Service Manual

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2009 - 2013

TITAN® ZX/MX

Service Manual

Residential Products

Summary of content (120 pages)

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Residential Products 2009 - 2013 TITAN® ZX/MX Service Manual
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ABOUT THIS MANUAL This service manual was written expressly for authorized Toro dealer service technicians. The Toro Company has made every effort to make the information in this manual complete and correct. Basic shop safety knowledge and mechanical/electrical skills are assumed. The Table of Contents lists the systems and the related topics covered in this manual. For service information on drive systems, please refer to the Hydro-Gear ZT-2800/ZT-3100/ZT-3400 service manual (BLN 52441).
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ABOUT THIS MANUAL THIS PAGE INTENTIONALLY LEFT BLANK.
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TABLE OF CONTENTS 1 - Safety Information General Information �� 1-1 Think Safety First �� 1-1 2 - Specifications 2009 - 2010 TITAN ZX Specifications ��
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TABLE OF CONTENTS 3 - Chassis cont.
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TABLE OF CONTENTS 6 - Mower Deck cont.
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TABLE OF CONTENTS 7 - Electrical cont.
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SAFETY INFORMATION General Information ! This symbol means WARNING or PER SONAL SAFETY INSTRUCTION – read the instruction because it has to do with your safety. Failure to comply with the instruction may result in personal injury or even death. This manual is intended as a service and repair manual only. The safety instructions provided herein are for troubleshooting, service, and repair of the TITAN® zero turn mowers.
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SPECIFICATIONS 2009 - 2010 TITAN ZX Specifications Configurations 22 HP Kawasaki V-Twin TITAN ZX5000 TITAN ZX4800 TITAN ZX5450 50” SD, 3 Blades 23 HP Kohler Courage ‘Pro’ V-Twin 48” SD, 3 Blades 25 HP Kohler Courage ‘Pro’ V-Twin Power Systems TITAN ZX5000 TITAN ZX4800 TITAN ZX5450 Electric Electric Electric Twin Hydro-Gear ZT2800 Hydrostatic Transaxle w/ charge pumps Twin Hydro-Gear ZT2800 Hydrostatic Transaxle w/ charge pumps Twin Hydro-Gear ZT2800 Hydrostatic Transaxle w/ charge pumps Be
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SPECIFICATIONS 2009 - 2010 TITAN ZX Specifications cont. Operator Zone Steering Controls 2 TITAN ZX5000 TITAN ZX4800 TITAN ZX5450 Dual Wrap-Around Levers with cushion grips Dual Wrap-Around Levers with cushion grips Dual Wrap-Around Levers with cushion grips Arm Rests Standard Standard Standard Beverage Holder Standard Standard Standard Hour Meter Standard Standard Standard Dimensions TITAN ZX500 TITAN ZX4800 TITAN ZX5450 605 lbs. (estimated) 665 lbs. (estimated) 679 lbs.
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SPECIFICATIONS 2009 - 2010 TITAN ZX Specifications cont.
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SPECIFICATIONS 2009 - 2010 TITAN ZX Specifications cont. Dimensions TITAN ZX6030 TITAN ZX6050 724 lbs (estimated) 724 lbs. (estimated) Width Outside Deck 75.1” (190.8cm) Deflector Down 75.1” (190.8cm) Deflector Down Width Outside Tires 46.3” (117.6cm) 46.3” (117.6cm) Wheel Base 49.4” (125.5cm) 49.4” (125.5cm) Overall Length 78.6” (199.6cm) 78.6 (199.6cm) Height 43.4” (110.2cm) 43.4” (110.
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SPECIFICATIONS 2011 - 2013 TITAN ZX & MX Specifications Configurations 21.
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SPECIFICATIONS 2011 - 2013 TITAN ZX & MX Specifications cont. Configurations 21.
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SPECIFICATIONS 2011 - 2013 TITAN ZX & MX Specifications cont. Configurations TITAN ZX5020 22 HP Kawasaki V-Twin 23 HP Kohler Courage ‘Pro’ VTwin 50” SD, 3 Blades 2 24 HP Kawasaki V-Twin Power Systems Clutch Transaxles Drive Maximum Ground Speed (Fwd/ Rev) Rear Drive Tires Front Caster Tires Fuel / Capacity TITAN ZX5020 Electric Twin Hydro-Gear ZT2800 Hydrostatic Transaxle w/ charge pumps Belt Drive with selftensioning system 7.5 mph/3.8 mph 20” x 10” 4 ply rated 11 x 4 5 gallons (18.
