Form No. 3442-160 Rev A Titan® ZX4800 or ZX5400 Riding Mower Model No. 75304—Serial No. 400000000 and Up Model No. 75305—Serial No. 400000000 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 rotary-blade, riding lawn mower is intended to be used by homeowners in residential applications.
information and Note emphasizes general information worthy of special attention. Contents The safety-alert symbol (Figure 2) appears both in this manual and on the machine to identify important safety messages that you must follow to avoid accidents. This symbol will appear with the word Danger, Warning, or Caution. Safety ....................................................................... 4 General Safety ................................................... 4 Slope Indicator .........................
Safety Replacing the Mower Belt ................................. 38 Mower Maintenance............................................. 39 Blade Safety ..................................................... 39 Servicing the Cutting Blades ............................. 39 Leveling the Mower Deck.................................. 42 Removing the Mower Deck............................... 44 Installing the Mower Deck................................. 45 Replacing the Grass Deflector ..........................
Slope Indicator g011841 Figure 3 You may copy this page for personal use. 1. The maximum slope you can 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.
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 missing. decaloemmarkt Manufacturer's Mark 1. This mark indicates that the blade is identified as a part from the original machine manufacturer. decal117-1194 117-1194 decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery. 1. Explosion hazard 6. Keep bystanders away from the battery. 2.
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. decal136-4243 136-4243 1. Fast 2. Slow 4. Reverse 5. Parking brake disengaged 3. Neutral 6. Parking brake engaged decal130-0765 130-0765 1. Read the Operator's Manual. 3. Remove the key before performing maintenance. decal136-4244 136-4244 2. Height-of-cut selection 1. Fast 2. Slow 3. Neutral 4.
decal138-2456 138-2456 1. Read the Operator’s Manual. 2. Park the machine on a level surface when filling the fuel tank. 3. Do not overfill the fuel tank. decal139-3550 139-3550 1. Height of cut decal139-7473 139-7473 1. Fast 4. PTO—disengage 2. Slow 5. PTO—engage 3.
decal140-3451 140-3451 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 the conditions on that day and at that site.
Product Overview g335166 Figure 4 4. Controls 7. Mower deck 2. Height-of-cut pin 5. Engine 8. Anti-scalp roller 3. Motion-control lever 6. Fuel cap 9. Caster wheel 1. Deck-lift pedal 10 10.
Controls Choke Control Become familiar with all the controls before you start the engine and operate the machine. Use the choke control to start a cold engine (Figure 5). Hour Meter Control Panel The hour meter records the number of hours the engine has operated. It operates when the engine is running. Use these times for scheduling regular maintenance (Figure 5). Motion-Control Levers Use the motion-control levers to drive the machine forward, reverse, and turn either direction (Figure 4).
Height-of-Cut Pin Operation The height-of-cut pin works with the foot pedal to lock the deck in a specific cutting height. Adjust the height of cut only when the machine is not moving (Figure 4). Note: Determine the left and right sides of the machine from the normal operating position. Attachments/Accessories Before Operation A selection of Toro approved attachments and accessories is available for use with the machine to enhance and expand its capabilities.
Fuel Safety compartment to help prevent fires. Clean up oil or fuel spills. • Fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. Adding Fuel – To prevent a static charge from igniting the fuel, place the container and/or machine directly on the ground before filling, not in a vehicle or on an object. Recommended Fuel – Fill the fuel tank outdoors on level ground, in an open area, and when the engine is cold.
Using the Safety-Interlock System 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. • Check the operation of the interlock switches daily and replace any damaged switches before operating the machine. Understanding the Safety-Interlock System The safety-interlock system is designed to prevent the engine from starting unless: • The blade-control switch (PTO) is disengaged.
4. 5. Adjusting the Motion-Control Levers Sit on the seat, engage the parking brake, move the blade-control switch (PTO) to the OFF position, and move the motion-control levers to NEUTRAL-LOCK position. Start the engine. While the engine is running, center either motion-control lever and move it forward or reverse; the engine should shut off. Repeat for other motion-control lever. Adjusting the Height You can adjust the motion-control levers higher or lower for maximum comfort (Figure 9).
