch to Off. Move either motion control lever (forward or reverse). Try starting the engine; the engine should not crank.
Operating the Parking Brake Operating the Choke Use the choke to start a cold engine as follows: Always set the parking brake when you stop the machine or leave it unattended. 1. Pull up on the choke knob to engage the choke before using the ignition switch (Figure 13). 2. Push down on the choke to disengage the choke after the engine has started (Figure 13). Setting the Parking Brake g027638 Figure 10 Releasing the Parking Brake g008959 Figure 13 1. On 2.
g008947 Figure 14 2. To stop the engine, turn the ignition key to the stop position. Starting and Stopping the Engine Starting the Engine Note: A warm or hot engine may not require choking (Figure 15). 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.
Driving Forward or Backward 1. Release the parking brake; refer to Releasing the Parking Brake (page 19). 2. Move the levers to the center, unlocked position. 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. 3. To go forward, slowly push the motion control levers forward (Figure 20). CAUTION Machine can spin very rapidly.
Using the Foot Pedal Deck Lift System • Press the pedal down to raise the deck; continue to press the pedal until the deck is locked in the transport position (Figure 22). • Push on the deck lift pedal with your foot and pull the transport lock handle rearward to disengage the transport lock (Figure 22). g008953 Figure 21 Stopping the Machine CAUTION Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended.
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 24).
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.
Using the Side Discharge Transporting the Machine The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. 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.
Loading the Machine 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 loading or unloading machines onto a trailer or a truck. Use a full-width ramp that is wider than the machine for this procedure. Back up ramps and drive forward down ramps (Figure 29). • Use extreme caution when operating a machine on a ramp.
g027996 Figure 30 1. Full-width ramp in stowed position 4. Ramp is at least four times (4X) as long as the height of the trailer or truck bed to the ground 2. Side view of full-width ramp in loading position 5. H= height of the trailer or truck bed to the ground 3. Not greater than 15 degrees 6.
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 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. Clean the blower housing (more often under extremely dusty, dirty conditions). Check the mower blades.
decal130-6996 Figure 31 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 Pre-Maintenance 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. Keep hands, feet, face, clothing and other body parts away the muffler and other hot surfaces. Servicing the Air Cleaner Service Interval: Before each use or daily—Check the air cleaner for dirty, loose or damaged parts. g009949 Figure 32 Every 25 hours—Service or replace the air-cleaner foam element (more often under extremely dusty, dirty conditions). 1. Front caster tire 4.
do not use if the sealing surfaces are bent or damaged. 2. Clean the air-cleaner base as required, and check the condition. Installing the Elements Install the foam element onto the paper element. 2. Install the elements onto the air-cleaner base (Figure 34). 3. Install the cover, and secure it with the latches (Figure 33). Servicing the Engine Oil g028105 Figure 33 1. Air-cleaner cover 1. Oil Type: Detergent oil (API service SJ or higher) 2. Air-cleaner latch 3.
g027515 Figure 36 g027934 Figure 37 Changing the Engine Oil and the Engine-Oil Filter 4. Service Interval: Every 100 hours—Change the engine oil and the engine-oil filter. Note: The drain plug is attached to the drain hose. Note: Dispose of the used oil at a recycling center. Fill with oil as specified in the “Viscosity Grades” table (Figure 35). 1. Park the machine, so that the drain side is slightly lower than the opposite side, to ensure that the oil drains completely. 2.
g027517 Figure 39 Servicing the Spark Plug Service Interval: Every 500 hours—Replace the spark plug(s). The spark plug is RFI compliant. Equivalent alternate brand plugs can also be used. g028127 Figure 38 Type: Champion XC12YC (or equivalent) 5. Air Gap: 0.76 mm (0.03 inch) Slowly pour approximately 80% of the specified oil into the filler tube (Figure 39). Removing the Spark Plug 35 1.
Installing the Spark Plug Tighten the spark plug to 27 N-m (20 ft-lb). g027478 Figure 40 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. Note: 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. g028109 Figure 42 Set the gap to 0.76 mm (0.030 inch).
