Form No. 3400-849 Rev C TITAN® ZX4800, ZX5400, or ZX6000 Zero-Turn-Radius Riding Mower Model No. 74861—Serial No. 316000001 and Up Model No. 74862—Serial No. 316000001 and Up Model No. 74863—Serial No. 316000001 and Up Register at www.Toro.com.
Introduction It is a violation of California Public Resource Code Section 4442 or 4443 to use or operate the engine on any forest-covered, brush-covered, or grass-covered land unless the engine is equipped with a spark arrester, as defined in Section 4442, maintained in effective working order or the engine is constructed, equipped, and maintained for the prevention of fire. This machine is a ride-on, rotary-blade lawnmower intended to be used by homeowners in residential applications.
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 Changing the Hydraulic Filter and Fluid .............................................................. 40 Mower Deck Maintenance.................................... 42 Servicing the Cutting Blades ............................. 42 Leveling the Mower Deck.................................. 44 Inspecting the Belts .......................................... 46 Replacing the Mower Belt ................................. 46 Removing the Mower........................................
Rollover-Protection System (ROPS) properly. Do not operate the machine 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 Toro Riding Mower Safety • Disengage drives, set parking brake, stop engine The following list contains safety information specific to Toro products or other safety information that you must know that may not be included in the ANSI standards. and remove key or disconnect spark-plug wire. Wait for all movement to stop before adjusting, cleaning or repairing. • Clean grass and debris from cutting unit, drives, • Use only Toro approved attachments.
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. decal115-9632 115-9632 decal99-8936 99-8936 1. Machine speed 4. Neutral 2. Fast 3. Slow 5. Reverse 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 decaloemmarkt Manufacturer's Mark 1.
decal117-1194 117-1194 1. Engine decal130-0655 130-0655 1. Fuel tank 2. Full 3. Half 4. Empty decal130-0731 130-0731 1. Warning—thrown object hazard; keep the deflector shield in place. decal130-0654 130-0654 1. Transport—lock 3. Height-of-cut 2. Transport—unlock 9 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. 2. Height-of-cut selection decal130-6927 130-6927 1. Warning—always use the ROPS and wear the seat belt when seated in the operator's position. decal130-6922 130-6922 1. Bypass lever position for operating the machine. 2. Bypass lever position for pushing the machine.
decal132-0873 132-0873 1. Thrown object hazard—keep bystanders away from the machine. 3. Cutting/dismemberment of hand or foot—stay away from moving parts. 2. Thrown object hazard, mower—do not operate the without 4. Entanglement hazard, belt—keep all guards in place. deflector, discharge cover, or grass collection system in place. 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.
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. Rollover-Protection System (ROPS) 6. Parking brake 9.
Controls 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.
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 read all safety instructions and symbols in the safety section. Knowing this information could help you or bystanders avoid injury. DANGER Wear hearing protection when operating this machine. Operating the machine on wet grass or steep slopes can cause sliding and loss of control.
Understanding the Safety-Interlock System Checking the Engine-Oil Level Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking the Engine-Oil Level (page 32). WARNING If the safety-interlock switches are disconnected or damaged, the machine could operate unexpectedly, causing personal injury. • Do not tamper with the interlock switches.
Operating the Throttle Operating the Ignition Switch The throttle control can be moved between the SLOW and FAST positions (Figure 12). 1. Always use the FAST position when turning on the mower deck with the blade-control switch (PTO). Turn the ignition key to the START position (Figure 14). Note: When the engines starts, release the key. Note: Additional starting cycles may be required when starting the engine for the first time after the fuel system has been without fuel completely.
g028224 Figure 16 g028223 Figure 15 Operating the Blade-Control Switch (PTO) Stopping the Engine The blade-control switch (PTO) starts and stops the mower blades and any powered attachments. CAUTION Injury can occur if children or bystanders move or attempt to operate the machine while it is unattended. Engaging the Blade-Control Switch (PTO) Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes.
g008945 Figure 17 Disengaging the Blade-Control Switch (PTO) g009174 Figure 18 g004532 Figure 19 Driving the Machine 1. Motion-control lever—NEUTRAL-LOCK position 4. Backward 2. Center, unlocked position 5. Front of the machine 3. Forward 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.
Stopping the Machine WARNING Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. Always remove the ignition key and move the motion-control levers outward to the PARK position when leaving the machine unattended, even if just for a few minutes. To stop the machine, move the traction-control levers to the NEUTRAL position and move to the locked position, disengage the blade-control switch (PTO), and turn the ignition key to the OFF position.
g024410 Figure 23 g024409 1. Deck-lift pedal 3. Height-of-cut positions 2. Handle 4. Pin Figure 22 Transport Lock Position Adjusting the Anti-Scalp Rollers Adjusting the Height of Cut 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.
4. Align the bolt and anti-scalp roller in the hole of the bracket that matched the closest height-of-cut position (Figure 24). 5. Insert the bolt into the bracket hole and secure the bolt and anti-scalp roller with the flange nut (Figure 24). Positioning the Seat The seat can move forward and backward (Figure 25). Position the seat where you have the best control of the machine and are most comfortable.
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. • Never remove the grass deflector from the mower because the grass deflector routes material down toward the turf.
Transporting 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. g028043 Figure 29 1. Back the machine up the ramp.
g027996 Figure 30 1. Full-width ramp in stowed position 4. Ramp is at least 4 times 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.
Operating Tips raise the cutting height higher than usual and cut the grass at this setting. Then cut the grass again using the lower, normal setting. Using the Fast Throttle Setting For best mowing and maximum air circulation, operate the engine at the FAST position. Air is required to thoroughly cut grass clippings, so do not set the height-of-cut so low as to totally surround the mower in uncut grass.
