TITAN® ZX 4800 and ZX 5400 Zero-Turn-Radius Riding Mower

• Read the instructions carefully. Be familiar with the controls and the proper use of the equipment.

• Never allow children or people unfamiliar with these instructions to use the lawnmower. Local regulations can restrict the age of the operator.

• Never mow while people, especially children, or pets are nearby.

• Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people or their property.

• Do not carry passengers.

• All drivers should seek and obtain professional and practical instruction. Such instruction should emphasize:

  • the need for care and concentration when working with ride-on machines;

  • control of a ride-on machine sliding on a slope will not be regained by the application of the brake. The main reasons for loss of control are:

    • insufficient wheel grip;

    • being driven too fast;

    • inadequate braking;

    • the type of machine is unsuitable for its task;

    • lack of awareness of the effect of ground conditions, especially slopes;

    • incorrect hitching and load distribution.

• While mowing, always wear substantial, slip-resistant footwear and long trousers. Do not operate the equipment when barefoot or wearing open sandals.

• Thoroughly inspect the area where the equipment is to be used and remove all objects which may be thrown by the machine.

• Warning-Fuel is highly flammable.

  • Store fuel in containers specifically designed for this purpose.

  • Refuel outdoors only and do not smoke while refueling.

  • Add fuel before starting the engine. Never remove the cap of the fuel tank or add fuel while the engine is running or when the engine is hot.

  • If fuel is spilled, do not attempt to start the engine but move the machine away from the area of spillage and avoid creating any source of ignition until fuel vapors have dissipated.

  • Replace all fuel tanks and container caps securely.

• Replace faulty silencers.

• Before using, always visually inspect to see that the blades, blade bolts and cutter assembly are not worn or damaged. Replace worn or damaged blades and bolts in sets to preserve balance.

• On multi-bladed machines, take care as rotating one blade can cause other blades to rotate.

• Be alert, slow down and use caution when making turns. Look behind and to the side before changing directions.

• Do not operate the engine in a confined space where dangerous carbon monoxide fumes can collect.

• Mow only in daylight or in good artificial light.

• Before attempting to start the engine, disengage all blade attachment clutches and shift into neutral.

• Do not use on slopes of more than 15 degrees.

• Remember there is no such thing as a safe slope. Travel on grass slopes requires particular care. To guard against overturning:

  • do not stop or start suddenly when going up or downhill;

  • use low speeds on slopes and during tight turns;

  • stay alert for humps and hollows and other hidden hazards;

• Use care when pulling loads.

  • Use only approved drawbar hitch points.

  • Limit loads to those you can safely control.

  • Do not turn sharply. Use care when reversing.

• Watch out for traffic when crossing or near roadways.

• Stop the blades rotating before crossing surfaces other than grass.

• When using any attachments, never direct discharge of material toward bystanders nor allow anyone near the machine while in operation.

• Never operate the machine with damaged guards or without safety protective devices in place.

• Do not change the engine governor settings or overspeed the engine. Operating the engine at excessive speed can increase the hazard of personal injury.

• Before leaving the operator's position:

  • disengage the power take-off and lower the attachments;

  • change into neutral and set the parking brake;

  • stop the engine and remove the key.

• Disengage drive to attachments, stop the engine, and disconnect the spark plug wire(s) or remove the ignition key.

  • before clearing blockages or unclogging chute;

  • before checking, cleaning or working on the lawnmower;

  • after striking a foreign object. Inspect the lawnmower for damage and make repairs before restarting and operating the equipment;

  • if the machine starts to vibrate abnormally (check immediately).

• Disengage drive to attachments when transporting or not in use.

• Stop the engine and disengage drive to attachment.

  • before refuelling;

  • before removing the grass catcher;

  • before making height adjustment unless adjustment can be made from the operator's position.

• Reduce the throttle setting during engine run-out and, if the engine is provided with a shut-off valve, turn the fuel off at the conclusion of mowing.

• 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.

• Keep all nuts, bolts and screws tight to be sure the equipment is in safe working condition.

• Never store the equipment with fuel in the tank inside a building where fumes can reach an open flame or spark.

• Allow the engine to cool before storing in any enclosure.

• To reduce the fire hazard, keep the engine, silencer, battery compartment and fuel storage area free of grass, leaves, or excessive grease.

• Check the grass catcher frequently for wear or deterioration.

