I would stay with the 5' the 6' will be a bit much for that tractor. Is 1800 rpms is where your 540 is or are you just backing it down. If you are just backing it down you may be doing more harm than good.
That is somthing that I never thought about. I also have a tc30 with 5' bush hog. Normally when I cut shorter or thinner grass I run the engine at around 2000 rpms with is slower than the indicated 540 rpm. My engine does not bog down nor is it lugging. How is it doing more harm than good? I do have to agree with most on using the 5 footer. When I cut overgrown property the 5' is about all the tc30 wants and I do run it at the 540 rpm. Mine is a 9x3 trans and usually run it in high range and 2nd gear.