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SPECIFICATIONS 2011 - 2013 TITAN ZX & MX Specifications cont. Operator Zone Steering Controls 2 TITAN ZX5020 Dual Wrap-Around Levers with cushion grips Arm Rests Standard Beverage Holder Standard Hour Meter Standard Dimensions TITAN ZX5020 Weight 605 lbs. (estimated) Width Outside Tires 45.3” (115.1cm) Width Outside Deck 63.1” (160.3cm) Deflector down Wheel Base 49.4” (125.5cm) Overall Length 77.3” (196.3cm) Height 43.4” (110.
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SPECIFICATIONS Engine Specifications Model # Model Engine Information 74820 ZX5000 Briggs & Stratton, 22hp, High Idle: 3550 ± 100 RPM 74822 ZX5400 Kohler, 23hp, High Idle: 3600 ± 75 RPM 74823 ZX6000 Kohler, 25hp, High Idle: 3600 ± 75 RPM 74824 ZX6050 Kawasaki, 26hp, High Idle: 3600 ± 75 RPM 74830 ZX4800 Kohler, 23hp, High Idle: 3600 ± 75 RPM 74832 ZX5450 Kohler, 25hp, High Idle: 3600 ± 75 RPM 74833 ZX6030 Kohler, 27hp, High Idle: 3600 ± 75 RPM 74840 ZX5020 Kohler, 23hp, High Idle:
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SPECIFICATIONS Hydro-Gear ZT-2800 & ZT-3100 Hydrostatic Transaxles 2 Fig. 001 PICT-1002 Lubrication Toro HYPR-OIL 500® or 20w50 Engine Oil Oil Capacity ZT-2800 77.23 fl. oz. (2284ml) each Oil Level Check Check expansion reservoir and if necessary add the specified oil to the FULL COLD line. See illustration below. Also see the Hydro-Gear ZT-2800 / ZT-3100 service manual (BLN-52441).
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SPECIFICATIONS Torque Specifications Fastener Identification Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in the service manual. These torque specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in the service manual.
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SPECIFICATIONS Standard Torque for Dry, Zinc Plated & Steel Fasteners (Inch Series) Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size 2 Grade 1, 5, & SAE Grade 1 Bolts, Screws, SAE Grade 5 Bolts, Screws, SAE Grade 8 Bolts, Screws, 8 with Thin Studs, & Sems with Regular Studs, & Sems with Regular Studs, & Sems with Regular Height Nuts Height Nuts (SAE J995 Height Nuts (SAE J995 Height Nuts (SAE J995 Grade 2 or Stronger Nuts) Grade 2 or Stronger Nuts) Grade 2 or Stronger Nu
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SPECIFICATIONS Standard Torque for Dry, Zinc & Steel Fasteners (Metric Fasteners) Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners) Thread Size Class 8.8 Bolts, Screws, and Studs with Regular Height Nuts (Class 8 or Strong Nuts) Class 10.9 Bolts, Screws, and Studs with Regular Height Nuts ( Class 10 or Strong Nuts) M5 X 0.8 57 ± 5 in-lb 644 ± 68 N-cm 78 ± 8 in-lb 881 ± 90 N-cm M6 X 1.0 96 ± 10 in-lb 1085 ± 113 N-cm 133 ± 14 in-lb 1503 ± 158 N-cm M8 X 1.
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SPECIFICATIONS OtherTorque TorqueSpecifications Specifications Other Wheel Bolts and Lug Nuts SAE Grade 8 Steel Set Screws Recommended Torque Thread Size 2 Square Head Hex Socket 1/4 - 20 UNC 140 ± 20 in-lb 73 ± 12 in-lb 5/16 - 18 UNC 215 ± 35 in-lb 145 ± 20 in-lb 3/8 - 16 UNC 35 ± 10 ft-lb 18 ± 3 ft-lb 1/2 - 13 UNC 75 ± 15 ft-lb 50 ± 10 ft-lb Thread Size Recommended Torque** 7/16 - 20 UNF Grade 5 65 ± 10 ft-lb 88 ± 14 N-m 1/2 - 20 UNF Grade 5 80 ± 10 ft-lb 108 ± 14 N-m M12 X 1.