Replacing the Fuel Filter Fuel System Maintenance Service Interval: Every 100 hours/Yearly (whichever comes first) (more often under dusty, dirty conditions). 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. • Perform any fuel related maintenance when the engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills. 1.
Electrical System Maintenance WARNING 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 • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. Service Interval: Monthly WARNING • Always reconnect the positive (red) battery cable before reconnecting the negative (black) cable.
Installing the Battery 1. Position the battery in the tray with the terminal posts opposite from the fuel tank (Figure 44). 2. Install the positive (red) battery cable to the positive (+) battery terminal. 3. Install the negative battery (black) cable to the negative (-) battery terminal. 4. Secure the cables with 2 bolts, 2 washers, and 2 locknuts (Figure 44). 5. Slide the red terminal boot onto the positive (red) battery post. 6. Install the clamp and secure it with the wing nut (Figure 44).
Drive System Maintenance Checking the Tire Pressure Service Interval: Every 25 hours—Check tire pressure. 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 48). Check the tires when they are cold to get the most accurate pressure reading. Refer to the maximum pressure suggested by the tire manufacturer on the sidewall of the caster wheel tires. Inflate the rear drive wheel tires to 89.6 kPa (13 psi).
Removing the Hydraulic System Filters Hydraulic System Maintenance 1. Stop engine, wait for all moving parts to stop, and allow engine to cool. Oil Type: 20w-50 engine oil. 2. Remove the key and engage the parking brake. System Capacity: approximately 4.495 liter (152 oz) with a filter change. 3. Locate the filter and guards on each transaxle drive system (Figure 50). Hydraulic System Oil Specification Important: Use oil specified or equivalent. Other fluids could cause system damage.
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 51). 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 51). 3. Repeat step 2 for the other filter. 4. Align the filter guards over each filter; refer to step 4 of Removing the Hydraulic System Filters (page 41). 5.
Bleeding the Hydraulic System 1. 8. 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 52 1. Jacking points 2. Go to the operator's position. 3. Start engine and move throttle control ahead to 1/2 throttle position. 4. Disengage parking brake. 5. Cycle the hydraulic system by performing the following: A.
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 53 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. g014973 Figure 57 1. Opposing blade edge, in position for measuring g014973 Figure 55 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. A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders.
• If the blade stays in a horizontal position, the • blade is balanced and can be used. If the blade is not balanced, perform the following steps: A. File some metal off the end of the sail area only (Figure 58). B. Repeat this procedure until the blade is balanced. g000277 Figure 60 1. Blade 2. Balancer g010341 Installing the Blades Figure 58 1. Sail Area of Blade 2. Blade 1. 3. Curved washer 4. Blade Bolt Install the blade onto the spindle shaft (Figure 58).
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. Carefully rotate the blades side to side. 4. Measure between the outside cutting edges and the flat surface (Figure 61). Note: If both measurements are not within 5 mm (3/16 inch), an adjustment is required; continue to the Leveling procedure. g007199 Figure 62 1. Blades front to rear 3.
Removing the 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. Replace the mower belt if any of these conditions is evident. g024313 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.
g020312 Figure 66 1. Spring removal tool (Toro part no. 92-5771) 4. Idler arm 2. Idler spring 5. Mower belt g020313 Figure 67 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. 8. Place the height-of-cut pin in the lock position for lowest height-of-cut. Removing the Mower 9. Remove the belt from the mower deck pulleys and remove the existing belt.
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 68). 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 3. Position the new discharge deflector assembly with the bracket ends between the welded brackets on the deck as shown in Figure 70. Service Interval: Before each use or daily—Inspect the grass deflector for damage 4. Install the spring onto the straight end of the rod. Position the spring on the rod as shown in Figure 70 so the shorter spring end is coming from under the rod before the bend and going over the rod as it returns from the bend. 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 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 g028048 Wire Diagram (Rev.
Notes:
Notes:
The Toro Total Coverage Warranty TimeCutter and TITAN Mowers Limited Warranty (see warranty periods below) Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to the original purchaser to repair the Toro Products listed below if defective in materials or workmanship.