• Replace worn or damaged parts for safety.

• If the fuel tank has to be drained, this should be done outdoors.

• When machine is to be parked, stored or left unattended, lower the cutting means.

This unit has a guaranteed sound power level of 105 dBA, which includes an Uncertainty Value (K) of 1 dBA.

Sound power level was determined according to the procedures outlined in ISO 11094.

This unit has a sound pressure level at the operator’s ear of 92 dBA, which includes an Uncertainty Value (K) of 1 dBA.

Sound power level was determined according to the procedures outlined in EN ISO 5395:2013.

Measured vibration level for left hand = 4.8  m/s2

Measured vibration level for right hand = 4.4  m/s2

Uncertainty Value (K) = 2.4 m/s2

Measured values were determined according to the procedures outlined in EN ISO 5395:2013. 

Measured vibration level = 0.39  m/s2

Uncertainty Value (K) = 0.19 m/s2

Measured values were determined according to the procedures outlined in EN ISO 5395:2013 (Riding & Stand-Ons). 

This unit has a guaranteed sound power level of 105 dBA, which includes an Uncertainty Value (K) of 1 dBA.

Sound power level was determined according to the procedures outlined in ISO 11094.

This unit has a sound pressure level at the operator’s ear of 92 dBA, which includes an Uncertainty Value (K) of 1 dBA.

Sound power level was determined according to the procedures outlined in EN ISO 5395:2013.

Measured vibration level for left hand = 5.8  m/s2

Measured vibration level for right hand = 3.6  m/s2

Uncertainty Value (K) = 2.3 m/s2

Measured values were determined according to the procedures outlined in EN ISO 5395:2013.

Measured vibration level = 0.45  m/s2

Uncertainty Value (K) = 0.22 m/s2

Measured values were determined according to the procedures outlined in EN ISO 5395:2013 (Riding & Stand-Ons).

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

• Keeps gasoline 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 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 7).

Figure 7

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 7).

2. Slowly add regular, unleaded gasoline until the fuel reaches the base of the filler neck Figure 8.

   

   Figure 8

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 16).

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 16

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 18

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 in Operation.

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

3. To go forward, slowly push the motion control levers forward (Figure 21).

   

   Figure 21

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 22).

   

   Figure 22

• Press the pedal down to raise the deck; continue to press the pedal until the deck is locked in the transport position (Figure 23).

• Push on the deck lift pedal with your foot and pull the transport lock handle rearward to disengage the transport lock (Figure 23).

Figure 23

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 24).

2. To adjust, remove the pin from the height-of-cut bracket (Figure 24).

3. Select a hole in the height-of-cut system corresponding to the height-of-cut desired and insert the pin (Figure 24).

4. Push on the deck lift pedal with your foot and pull the handle rearward to disengage the transport lock (Figure 23).

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

   

   Figure 24

   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 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 28.

   

   Figure 28

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

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, set the parking brake, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3. Remove the mower as described in the Removing the Mower procedure in the Maintenance section for more information.

4. Turn the mower upside down.

5. Remove the existing mower blades installed on your deck. Refer to the Removing the Blades procedure in the Maintenance section for more information.

6. Remove the two locknuts (5/16 inch) secured to the welded posts of the left baffle on the top of the mower deck at the center and left of center positions (Figure 29). Remove the carriage bolt and locknut on the side wall of the mower deck securing the left baffle to the deck.

   

   Figure 29

   1. Locknut (5/16 inch)
   2. Carriage bolt (5/16 x 3/4 inch)
   3. Left baffle

7. Remove the left baffle from the mower deck as shown in Figure 29.

8. Remove the carriage bolt (5/16 x 3/4 inch) and locknut (5/16 inch) on the rear wall of the mower deck securing the baffle to the deck (Figure 30).

   

   Figure 30

   1. Baffle guard
   2. Locknut (5/16 inch)
   3. Carriage bolt (5/16 x 3/4 inch)
   4. Right baffle

9. Locate the baffle guard at the front edge of the side discharge opening. Remove the fasteners securing the baffle guard and the right baffle to the mower deck as shown in Figure 30. Remove the baffle guard and retain all fasteners.

10. Remove the two locknuts (5/16 inch) to securing the welded posts of the right baffle to the top of the mower deck at center and right of center positions (Figure 31). Remove the right baffle from the mower deck.