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SPECIFICATIONS Equivalents & Conversions Equivalents and Conversions Decimal & Millimeter Equivalents Decimal and Millimeter Equivalents Fractions 1/64 1/32 3/64 1/16 5/64 3/32 1/8 9/64 5/32 11/64 3/16 13/64 7/32 15/64 1/4 17/64 9/32 19/64 5/16 21/64 11/32 23/64 3/8 25/64 13/32 27/64 7/16 29/64 15/32 31/64 1/2 Decimals mm 0.015625 0.397 0.03125 0.794 0.046875 1.191 0.0625 1.588 0.078125 1.984 0.9375 2.381 0.1250 3.175 0.140625 3.572 0.15625 3.969 0.171875 4.366 0.1875 4.762 0.
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SPECIFICATIONS U.S. to Metric Conversions 2 U.S. to Metric Conversions To Convert Into Linear Measurement Miles Yards Feet Feet Inches Inches Inches Kilometers Meters Meters Centimeters Meters Centimeters Millimeters Area Square Miles Square Feet Square Inches Acre Square Kilometers Square Meters Square Centimeters Hectare Volume Cubic Yards Cubic Feet Cubic Inches Cubic Meters Cubic Meters Cubic Centimeters 0.7646 0.02832 16.
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CHASSIS Model and Serial Number Identification Grease & Lubrication Point The model and serial number identification plate is located on the frame, near the engine, on the RH side of the unit (Fig. 003). Grease Type – No. 2 general-purpose lithium base grease A grease fitting is located on each of the front wheel hubs. The front wheel hubs should be greased every 25 hrs. (Fig. 004) 3 Fig. 003 PICT-2057 Fig.
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CHASSIS Front Axle / Caster Fork / Bearing Service Front Axle / Caster Fork / Bearing Disassembly 3 Front Axle / Caster Fork / Bearing Assembly 1. Using a proper bearing installation tool, install new upper and lower bearings into the frame hub making sure they are fully seated. 2. Install thrust washer (D) onto the caster fork shaft. 1. Safely raise and support unit so front wheels are off the ground. 3. Install the caster assembly up through the bearings and hold in position. 2.
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CHASSIS Caster Wheel / Bushing Service – TITAN ZX Chassis Caster Wheel / Bushing Assembly Caster Wheel / Bushing Disassembly 1. Lightly lubricate bushings (C) and wheel spanner (B) with No. 2 general-purpose lithium base grease. Fill center of wheel hub with grease. 1. Safely raise and support unit so front wheels are off the ground. 2. Install the (2) bushings (C) into front wheel hub, making sure they are fully seated. 2. Support under caster wheel and remove the nut / bolt (A). 3.
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CHASSIS Caster Wheel, Bushing & Bearing Service – TITAN MX Chassis Disassembly 1. Safely raise and support unit so front wheels are off the ground. 2. Support under caster wheel and remove the nut / bolt fastener (A). 3 3. Remove and inspect wheel spanner (B). Replace if excessively worn. 4. Use an appropriate punch to remove the (2) bushings (C) from the wheel hub. Inspect bushings and replace if excessively worn. 5. Remove the (2) bearings (D) from the wheel hub. Replace if excessively worn. 6.
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CHASSIS Pod / Fender Service Pod / Fender Installation - RH Pod / Fender Removal - RH 1. Maneuver RH fender into position. 1. Raise seat and disconnect battery terminals. 2. Install the (3) screws (B) that secure the RH fender to frame and torque to specification – 7 ft-lbs. (9 Nm). 2. Remove the (4) screws securing control panel (A) to RH fender. Move control panel inward towards the center of the unit. 3. Remove the (3) screws (B) securing the RH fender to frame. 4.
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CHASSIS Pod / Fender Removal - LH Pod / Fender Installation - LH 1. Raise seat and disconnect battery terminals. 1. Lubricate rubber fuel tank neck grommet with soapy water. 2. Remove the (3) screws (A) securing the LH fender to the unit frame. 3. Lubricate rubber fuel tank neck grommet with soapy water (Fig. 009). 2. Remove fuel cap from fuel tank. 3. Install LH fender assembly onto unit frame. Use care while installing LH fender as the fuel tank neck slips through the grommet. 4. Install fuel cap. 5.
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CHASSIS Fuel Tank Service 6. Remove the (2) bolts and nuts that secure the seat support (E) to the frame brackets. Fuel Tank Removal 1. Raise seat and disconnect battery terminals. 2. Remove LH pod / fender as shown in this chapter. 3. Remove the (2) bolts that secure the hydro expansion tank (A) to the seat support. Move the tank rearward for fuel tank removal clearance. 4. Remove the (1) fastener securing the fuel tank retaining rod (B) and remove it from the chassis. 7.