3. Tighten both bolts to secure the control lever in the new position. During Operation 4. Repeat the adjustment for the other control lever. During Operation Safety General Safety • The owner/operator can prevent and is responsible • • • • • • • • • • • • 16 for accidents that may cause personal injury or property damage. Use your full attention while operating the machine. Do not engage in any activity that causes distractions; otherwise, injury or property damage may occur.
• Before backing up or turning the machine, look – Shut off the engine and remove the key. down and all around for small children. – Wait for all moving parts to stop. • Do not carry children on the machine, even when • Operate the engine only in well-ventilated areas. the blades are not moving. Children could fall off and be seriously injured or prevent you from safely operating the machine.
• The stopping distance may increase with the • Use extra care while operating with accessories or weight of a towed load. Travel slowly and allow extra distance to stop. attachments, such as grass-collection systems. These can change the stability of the machine and cause a loss of control. Follow directions for counterweights. • Make wide turns to keep the attachment clear of the machine. • If possible, keep the deck lowered to the ground while operating on slopes.
Engaging the Blade-Control Operating the Throttle You can move the throttle control between the FAST Switch (PTO) and SLOW positions (Figure 18). Always use the FAST position when engaging the PTO. g008945 Figure 15 Note: Always engage the blades with the throttle in the FAST position (Figure 16). g295539 Figure 18 Operating the Choke Use the choke to start a cold engine. 1. Pull up the choke knob to engage the choke before using the key switch (Figure 19). 2.
Operating the Key Switch 1. Starting the Engine Turn the key to the START position (Figure 20). Note: A warm or hot engine may not require choking. Note: When the engine starts, release the key. Important: Do not engage the starter for more Important: Do not engage the starter motor than 5 seconds at a time. Engaging the starter motor for more than 5 seconds can damage the starter motor. If the engine fails to start, wait 10 seconds before operating the engine starter again.
Driving the Machine Shutting Off the Engine 1. Disengage the blades by moving the blade-control switch to the OFF position. 2. Engage the parking brake. 3. Move the throttle control to between the half and full throttle position. 4. Turn the key to the OFF position and remove the key. The drive wheels turn independently, powered by hydraulic motors on each axle. You can turn 1 side in reverse while you turn the other forward, causing the machine to spin rather than turn.
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 a 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 deck because the grass deflector routes material down toward the turf.
Adjusting the Height of Cut Adjusting the Anti-Scalp Rollers The machine is equipped with a foot pedal deck-lift system. You can use the foot pedal to lift the deck briefly to avoid obstacles and to raise the deck. Whenever you change the height of cut, adjust the height of the anti-scalp rollers. You can adjust the height of cut from 38 to 114 mm (1-1/2 to 4-1/2 inches) in 6 mm (1/4 inch) increments by moving the height-of-cut pin into different hole locations.
Operating Tips drop onto your lawn. To avoid this, move onto a previously cut area with the blades engaged or you can disengage the mower deck while moving forward. 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 deck in uncut grass.
After Operation After Operation Safety General Safety • Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operator’s position. Allow the machine to cool before servicing, adjusting, fueling, cleaning, or storing it. • Clean grass and debris from the cutting unit, g298692 muffler, drives, grass catcher, and engine compartment to help prevent fires. Clean up oil or fuel spills. Figure 27 1.
Transporting the Machine Use a heavy-duty trailer or truck to transport the machine. Use a full-width ramp. Ensure that the trailer or truck has all the necessary brakes, lighting, and marking as required by law. Please carefully read all the safety instructions. Knowing this information could help you or bystanders avoid injury. Refer to your local ordinances for trailer and tie-down requirements.
1. If using a trailer, connect it to the towing vehicle and connect the safety chains. 2. If applicable, connect the trailer brakes and lights. 3. Lower the ramp, ensuring that the angle between the ramp and the ground does not exceed 15 degrees (Figure 28). 4. Back the machine up the ramp (Figure 29). g027995 Figure 29 1. Back the machine up the ramp. 2. Drive the machine forward down the ramp. 5. Shut off the engine, remove the key, and engage the parking brake. 6.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Maintenance Safety • If you leave the key in the switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the switch before you perform any maintenance. • Before you leave the operator’s position, do the following: – Park the machine on a level surface. – Disengage the drives. – Engage the parking brake. – Shut off the engine and remove the key.