Maintenance Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 50 hours • Change the hydraulic filter and fluid. 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. Inspect the grass deflector for damage.
Pre-Maintenance Procedures Service-Interval Chart decal130-6996 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. 4. Check the hydraulic oil every 25 hours. 3. Check the drive wheel tire pressure every 25 hours. 6. Lubricate the caster wheel every 25 hours. 5. Check the caster wheel tire pressure every 25 hours.
Engine Maintenance Lubrication WARNING Greasing the Bearings Contact with hot surfaces may cause personal injury. Service Interval: Every 25 hours—Grease all lubrication points. Keep hands, feet, face, clothing and other body parts away the muffler and other hot surfaces. Grease Type: No. 2 lithium grease 1. Park the machine on a level surface and disengage the blade-control switch. 2.
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 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 6. 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 34 1.
Installing the Spark Plug Tighten the spark plug to 27 N•m (20 ft-lb) as shown in Figure 42. 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 Set the gap to 0.76 mm (0.03 inch).
Fuel System Maintenance cooling shrouds removed, will cause engine damage due to overheating. 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.
Replacing the Fuel Filter Electrical System Maintenance Service Interval: Every 100 hours/Yearly (whichever comes first) (more often under dusty, dirty conditions). 1. 2. 3. Servicing the Battery Disengage the blade-control switch (PTO), move the motion-control levers to the NEUTRAL-LOCK position, and set the parking brake. Service Interval: Monthly DANGER Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
1. Charge battery for 10 to 15 minutes at 25 to 30 amps or 30 minutes at 10 amps. 2. When the battery is fully charged, unplug the charger from the electrical outlet, then disconnect the charger leads from the battery posts (Figure 45). 3. Install the battery in the machine and connect the battery cables. g020310 Figure 44 4. 5. 6. 7. Remove the clamp (Figure 44). First disconnect the negative battery cable (black) from the negative (-)(black) battery terminal (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 90 kPa (13 psi).
Hydraulic System Maintenance drain out. Use a container that holds 4.5 L (152 oz) or larger. 1. Shut off the engine, wait for all moving parts to stop, allow the engine to cool, remove the key, and engage the parking brake. 2. Locate the filter and guards on each transaxle drive system and remove the 3 screws securing the filter guard (Figure 50). Oil Type: Toro HYPR-OIL® 500 or 20W-50 motor oil. System Capacity: 4.495 L (152 oz) with a filter change. Important: Use oil specified or equivalent.
4. Install the vent plug and torque it to 20 N•m (180 in-lb). 5. Continue to add fluid through the expansion reservoir until fluid comes out of the remaining vent-plug hole on the second transmission. 6. Install the second vent plug and torque it to 20 N•m (180 in-lb). 7. Continue to add fluid through the expansion reservoir until it reaches the Full Cold line on the expansion reservoir. Bleeding the Hydraulic System 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. 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 flat surface (Figure 55). g009680 Figure 57 1. Opposite blade edge (in position for measuring) g009680 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 the surface (A) 4. A. Rotate the same blade 180 degrees so that the opposing cutting edge is now in the same position (Figure 56).
3. Repeat this procedure until the blade is balanced. Installing the Blades 1. Install the blade onto the spindle shaft (Figure 58). Important: The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting. g010341 3. Curved washer 4. Blade bolt 3. Torque the blade bolt to 135 to 150 N•m (100 to 110 ft-lb). Ensure that the mower deck is level any time you install the mower deck or when you see an uneven cut on your lawn.
g007202 g007199 Figure 61 1. Blades side to side Figure 62 3. Measure from the tip of the blade to the flat surface here. 1. Blades front to rear 2. Outside cutting edges 2. Outside cutting edges Checking the Front-to-Rear Blade Slope Leveling the Mower Deck 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.
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. Replace the mower belt if any of these conditions are evident. 1. Disengage the blade-control switch (PTO), move the motion-control levers to the NEUTRAL-LOCK position, and set the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3.
Removing the Mower Deck WARNING 1. The spring is under tension when installed and can cause personal injury. Remove the hairpin cotter and washer securing the link pin to the frame and deck, and remove the link bar (Figure 66). Be careful when removing the belt. 11. Using a spring-removal tool (Toro Part No. 92-5771), install the idler spring over the deck post and placing tension on the idler pulley and mower belt (Figure 65). 12. Ensure that the belt is properly seated in all pulleys. 13.
Installing the Mower Deck 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, shut off 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. Lower the height-of-cut lever to the lowest position. 5. Place the height-of-cut pin in the lock position for lowest height of cut. 6.
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, shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3.
4. Lower the mower to the lowest height of cut. 5. Sit on the seat, start the engine, engage the blade-control switch, and let the mower run for 1 to 3 minutes. 6. Disengage the blade-control switch, shut off the engine, remove the ignition key, and wait for all moving parts to stop. 7. Turn the water off and remove the coupling from the washout fitting. Note: If the mower is not clean after one washing, soak it and let it stand for 30 minutes. Then repeat the process. 8.
Storage B. Run the engine to distribute conditioned fuel through the fuel system (5 minutes). Cleaning and Storage C. Shut off 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. 1. 2. Disengage the blade-control switch (PTO), set the parking brake, turn the ignition key to the OFF position, and remove the key.
Troubleshooting Problem The starter does not crank. Engine does 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. Set the parking brake.
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:
TimeCutter and TITAN Mowers The Toro Warranty 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 repair the Toro Products listed below if defective in materials or workmanship. 1. Contact any Authorized Toro Service Dealer to arrange service at their dealership. To locate a dealer convenient to you, access our web site at www.Toro.com.