    

    Figure 31

    1. Locknut (5/16 inch)
    2. Right baffle
    3. Welded posts, right baffle

11. Locate the cut off baffle in the loose parts bag. Remove the fasteners at the rear holes of the discharge plate. Install the baffle at the side discharge opening on the mower deck (Figure 32).

    

    Figure 32

    1. Carriage bolt, existing
    2. Rear holes in the discharge plate
    3. Cut off baffle, shipped loose
    4. Locknut, existing

12. Use the fasteners removed to secure the cut off baffle to the deck.

13. Install the blades to the deck. Refer to the Installing the Blades procedure in the Maintenance section for more information.

14. Install the mower as described in the Installing the Mower procedure in the Maintenance section for more information.

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, set the parking brake, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3. Remove the mower as described in the Removing the Mower procedure in the Maintenance section for more information.

4. Turn the mower upside down.

5. Remove the existing mower blades installed on your deck. Refer to the Removing the Blades procedure in the Maintenance section for more information.

6. Remove the three locknuts (5/16 inch) secured to the welded posts of the left baffle on the top of the mower deck at the center, left of center and left positions (Figure 33). Remove the carriage bolt and locknut on the side wall of the mower deck securing the left baffle to the deck.

   

   Figure 33

   1. Locknut (5/16 inch)
   2. Carriage bolt (5/16 x 3/4 inch)
   3. Left baffle
   4. Install fasteners here

7. Remove the left baffle from the mower deck as shown in Figure 33.

8. Locate the two bolts in loose parts and use the existing locknuts. Install these fasteners into the holes shown in Figure 33 on the mower deck to prevent flying debris. Install the bolt up, through the underside of the deck and use an existing locknut to secure from the topside.

   Warning

   Open holes in the mower expose you and others to thrown debris which can cause severe injury.

   • Never operate the mower without hardware mounted in all holes in the mower housing.

   • Install the hardware in the mounting holes when you remove the mulching baffle.

9. Remove the carriage bolt (5/16 x 3/4 inch) and locknut (5/16 inch) on the rear wall of the mower deck securing the baffle to the deck (Figure 34).

   

   Figure 34

   1. Carriage bolt (5/16 x 3/4 inch)
   2. Locknuts, front of discharge plate (reinstall after baffle is removed)
   3. Locknut, forward hole in deck (reinstall after baffle is removed)
   4. Baffle guard, 54 inch decks
   5. Hex head bolt, forward hole in deck (reinstall after baffle is removed)
   6. Carriage bolts, front of discharge plate (reinstall after baffle is removed)
   7. Locknut (5/16 inch)

10. Locate the baffle guard at the front edge of the side discharge opening. Remove the fasteners securing the baffle guard and the right baffle to the mower deck as shown in Figure 34. Remove the baffle guard and retain all fasteners.

11. Remove the two locknuts (5/16 inch) securing the welded posts of the right baffle to the top of the mower deck at center and right of center positions (Figure 35).

12. Remove the carriage bolt and locknut securing the right baffle to the top of the mower deck. Remove the right baffle from the mower deck (Figure 35).

    

    Figure 35

    1. Locknut (5/16 inch)
    2. Right baffle
    3. Welded posts, right baffle
    4. Carriage bolt

13. Install the fasteners removed previously at the front holes in the discharge plate and forward hole in the deck (Figure 34).

14. Locate the cut off baffle in the loose parts bag. Remove the fasteners at the rear holes of the discharge plate. Install the baffle at the side discharge opening on the mower deck (Figure 36).

    

    Figure 36

    1. Carriage bolt
    2. Rear holes in the discharge plate
    3. Cut off baffle
    4. Locknut

15. Use the fasteners removed to secure the cut off baffle to the deck.

16. Install the blades to the deck. Refer to the Installing the Blades procedure in the Maintenance section for more information.

17. Install the mower as described in the Installing the Mower procedure in the Maintenance section for more information.

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 15.24 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 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 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 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

Loosen the 2 bottom bolts of the curtain to gain access to the top of the mower deck (Figure 41).

Figure 41

1. Bottom bolt
2. Curtain

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 (Figure 42 and Figure 40) with a rag. Make sure to scrape any paint off of the front of the fitting(s).

   

   Figure 42

   1. Front caster tire

4. Connect a grease gun to each fitting (Figure 40 and Figure 42). Pump grease into the fittings until grease begins to ooze out of the bearings.