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CHASSIS Fuel Tank Installation 1. Position the fuel tank assembly into the unit frame. 2. Install the (2) bolts and nuts that secure the seat support (E) to the frame brackets and torque to specification – 17 ft-lbs. (23 Nm). 3. Install the fuel tank retaining rod (B) and torque retaining bolt to specification – 8 ft-lbs. (11 Nm). Be sure the front rod end is engaged into the control box assembly (Fig. 013). 4.
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CHASSIS Motion Control Damper Service Motion Control Damper Installation Motion Control Damper Removal 1. Install the washer and upper damper eyelet to the actuator arm and torque the shoulder bolt (A) to specification – 7.5 ft-lbs. (10 Nm). 1. Tilt seat forward and disconnect the battery. 2. Remove the appropriate fender / pod as shown in this chapter. 2. Install the lower damper eyelet to the Control Box and torque the nut (B) to specification – 7.5 ft-lbs. (10 Nm). 3.
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CHASSIS Motion Control Box / Seat Pivot Service Seat Style 2 – Remove the (4) bolts and washers (C) that attach the seat base to the rubber mounts (D) (Fig. 019). Note: The entire Control Box / Motion Control assembly does not need to be removed to service the Actuator Arm assembly. The Control Box is shown removed from the frame for clarity and ease of service. Motion Control Box / Seat Pivot Removal 3 1. Raise seat, disconnect battery terminals and remove the battery from the unit. C 2.
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CHASSIS 7. Remove the (2) control covers (E) (Fig. 020). 10. Remove the parking brake pin and washer (G). Remove the parking brake link from the handle stud (Fig. 022). G 3 E Fig. 022 PICT-2076 11. Remove the (4) fasteners (H) that secure the Control Box to the frame (Fig. 023). Fig. 020 PICT-2010 8. Make note of wire harness routing. Disconnect the RH and LH neutral switches and the parking brake switch. Open the loom routing clip and completely remove harness from the Control Box. 9.
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CHASSIS 13. Remove the (2) bolts/nuts (J) that secure the front motion control box to the frame (Fig. 024). Motion Control Box / Seat Pivot Installation 1. Install the control box / motion control assembly onto the frame. 2. Install the (6) fasteners securing the control box assembly to the frame and torque to specification: • (H) (4) Bolts- 6 ft-lbs. (8 Nm) • (I) (2) Carriage Bolt Fasteners - 17 ft-lbs. (23 Nm) (Fig. 025) J 3 J Fig. 024 H PICT-2088 14.
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CHASSIS 4. Install the floor pan and torque the (2) fasteners to specification - 7 ft-lbs. (10 Nm). 7. Properly route the wire harness and connect the RH and LH neutral switches, and parking brake switch. 5. Install the motion control rod and clips and pins (F) (Fig. 027). 8. Install the control covers and torque the fasteners to specification – 5 ft-lbs. (7 Nm). 9. Safely install the fuel tank as shown in this chapter. 10. Install the RH and LH fenders as shown in this chapter. F 11.
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CHASSIS Motion Control / Actuator Arm Service 4. Remove the actuator arm nut (C) and (2) washers (Fig. 030). Note: The entire Control Box / Motion control assembly does not need to be removed from the frame to service the Actuator Arm assembly. The fenders and control box are shown removed from the frame for clarity and ease of service. 3 5. Remove the shoulder bolt (D), actuator arm (E) and the (2) washers from the activator arm (F) (Fig. 030). C Motion Control Disassembly (LH Side Shown) E 1.
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CHASSIS Motion Control Assembly 4. Apply Loctite® 242 to the actuator arm pivot bolt threads (D). 1. Install the activator arm assembly (F) into the control box and torque the pivot bolt (G) to specification – 30 ft-lbs. (40 Nm). Do not apply lubrication to the activator arm pivot bolt (G). 5. Tighten nut (C) until the control lever has an acceptable and safe resistance feel when moved from stop to stop. 2. Apply anti-seize compound to the actuator arm shoulder bolt (D) and the (4) washers.
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CHASSIS 6. Install the upper motion control damper washer and shoulder bolt (A) to the activator arm (F) and torque to specification - 7.5 ft-lbs. (10 Nm). 7. Index and install the eccentric and fastener (B). Torque nut to specification – 8ft-lbs. (11 Nm). 9. Install the control lever and torque the fasteners to specification - 30 ft-lbs. (40 Nm). 10. Perform the “Neutral Adjustment” and “Tracking Adjustment” procedures on pages 5-4 and 5-6. (Fig. 034) 8.
