TITAN® MX4800, MX5400, or MX6000 Zero-Turn-Radius Riding Mower

• Read the Operator's Manual and other training material. If the operator(s) or mechanic(s) cannot read English it is the owner's responsibility to explain this material to them.

• Become familiar with the safe operation of the equipment, operator controls, and safety signs.

• All operators and mechanics should be trained. The owner is responsible for training the users.

• Never let children or untrained people operate or service the equipment. Local regulations may restrict the age of the operator.

• The owner/user can prevent and is responsible for accidents or injuries occurring to people or damage to property.

• Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job. Use only accessories and attachments approved by the manufacturer.

• Wear appropriate clothing including substantial slip-resistant footwear, a hard hat, eye protection, and hearing protection. Tie back long hair. Do not wear jewelry.

• Inspect the area where the equipment is to be used and remove all objects such as rocks, toys and wire which can be thrown by the machine.

• Check that operator-presence controls, safety switches and shields are attached and functioning properly. Do not operate the machine unless they are functioning properly.

• 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.

• Ensure that all drives are in NEUTRAL and that the parking brake is engaged before starting engine. Start the engine only from the operator's position.

• Slow down and use extra care on hillsides. Be sure to travel side to side on hillsides. Turf conditions can affect the machine's stability. Use caution while operating near drop-offs.

• Slow down and use caution when making turns and when changing directions on slopes.

• Never raise the deck with the blades running.

• Never operate with the PTO shield, or other guards not securely in place. Ensure that all interlocks are attached, adjusted properly, and functioning properly.

• Never operate with the discharge deflector raised, removed or altered, unless using a grass catcher.

• Do not change the engine governor setting or overspeed the engine.

• Stop on level ground, disengage the drives, engage the parking brake (if provided), shut off the engine before leaving the operator's position for any reason including emptying the catchers or unclogging the chute.

• Stop equipment and inspect blades after striking objects or if an abnormal vibration occurs. Make necessary repairs before resuming operations.

• Keep hands and feet away from the cutting unit.

• Look behind and down before backing up to be sure of a clear path.

• Keep pets and bystanders away.

• Slow down and use caution when making turns and crossing roads and sidewalks. Stop the blades if you are not mowing.

• Be aware of the mower discharge direction and do not point it at anyone.

• Do not operate the mower while ill, tired, or under the influence of alcohol or drugs.

• Use care when loading or unloading the machine into or from a trailer or truck.

• Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision.

• Do not remove the ROPS.

• The ROPS is an integral and effective safety device. Keep the ROPS on the machine and use the seat belt when operating the machine.

• Be certain that the seat belt can be released quickly in the event of an emergency.

• Check the area to be mowed where there are slopes, dropoffs, or water.

• Carefully check for overhead clearances (i.e., branches, doorways, electrical wires) before driving under any objects and do not contact them.

• Keep the ROPS in safe operating condition by periodically thoroughly inspecting for damage and keeping all mounting fasteners tight.

• Replace a damaged ROPS. Do not repair or revise.

• Any alterations to a ROPS must be approved by the manufacturer.

• To avoid personal injury or property damage, use extreme care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive.

• Extinguish all cigarettes, cigars, pipes, and other sources of ignition.

• Use only an approved fuel container.

• Never remove fuel cap or add fuel with the engine running.

• Allow engine to cool before refueling.

• Never refuel the machine indoors.

• Never store the machine or fuel container where there is an open flame, spark, or pilot light such as on a water heater or on other appliances.

• Never fill containers inside a vehicle or on a truck or trailer bed with a plastic liner. Always place containers on the ground away from your vehicle before filling.

• Remove equipment from the truck or trailer and fuel it on the ground. If this is not possible, then refuel such equipment with a portable container rather than from a fuel dispenser nozzle.

• Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. Do not use a nozzle lock open device.

• If fuel is spilled on clothing, change clothing immediately.

• Never overfill the fuel tank. Replace the fuel cap and tighten it securely.

• 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.

• Clean grass and debris from cutting unit, drives, mufflers, and engine to help prevent fires. Clean up oil or fuel spillage.

• Let the engine cool before storing and do not store near flame.

• Shut off the fuel while storing or transporting. Do not store fuel near flames or drain indoors.

• Park the machine on level ground. Set the parking brake. Never allow untrained personnel to service the machine.

• Use jack stands to support components when required.

• Carefully release pressure from components with stored energy.

• Disconnect the battery or remove spark-plug wire before making any repairs. Disconnect the negative terminal first and the positive last. Reconnect the positive first and negative last.

• Use care when checking blades. Wrap the blade(s) or wear thickly-padded gloves, and use caution when servicing them. Only replace blades. Never straighten or weld them.

