TITAN® ZX4800, ZX5400, or ZX6000 Zero-Turn-Radius Riding Mower

• Read the Operator's Manual and other training material. If the operator(s) or mechanic(s) can not 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. Only use accessories and attachments approved by the manufacturer.

• Wear appropriate clothing including hard hat, safety glasses and hearing protection. Long hair, loose clothing or jewelry may get tangled in moving parts.

• 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's presence controls, safety switches and shields are attached and functioning properly. Do not operate 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.

• Be sure all drives are in neutral and parking brake is engaged before starting engine. Only start engine 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 deck with the blades running.

• Never operate with the PTO shield, or other guards not securely in place. Be sure 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 drives, engage parking brake (if provided), shut off 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 blades if not mowing.

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

• Do not operate the mower 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, drop offs or water.

• Check carefully 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 refuel 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 fuel tank. Replace fuel cap and tighten 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 engine cool before storing and do not store near flame.

• Shut off 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.

• 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:

• Fuel stabilizer/conditioner keeps gasoline fresh during storage of 90 days or less. When storing the machine for longer periods, drain the fuel system.

• It cleans the engine while it runs

• It 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 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.

Use the fuel window below the operator to verify the level of gasoline before filling the tank (Figure 6).

Figure 6

1. Fuel gauge window

Make sure the engine is shut off and the motion controls are in 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.

   Note: You can use the fuel window below the operating position verify the presence of gasoline before filling the tank (Figure 6).

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

   

   Figure 7

3. Install the fuel tank cap securely and tighten until it “clicks.” Wipe up any gasoline that may have spilled.

The safety interlock system is designed to prevent the engine from starting unless:

• The parking brake is engaged.

• The blades are disengaged.

• The motion control levers are in the neutral lock position.

The safety interlock system also is designed to stop the engine when the control levers are out of the neutral lock position with the parking brake on or if you rise from the seat when the blades are engaged.

Test the safety interlock system before you use the machine each time. If the safety system does not 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. Repeat with the other motion control lever.

3. While sitting on the seat, engage the parking brake, move the blade control switch to Off, and lock the motion control levers in neutral. Start the engine. While the engine is running, release the parking brake, engage the blade control switch, and rise slightly from the seat; the engine should stop.

4. While sitting on the seat, engage the parking brake, move the blade control switch to Off, and lock the motion control levers in neutral. Start the engine. While the engine is running, center the motion controls; the engine should stop.

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.

Note: If the fuel system was depleted of fuel—add fuel to the machine and use additional starting cycles when starting the engine.

Figure 15

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

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

1. Release the parking brake; refer to Releasing the Parking Brake.

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

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

   

   Figure 20

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 inch) 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 inch) cutting height position) (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 height-of-cut desired 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 26).

Figure 26

The motion control levers can be tilted fore or aft 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 fore or aft. Tighten both bolts to secure the control in the new position.

3. Repeat the adjustment for the opposite control lever.

1. Park the machine on a level surface and disengage the blade control switch.

2. Move the motion control levers outward to neutral lock position, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Make sure the parking brake is disengaged.

3. Do this procedure on each side of the machineFigure 27.

   

   Figure 27

Move the bypass to the position for operating the machine (Figure 27) to engage the wheel motors.

For best mowing and maximum air circulation, operate the engine at the fast throttle position. Air is required to thoroughly cut grass clippings, so do not set the height-of-cut so low as to totally surround the mower by uncut grass. Always try to have one 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 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 six inches tall, you may want to cut the lawn twice to ensure an acceptable quality of cut.

It is best to cut only about 1/3 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 mowing direction to keep the grass standing straight. This also helps disperse clippings which enhances decomposition and fertilization.

Normally, mow every four days. But remember, grass grows at different rates at different times. So to maintain the same cutting height, which is a good practice, 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 two days later at a lower height setting.

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

If the cutting width of the mower is wider than the mower you previously used, raise the cutting height to ensure that uneven turf is not cut too short.

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 the machine's forward motion must be stopped 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.

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 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.