Recommended Maintenance Schedule(s) Maintenance Service Interval Before each use or daily Maintenance Procedure • • • • Check the safety-interlock system. Check the engine-oil level. Inspect the blades. Inspect the grass deflector for damage. Every 25 hours • Clean the air-cleaner foam element (more often in dusty, dirty conditions). • Check tire pressure. • Check the belts for wear or cracks. Every 100 hours • Replace the air-cleaner foam element (more often in dusty, dirty conditions).
Engine Maintenance 5. Separate the foam and paper elements (Figure 32). Engine Safety • Keep your hands, feet, face, clothing, and other body parts away from the muffler and other hot surfaces. Allow engine components to cool before performing maintenance. Do not change the engine governor speed or overspeed the engine. • g305608 Figure 32 Servicing the Air Cleaner 1. Paper element Service Interval: Every 25 hours—Clean the air-cleaner foam element (more often in dusty, dirty conditions).
Servicing the Engine Oil Engine-Oil Specifications Oil Type: Detergent oil (including synthetic) of API service SJ or higher Crankcase Capacity: 1.9 L (64 fl oz) with oil filter Viscosity: See the table below. g017552 Figure 33 Checking the Engine-Oil Level Service Interval: Before each use or daily Note: Check the oil when the engine is cold. Important: If you overfill or underfill the engine crankcase with oil and run the engine, you may damage the engine. 1.
g027477 Figure 36 5. g225280 Figure 35 4. Change the engine-oil filter (Figure 36). Note: Ensure that the oil-filter gasket touches the engine and then turn the filter an extra 3/4 turn. 32 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 37).
g027478 Figure 38 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. 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. Set the gap to 0.75 mm (0.03 inch). g194610 Figure 37 6. Dispose of the used oil at a recycling center.
Cleaning the Blower Housing Fuel System Maintenance Service Interval: Every 100 hours/Yearly (whichever comes first) DANGER In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. To ensure proper cooling, ensure that the grass screen, cooling fins, and other external surfaces of the engine are kept clean at all times. Clean the cooling fins and external surfaces as necessary.
Electrical System Maintenance Electrical System Safety • Disconnect the battery before repairing the g305646 machine. Disconnect the negative terminal first and the positive last. Connect the positive terminal first and the negative last. • Charge the battery in an open, well-ventilated area, away from sparks and flames. Unplug the charger before connecting or disconnecting the battery. Wear protective clothing and use insulated tools.
Charging the Battery Service Interval: Before storage—Charge the battery and disconnect the battery cables. 1. Remove the battery from the chassis; refer to Removing the Battery (page 35). 2. Charge the battery for a minimum of 1 hour at 6 to 10 A. Note: Do not overcharge the battery. 3. g297596 Figure 42 1. Battery cover 4. 2. Fasteners When the battery is fully charged, unplug the charger from the electrical outlet, then disconnect the charger leads from the battery posts (Figure 44).
Servicing the Fuses Drive System Maintenance The electrical system is protected by fuses. It requires no maintenance; however, if a fuse blows, check the component/circuit for a malfunction or short. Checking the Tire Pressure Fuse type: • Main—F1 (15 A, blade-type) Service Interval: Every 25 hours—Check tire pressure. • Charge Circuit—F2 (25 A, blade-type) Maintain the air pressure in the front and rear tires as specified. Uneven tire pressure can cause uneven cut.
Belt Maintenance Inspecting the Belts Service Interval: Every 25 hours—Check the belts for wear or cracks. Replace the belt if it is worn. The signs of a worn belt include squealing while the belt is rotating; the blades slipping while cutting grass; and frayed edges, burn marks, and cracks on the belt.
7. Route the new belt around the engine pulley and mower pulleys (Figure 50). 8. Using a spring-removal tool (Toro Part No. 92-5771), install the idler spring over the deck hook and place tension on the idler pulley and the mower belt (Figure 50). 9. Mower Maintenance Blade Safety • Inspect the blades periodically for wear or damage. • Use care when checking the blades. Wrap the Tighten the nut securing the wire form to the idler pulley (Figure 49).
g006530 Figure 51 1. Cutting edge 3. Wear/slot forming 2. Curved area 4. Crack g014973 Figure 53 1. Blade (in position for measuring) Checking for Bent Blades 2. Level surface 3. Measured distance between blade and the surface (A) Note: The machine must be on a level surface for the following procedure. 4. 1. Raise the mower deck to the highest height-of-cut position. 2.