• Keep hands and feet away from moving parts. If possible, do not make adjustments with the engine running.

• Keep all parts in good working condition and all hardware tightened. Replace all worn or damaged decals.

• Use care when loading or unloading the machine into a trailer or truck.

• Use full width ramps for loading machine into trailer or truck. The ramp angle should not exceed 15 degrees.

• Tie the machine down securely using straps, chains, cable, or ropes. Both front and rear straps should be directed down and outward from the machine.

Use a fuel stabilizer/conditioner in the machine to provide the following benefits:

• Keeps fuel fresh during storage of 90 days or less. For longer storage it is recommended that the fuel tank be drained.

• Cleans the engine while it runs

• Eliminates gum-like varnish buildup in the fuel system, which causes hard starting

Important: Do not use fuel additives containing methanol or ethanol.

Add the correct amount of fuel stabilizer/conditioner to the gas.

Note: A fuel stabilizer/conditioner is most effective when mixed with fresh fuel. To minimize the chance of varnish deposits in the fuel system, use fuel stabilizer at all times.

Shut off the engine and move the motion controls to the PARK position.

Important: Do not overfill fuel tank. Fill the fuel tank to the bottom of the filler neck. The empty space in the tank allows the fuel to expand. Overfilling may result in fuel leakage or damage to the engine or emission system.

1. Clean around the fuel-tank cap and remove the cap.

2. Slowly add regular, unleaded fuel until it reaches the base of the filler neck Figure 7.

   

   Figure 7

3. Install the fuel-tank cap securely and tighten until it clicks.

   Note: Wipe up any spilled fuel.

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.

Figure 17

Use the motion-control levers as shown in Figure 19.

Figure 19

1. Motion-control lever—NEUTRAL-LOCK position
2. Center, unlocked position
3. Forward
4. Backward
5. Front of the machine

Note: The engine kills if the traction-control levers are moved with the parking brake engaged.

1. Release the parking brake.

2. Move the levers to the center, unlocked position.

3. To move forward, slowly push the motion-control levers forward (Figure 20).

   

   Figure 20

Note: Always use caution when backing up and turning.

1. Move the levers to the center, unlocked position.

2. To go backward, slowly pull the motion-control levers rearward (Figure 21).

   

   Figure 21

• 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).

Figure 22

Transport Lock Position

The height of cut can be adjusted from 38 to 114 mm (1-1/2 to 4-1/2 inches) in 6 mm (1/4 inch) increments by relocating the height-of-cut pin into different hole locations.

1. Push on the deck-lift pedal with your foot and raise the mower deck to the transport-lock position (also the 114 mm (4-1/2 inches) cutting height position) as shown in Figure 23.

2. To adjust, remove the pin from the height-of-cut bracket (Figure 23).

3. Select a hole in the height-of-cut system corresponding to the desired height of cut and insert the pin (Figure 23).

4. Push on the deck-lift pedal with your foot and pull the handle rearward to disengage the transport lock (Figure 22).

5. Lower the deck slowly until the lever makes contact with the pin.

   

   Figure 23

   1. Deck-lift pedal
   2. Handle
   3. Height-of-cut positions
   4. Pin

Note: Repeat the adjustment for the opposite control lever.

The motion-control levers can be adjusted higher or lower for maximum operator comfort (Figure 27).

Figure 27

The motion-control levers can be tilted forward or rearward for maximum operator comfort.

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 forward or rearward.

3. Tighten both bolts to secure the control in the new position.

4. Repeat the adjustment for the opposite control lever.

Move the bypass levers to the position for operating the machine (Figure 28) to engage the wheel motors.

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. Always try to have 1 side of the mower free from uncut grass, which allows air to be drawn into the mower.

Cut grass slightly longer than normal to ensure that the cutting height of the mower does not scalp any uneven ground. However, the cutting height used in the past is generally the best one to use. When cutting grass longer than 15 cm (6 inches) tall, you may want to cut the lawn twice to ensure an acceptable quality of cut.

It is best to cut only about a third of the grass blade. Cutting more than that is not recommended unless grass is sparse, or it is late fall when grass grows more slowly.

Alternate the mowing direction to keep the grass standing straight. This also helps disperse clippings which enhances decomposition and fertilization.

Grass grows at different rates at different times of the year. To maintain the same cutting height, mow more often in early spring. As the grass growth rate slows in mid summer, mow less frequently. If you cannot mow for an extended period, first mow at a high cutting height, then mow again 2 days later at a lower height setting.

To improve cut quality, use a slower ground speed in certain conditions.

When mowing uneven turf, raise the cutting height to avoid scalping the turf.

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.