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CHASSIS Seat Support / Fender Support Service 6. Remove the (2) bolts and nuts that secure the seat support (E) to the frame brackets. Seat Support Removal 7. Note the location of and remove any cable ties / loom clamps securing wiring / cables to the seat support bar (E). 1. Raise seat and disconnect battery terminals. 2. Remove RH and LH pod / fender as shown in this chapter. 8. Remove the seat support bar from the frame. (Fig. 036) A 3.
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CHASSIS Seat Support Installation 1. Position the Seat Support assembly into the unit frame. 9. Install and sufficiently tighten the (2) thread forming bolts that secure the rear guard tube (C) to the seat support (E). OR Install the bolts / nuts securing the rear engine guard to the ROPS frame (F) (Fig. 039). 2. Install the (2) bolts and nuts that secure the seat support (E) to the frame brackets and torque to specification – 17 ft-lbs. (23 Nm). 3 3.
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CHASSIS Deck Lift Service Deck Lift Installation Deck Lift Removal 1. Install the front and rear pivot rods (E and G) into the frame slots and support in position. Note: Exploded view shown on next page, 3-20. 1. Remove the PTO belt tensioner spring, then remove the PTO belt from the PTO clutch as shown in chapter 6, page 6-5 - 6-8. 2. Install the (4) pivot bushings, (4) gusset plates and (8) fasteners that secure the pivot rods to the frame. Torque the (8) fasteners to specification – 5 ft-lbs.
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CHASSIS C C A B 3 A H E G F D Fig.
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CHASSIS Parking Brake & Linkage Service Parking Brake & Linkage Removal 5. Remove the brake return spring (C) and the clip and washer (D) from the brake rod on the hydro (Fig. 043). 1. Tilt seat forward, disconnect and remove the battery. 2. Remove the LH control cover to access the parking brake handle area. 3. Remove the parking brake pin and washer (A). Remove the parking brake link from the handle stud (Fig. 042). C 4.
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CHASSIS Parking Brake & Linkage Installation 5. Lubricate the brake handle pivot bolt (B) friction surface with a light coating of engine assembly lube. 1. Position the brake bell crank (H) into the frame pivot holes. 6. Install the parking brake handle into the motion control box and torque the mounting fastener (B) to specification – 17 ft-lbs. (23 Nm). 2. Install the pivot bushings (G), washers and cotter pins to secure the bell crank into the frame. 7.
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CHASSIS ROPS Exploded View & Torque Values (Fig. 047) 3 E A D D A C B B Fig. 047 A PICT-2067 ROPS mounting torque sequence: 1. 2. 3. 4. Install, but do not tighten all ROPS mounting fasteners Torque the (6) bolts (A) to specification – 35 ft-lbs. (47 Nm) Torque the (4) bolts (B) to specification – 25 ft-lbs. (34 Nm) Torque the (2) bolts (C) to specification – 75 ft-lbs. (101 Nm) Torque values: D. Seat Belt Mounting Fasteners – 75 ft-lbs. (101 Nm) E. Rubber Bumper Mounting Fastener - 17 ft-lbs.
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CHASSIS 3 THIS PAGE INTENTIONALLY LEFT BLANK.
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ENGINE Engine Replacement PTO Clutch & Clutch Stop Mounting (All Models) (Fig. 048) Kawasaki Clutch / Clutch Stop Location 4 Kohler / Briggs and Stratton Clutch / Clutch Stop Location Fig.
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ENGINE Engine Mounting Exploded Views Engine Mounting – Kawasaki Engine (Fig. 049) C 4 B A Fig. 049 PICT-2052 A. PTO clutch bolt - apply Loctite® 242 - 55 ft-lbs. (76 Nm) B. Engine/clutch stop mounting bolts - Loctite 242 - 33 ft-lbs. (44 Nm) C. Muffler to engine fastener - 13 ft-lbs. (17.
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ENGINE Engine Mounting – Kohler Engine (Fig. 050) C 4 B A Fig. 050 PICT-2053 A. PTO clutch bolt - apply Loctite® 242 - 55 ft-lbs. (76 Nm) B. Engine/clutch stop mounting bolts - Loctite 242 - 33 ft-lbs. (44 Nm) C. Muffler to engine fastener - 13 ft-lbs. (17.