5. Wipe up any excess grease.

Note: Service the air cleaner more frequently (every few hours) if operating conditions are extremely dusty or sandy.

Oil Type: Detergent oil (API service SF, SG, SH, SJ, or SL)

Crankcase Capacity: 1.8 liter (61 ounce); when oil filter is removed: 2.1 liter (70 ounce)

Viscosity: See the table below.

Figure 44

Note: Using multi grade oils (5W-20, 10W-30, and 10W-40) will increase oil consumption. Check oil level more frequently when using them.

Make sure the air gap between the center and side electrodes is correct before installing the spark plug. Use a spark plug wrench for removing and installing the spark plug(s) and a gapping tool/feeler gauge to check and adjust the air gap. Install a new spark plug(s) if necessary.

Type: NGK BPR4ES (or equivalent)

Air Gap: 0.76 mm (0.030 inch)

Checking the Spark Plug

Important: Never 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 0.030 inches (0.76 mm).

Figure 50

Installing the Spark Plug

Tighten the spark plug(s) to 22 N-m (16 ft-lb).

Figure 51

Clean the air intake screen from grass and debris before each use.

1. Disengage the blade control switch and move the control levers to the neutral locked position and apply the parking brake.

2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3. Remove the air intake screen, air cleaner cover, and fan housing.

4. Clean debris and grass from the parts.

5. Install the air intake screen, air cleaner cover, and fan housing.

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 52

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 55).

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 55

   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 56

   1. Engine fuse

3. Grasp the engine fuse and pull it straight and away from the fuse block (Figure 56).

4. Align a new fuse with the slot in the fuse block (Figure 55).

5. Push the fuse into the fuse block until the fuse is seated (Figure 55).

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 57). 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 13 psi (90 kPa).

Figure 57

1. Valve stem

Check expansion reservoir and if necessary add oil to the FULL COLD line.

Figure 58

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.

Installing the Hydraulic System Filters

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

Figure 60

1. Apply a thin coat of oil on the surface of the rubber seal of each filter.

2. Turn the filter clockwise until rubber seal contacts the filter adapter then tighten the filter an additional 3/4 to 1 full turn. Repeat for the other filter

3. Install the filter guards over each filter as previously removed. Use the three screws to secure the filter guards.

4. Verify the vent plugs are removed before adding the oil.

5. Slowly pour the specified oil through expansion reservoir until oil comes out of one of the vent plug holes. Stop and install that vent plug. Torque the plug to 20.3 N-m (180 in-lb).

6. Continue to add oil through the expansion reservoir until oil comes out of the remaining vent plug hole on the second transmission. Stop and install that vent plug. Torque the plug to 20.3 N-m (180 in-lb).

7. Continue to add oil through the expansion reservoir until it reaches the FULL COLD line on the expansion reservoir. Proceed to the Bleeding the Hydraulic System section.

   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.

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

Blades must be replaced if a solid object is hit, if the blade is out of balance or is bent. To ensure optimum performance and continued safety conformance of the machine, use 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 67).

Figure 67

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 the Checking for Bent Blades procedure 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 tire must be properly inflated. Refer to Checking the Tire Pressure in the Drive System Maintenance section.

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 locked position and set the parking brake.

2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

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

4. Loosen the bottom two bolts holding the mower-deck curtain to the mower deck. Refer to Releasing the Mower-Deck Curtain.

5. For each of the belt covers, loosen the two bolts but do not remove them. 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; refer to the Removing the Floor Pan procedure in Premaintenance.

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 74).

   

   Figure 74

   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. Place the height-of-cut pin in the lock position for 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 74).

    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 74).

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

14. Tighten the bottom two bolts holding the mower-deck curtain to the mower deck (Releasing the Mower-Deck Curtain).

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 76).

7. Attach the front chains to the front lift arms (Figure 76).

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 75).

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

11. Tighten the bottom two bolts holding the mower-deck curtain to the mower deck (Figure 41).

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 77).

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 77). Remove the damaged or worn discharge deflector.

   

   Figure 77

   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 as shown in Figure 77.

4. Install the spring onto the straight end of the rod. 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 78).

   

   Figure 78

   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 78).

   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 77).

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 79).

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

   

   Figure 79

   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 and start the engine. Engage the blade control switch and let the mower run for one to three 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.