If you must stop the forward motion of the machine while mowing, a clump of grass clippings may 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.

Clean clippings and dirt from the underside of the mower after each use. If grass and dirt build up inside the mower, cutting quality will eventually become unsatisfactory.

Maintain a sharp blade throughout the cutting season because a sharp blade cuts 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. Check the mower blades after each use for sharpness, and for any wear or damage. File down any nicks and sharpen the blades as necessary. If a blade is damaged or worn, replace it immediately with a genuine Toro replacement blade.

Ensure that the motion-control levers are locked in the NEUTRAL-LOCK position and lift the seat forward.

The following components can be accessed by raising the seat:

• Service decal

• Fuses

• Battery and cables

Grease Type: No. 2 lithium grease

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. Clean the grease fittings (Figure 33 and Figure 32) with a rag.

   Note: Scrape any paint off the front of the fitting(s).

   

   Figure 33

   1. Front caster tire

4. Connect a grease gun to each fitting and pump grease into the fittings until grease begins to ooze out of the bearings (Figure 32 and Figure 33).

This engine is equipped with a replaceable, high-density paper and foam air-cleaner element. Check the air cleaner daily or before starting the engine. Check for a buildup of dirt and debris around the air-cleaner system. Keep this area clean. Also, check for loose or damaged components. Replace all bent or damaged air-cleaner components.

Note: Operating the engine with loose or damaged air-cleaner components could allow unfiltered air into the engine, causing premature wear and failure.

Note: Service the air cleaner more often under extremely dusty, dirty conditions.

Oil Type: Detergent oil (API service SJ or higher)

Crankcase Capacity: 1.9 L (64 oz) when the filter is changed

Viscosity: See the table below.

Figure 36

The spark plug is RFI compliant. Equivalent alternate brand plugs can also be used.

Type: Champion XC12YC

Air Gap: 0.76 mm (0.03 inch)

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.

Set the gap to 0.76 mm (0.03 inch).

Figure 42

Installing the Spark Plug

Tighten the spark plug to 27 N•m (20 ft-lb) as shown in Figure 43.

Figure 43

To ensure proper cooling, ensure that the grass screen, cooling fins, and other external surfaces of the engine are kept clean at all times.

Annually, or every 100 hours of operation (more often under extremely dusty, dirty conditions), remove the blower housing, and any other cooling shrouds. Clean the cooling fins and external surfaces as necessary. Make sure the cooling shrouds are installed.

Important: Operating the engine with a blocked grass screen, dirty or plugged cooling fins, and/or cooling shrouds removed, will cause engine damage due to overheating.

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. Replace the fuel filter as shown in Figure 44.

   

   Figure 44

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.

Note: The fuses are located on right hand console next to the seat (Figure 47).

Fuse type:

• Main—30 A, blade-type

• Engine—20 A, blade-type

1. To replace the main fuse, grasp the fuse and pull it straight and away from the fuse block (Figure 47).

   

   Figure 47

   1. Fuse block
   2. Main—30 A

   Important: Ensure that the new fuses are the same type and amperage as the fuses removed.

2. To replace the engine fuse, remove the console from the plastic fender.

   

   Figure 48

   1. Engine fuse—25 A

3. Grasp the engine fuse and pull it straight and away from the fuse block (Figure 48).

4. Align a new fuse with the slot in the fuse block (Figure 47).

5. Push the fuse into the fuse block until the fuse is seated (Figure 47).

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 49). 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).

Figure 49

1. Valve stem

Check the expansion reservoir, and, if necessary, add fluid to the Full Cold line.

Figure 50

1. Expansion reservoir
2. Full Cold line
3. Engine

The filter and fluid are changed at the same time. Once the new filter is installed and fluid is added, any air in the system must be purged.

The bleeding process is repeated until the fluid remains at the Full Cold line in the reservoir after purging. Failure to properly perform this procedure can result in irreparable damage to the transaxle drive system.

Installing the Hydraulic Filter

Maintenance Service Interval	Maintenance Procedure
After the first 50 hours	Change the hydraulic filter and fluid.
Every 400 hours	Change the hydraulic filter and fluid.

1. Using the 3 screws to install the filter guards over each filter removed previously.

2. Verify that the vent plugs are removed before adding the fluid.

3. Slowly pour the specified fluid through the expansion reservoir until fluid comes out of a vent-plug hole.

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.

   Important: Failure to perform the Bleeding the Hydraulic System procedure after changing hydraulic filters and oil can result in irreparable damage to the transaxle drive system.

Figure 52

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.