Removing the Blades Replace the blades if they hit a solid object, or if the blade is out of balance or bent. 1. Hold the blade end using a rag or thickly padded glove. 2. Remove the blade bolt, curved washer, and blade from the spindle shaft (Figure 56). g014973 Figure 55 1. Opposite blade edge (in position for measuring) 2. Level surface 3. Second measured distance between blade and surface (B) A.
Leveling the Mower Deck Check to ensure that the mower deck is level any time you install the mower or when you see an uneven cut on your lawn. g000553 Figure 58 1. Blade 3. Check the mower deck for bent blades prior to leveling, and remove and replace any bent blades; refer to Checking for Bent Blades (page 40) before continuing. 2. Balancer Repeat this procedure until the blade is balanced. Level the mower deck side-to-side first; then you can adjust the front-to-rear slope.
Leveling the Mower Deck Checking the Front-to-Rear Blade Slope 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. 1. 2. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 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 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and disconnect the spark-plug wires from the spark plugs. 3. Lower the mower to the 76 mm (3 inches) height-of-cut position. 4. Remove the mower belt from the engine pulley; refer to Replacing the Mower Belt (page 38). 5.
Replacing the Grass Deflector Service Interval: Before each use or daily—Inspect the grass deflector for damage. WARNING An uncovered discharge opening could allow the machine to throw objects toward you or bystanders, resulting in serious injury. Also, contact with the blade could occur. Never operate the machine unless you install a mulch plate, discharge deflector, or grass collection system. 1. g297515 Figure 65 1. Deck-lift arm 2. Chain 8. 9. 10. 3. Hook 4.
3. Position the new discharge deflector with the bracket ends between the welded brackets on the deck as shown in Figure 67. Cleaning 4. Install the spring onto the straight end of the rod. Disposing of Waste 5. Position the spring on the rod as shown in Figure 67 so that the shorter spring end comes from under the rod before the bend and going over the rod as it returns from the bend. Engine oil, batteries, hydraulic fluid, and engine coolant are pollutants to the environment.
Storage A. Add fuel stabilizer/conditioner to fresh fuel in the tank. Follow mixing instructions from the fuel stabilizer manufacturer. Do not use an alcohol-based stabilizer (ethanol or methanol). B. Run the engine to distribute conditioned fuel through the fuel system for 5 minutes. C. Shut off the engine, allow it to cool, and drain the fuel tank. D. Start the engine and run it until it shuts off. E. Dispose of fuel properly. Recycle the fuel according to local codes.
Storing the Battery 1. Fully charge the battery. 2. Let the battery rest for 24 hours, then check the battery voltage. Note: If the battery voltage is below 12.6 V, repeat steps 1 and 2. 3. Disconnect the cables from the battery. 4. Check the voltage periodically to ensure that the voltage is 12.4 V or higher. Note: If the battery voltage is below 12.4 V, repeat steps 1 and 2. Battery Storage Tips • Store the battery in a cool, dry area in an upright position.
Troubleshooting Problem Possible Cause The fuel tank is showing signs of collapsing or the machine is frequently showing signs of running out of fuel. 1. The air-cleaner paper element clogged. The engine overheats. 1. The engine load is excessive. 1. Reduce the ground speed. 2. The oil level in the crankcase is low. 3. The cooling fins and air passages under the engine-blower housing are plugged. 4. The air cleaner is dirty. 2. Add oil to the crankcase. 3.
Problem The machine does not drive. The machine vibrates abnormally. The cutting height is uneven. The blades do not rotate. Possible Cause Corrective Action 1. The bypass valves are open. 1. Close the tow valves. 2. The traction belts are worn, loose, or broken. 3. The traction belts are off the pulleys. 4. The transmission has failed. 2. Contact an Authorized Service Dealer. 1. The cutting blade(s) is/are bent or unbalanced. 1. Install new cutting blade(s). 2. The blade mounting bolt is loose.
Schematics g297640 Electrical Diagram (Rev.
California Proposition 65 Warning Information What is this warning? You may see a product for sale that has a warning label like the following: WARNING: Cancer and Reproductive Harm—www.p65Warnings.ca.gov. What is Prop 65? Prop 65 applies to any company operating in California, selling products in California, or manufacturing products that may be sold in or brought into California.