Make sure the motion control levers are locked in the neutral lock position. Lift the seat forward.

The following components can be accessed by raising the seat:

• Service decal

• Fuses

• Battery and cables

Grease Type: No. 2 General Purpose Lithium Base 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, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3. Clean the grease fittings with a rag (Figure 31 and Figure 32). Make sure to scrape any paint off of the front of the fitting(s).

   

   Figure 32

   1. Front caster tire

4. Connect a grease gun to each fitting (Figure 32 and Figure 31). Pump grease into the fittings until grease begins to ooze out of the bearings.

5. Wipe up any excess grease.

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 35

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

Type: Champion XC12YC  (or equivalent)

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 (0.030 inch).

Figure 41

Installing the Spark Plug

Tighten the spark plug to 27 N-m (20 ft-lb).

Figure 42

To ensure proper cooling, make sure 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. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

   

   Figure 43

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 46).

Fuses:

• Main, 30 amp, blade-type

• Engine, 20 amp, blade-type

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

   

   Figure 46

   1. Fuse block
   2. 30 amp main fuse

   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 47

   1. Engine fuse

3. Grasp the engine fuse and pull it straight and away from the fuse block (Figure 47).

4. Align a new fuse with the slot in the fuse block (Figure 46).

5. Push the fuse into the fuse block until the fuse is seated (Figure 46).

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).

Figure 48

1. Valve stem

Check expansion reservoir and if necessary add 20W-50 engine oil to the FULL COLD line

Figure 49

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

The filter and oil are changed at the same time. Do not reuse oil. Once the new filter is installed and oil is added any air in the system must be purged.

The bleeding process is repeated until the oil 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.

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.

Removing the Blades

Replace a blade whenever it strikes an object, is out of balance, or is bent. To ensure optimum performance and continued safety conformance of the machine, use only genuine Toro replacement blades. Replacement blades made by other manufacturers may result in non-conformance with safety standards.

Hold the blade end using a rag or thickly-padded glove. Remove the blade bolt, curved washer, and blade from the spindle shaft (Figure 58).

Figure 58

1. Sail Area of Blade
2. Blade
3. Curved washer
4. Blade Bolt

Check to ensure the mower deck is level any time you install the mower or when you see an uneven cut on your lawn.

The mower deck must be checked for bent blades prior to leveling; any bent blades must be removed and replaced; refer to Checking for Bent Blades before continuing.

The mower deck must be leveled side-to-side first then the front to rear slope can be adjusted.

Requirements:

• The machine must be on a level surface.

• All four 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 is evident.

Note: Lift the floor pan to gain access to the belt and idler pulley.

Park the machine on a level surface and disengage the blade control switch. Move the motion control levers outward to the neutral position, engage parking brake, stop 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, 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. 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 69).

7. Attach the front chains to the front lift arms (Figure 69).

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

9. Secure the link pin with the hair pin cotters and washers removed previously (Figure 68).

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

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

1. 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 70).

   

   Figure 70

   1. Deflector assembly
   2. Deck brackets
   3. Rod
   4. Spring
   5. Spring installed over the rod

2. Remove the damaged or worn discharge deflector.

3. Position the new discharge deflector assembly with the bracket ends between the welded brackets on the deck as shown in Figure 70.

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. Lift the loop end of the spring and place it into the notch on the deflector assembly bracket (Figure 71).

   

   Figure 71

   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 mower bracket
   4. Short end, retained by 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 71).

   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.

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. Attach the hose coupling to the end of the mower washout fitting, and turn the water on high (Figure 72).

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

   

   Figure 72

   1. Washout fitting locations on 54 inch decks
   2. Washout fitting locations on 48 and 60 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 and start the engine. Engage the blade control switch and let the mower run for 1 to 3 minutes.

6. Disengage the blade control switch, stop the engine, and remove the ignition key. Wait for all moving parts to stop.

7. Turn the water off and remove the coupling from the washout fitting.

   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 one to three 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 oil, and engine coolant are pollutants to the environment. Dispose of these according to your state and local regulations.