Check the cutter blades daily for sharpness, and for any wear or damage. File down any nicks and sharpen the blades as necessary. If a blade is damaged or worn, replace it immediately with a genuine Toro replacement blade. For convenient sharpening and replacement, you may want to keep extra blades on hand.

Ensure that the mower deck is level any time you install the mower deck or when you see an uneven cut on your lawn.

Check the mower deck for bent blades prior to leveling; remove and replace any bent blades; refer to Checking for Bent Blades before continuing.

Level the mower deck side-to-side before adjusting the front-to-rear slope.

Requirements:

• The machine must be on a level surface.

• All 4 tires must be properly inflated; refer to Checking the Tire Pressure.

Check the belts for squealing when the belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks and cracks are signs of a worn mower belt. Replace the mower belt if any of these conditions are evident.

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. Lower the mower to the 76 mm (3 inch) height-of-cut position.

4. For each of the belt covers, loosen the 2 bolts, but do not remove them.

5. Slide the cover until it is clear of the bolts and lift it up and out to remove it.

6. Remove the floor pan to access the idler pulley.

7. Using a spring removal tool, (Toro Part No. 92-5771), remove the idler spring from the deck post to remove tension on the idler pulley (Figure 66).

   

   Figure 66

   1. Spring-removal tool (Toro Part No. 92-5771)
   2. Idler spring
   3. Deck post
   4. Idler arm
   5. Mower belt

8. Lower the mower to the lowest height of cut and place the height-of-cut pin in the lock position for the lowest height-of-cut.

9. Remove the belt from the mower-deck pulleys and remove the existing belt.

10. Install the new belt around the mower pulleys and the clutch pulley under the engine (Figure 66).

    Warning

    The spring is under tension when installed and can cause personal injury.

    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 66).

12. Ensure that the belt is properly seated in all pulleys.

13. To install the belt covers, insert the tabs on the each cover into the corresponding slots on the deck bracket, ensuring that they seat.

14. Rotate the cover to the deck and slide the notches under the loosened bolts until they are seated.

15. Tighten the bolts to secure the cover to the deck.

Park the machine on a level surface and disengage the blade-control switch. Move the motion-control levers outward to the NEUTRAL-LOCK position, engage the parking brake, shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

Lower the mower to the lowest height of cut. Select one of the following procedures depending on the mower deck size installed to complete the removal.

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. Lift the rear of the mower deck and attach the chains to the rear lift arms (Figure 68).

7. Attach the front chains to the front lift arms (Figure 68).

8. Install the long link bar through the frame hanger and deck.

9. Secure the link pin with the hairpin cotters and washers removed previously (Figure 67).

10. Install the mower belt onto the engine pulley; refer to Replacing the Mower Belt.

Inspect the grass deflector for damage before each use. Replace any damaged parts before use.

1. Remove the cotter pin from the end of the rod (Figure 69).

2. Disengage the spring from the notch in the deflector bracket and slide the rod out of the welded deck brackets, spring, and discharge deflector (Figure 69).

   Note: Remove the damaged or worn discharge deflector.

   

   Figure 69

   1. Deflector
   2. Deck brackets
   3. Rod
   4. Spring
   5. Spring installed over the rod
   6. Cotter pin

3. Position the new discharge deflector with the bracket ends between the welded brackets on the deck (Figure 69).

4. Install the spring onto the straight end of the rod.

   Note: Position the spring on the rod as shown in 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. Lift the loop end of the spring and place it into the notch on the deflector bracket (Figure 70).

   

   Figure 70

   1. Rod and spring assembly partially installed
   2. Loop end of the spring installed into the notch in the deflector bracket
   3. Rod, short end, moved behind the mower bracket
   4. Short end, retained by the mower bracket

6. Secure the rod and spring assembly by twisting it so the short end of the rod can be placed behind the front bracket welded to the deck (Figure 70).

   Important: The grass deflector must be spring loaded in the down position. Lift the deflector up to test that it snaps to the full down position.

7. Install the cotter pin into the end of the rod (Figure 69).

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. Attach the hose coupling to the end of the mower washout fitting, and turn the water on high (Figure 71).

   Note: Spread petroleum jelly on the washout fitting O-ring to make the coupling slide on easier and protect the O-ring.

   

   Figure 71

   1. Washout fitting locations on 54-inch decks
   2. Washout fitting locations on 48-inch decks
   3. Washout fitting
   4. O-ring
   5. Hose
   6. Coupling

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. Run the mower again for 1 to 3 minutes to remove excess water.

   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.

   • Replace broken or missing washout fitting immediately, before using mower again.

   • Never put your hands or feet under the mower or through openings in the mower.

Engine oil, batteries, hydraulic fluid, and engine coolant are pollutants to the environment. Dispose of these according to your state and local regulations.