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ENGINE Engine Mounting – Briggs & Stratton Engine (Fig. 051) C 4 B A Fig. 051 PICT-2054 A. PTO clutch bolt - apply Loctite® 242 - 55 ft-lbs. (76 Nm) B. Engine/clutch stop mounting bolts - Loctite 242 - 33 ft-lbs. (44 Nm) C. Muffler to engine fastener - 13 ft-lbs. (17.
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ENGINE Engine Removal 1. Raise seat and disconnect battery terminals. 11. Remove the (4) engine to frame mounting bolts. Make note of clutch stop bracket (C) mounting and orientation (Fig. 053). 2. Safely raise and support rear of unit so rear wheels are off the ground. C 3. Remove PTO belt tensioner spring (A) from the deck to relieve PTO belt tension as shown in chapter 6 (Fig. 052). B Fig. 053 A Fig. 052 PICT-2055 12. Safely disconnect the fuel and vent lines from engine. PICT-2041 13.
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ENGINE Engine Installation 11. Install the heat shield and muffler to frame mounting screws and torque to specification - 17 ft-lbs. (23 Nm). 1. Position the engine onto the frame. 2. Connect the battery ground wires (E) to the engine block, and connect the positive battery wire (F) to the engine starter motor. 3. Connect the chassis to engine harness connector (D) (Fig. 055). 12. Apply anti-seize to the engine crankshaft and the ends of the drive pulley shaft. 13.
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ENGINE 16. Apply Loctite® 242 to the PTO clutch bolt threads. 17. Install the PTO clutch onto crankshaft. Be sure PTO clutch engages with the clutch stop bracket. 18. Install and torque the PTO clutch bolt to specification – 55 ft-lbs. (76 Nm). 19. Install PTO belt onto PTO clutch. Verify proper PTO belt routing; see PTO Belt Replacement and Belt Routing” on page 6-5. Install the PTO belt tensioner spring to the deck. 20. Connect battery cables and verify engine oil level. 21.
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ENGINE 4 THIS PAGE INTENTIONALLY LEFT BLANK.
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HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Exploded Views (Fig. 058) 5 Fig.
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HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Belt Routing (Fig. 059) Bottom View 5 Rear View Fig.
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HYDROSTATIC DRIVE SYSTEM Hydro-Gear ZT-2800 & ZT-3100 Hydrostatic Transaxles Fig. 060 PICT-1002 Lubrication Toro HYPR-OIL® 500 or 20w50 Engine Oil Oil Capacity ZT-2800 77.23 fl. oz. (2284ml) each Oil Level Check Check expansion reservoir and if necessary add the specified oil to the FULL COLD line. See illustration below. Also see the Hydro-Gear ZT-2800 / ZT-3100 service manual (BLN-52441).
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HYDROSTATIC DRIVE SYSTEM Neutral Adjustment Note: Do not make neutral adjustments on cold hydrostatic drive systems. Safely warm the drive system before making adjustments. 1. Safely raise and support unit so rear wheels are off the ground. 5. Release the parking brake and observe rear tire movement. If the tire is creeping in either forward or reverse, a neutral adjustment is required. Note: A slight amount of reverse creep is acceptable. (Fig. 063) 2.
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HYDROSTATIC DRIVE SYSTEM 8. Remove the hairpin and clevis from the adjustable yoke (Fig. 065). Fig. 065 10. Turn the yoke assembly to lengthen / shorten the control rod as needed to achieve proper neutral adjustment (Fig. 067). PICT-6471a Fig. 067 9. Loosen the jam nut on the hydro linkage rod (Fig. 066). PICT-6478a 11. Install the clevis pin and hairpin back into the yoke assembly. 12. Start the engine and run it at full RPM. 13. Stroke the control handles in forward and reverse.
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HYDROSTATIC DRIVE SYSTEM Tracking Adjustment Note: Do not make tracking adjustments on cold hydrostatic drive systems. Safely warm the drive system before making adjustments. 2. Hold the pivot bolt in position with a 1/4” hex wrench, and then slightly loosen the eccentric pivot nut (A) (Fig. 069). A - Adjust the eccentric on the LEFT side if the unit pulls to the RIGHT - Adjust the eccentric on the RIGHT side in the unit pulls to the LEFT. 1.
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HYDROSTATIC DRIVE SYSTEM Purging Procedure Due to the effects air has on efficiency in hydrostatic drive applications, it is critical that it is purged from the system. This purge procedure should be implemented any time a hydrostatic system has been opened to facilitate maintenance, any additional oil has been added to the system, or a replacement transaxle has been installed. Air creates inefficiency because its compression and expansion rate is higher than that of the oil in hydrostatic drive systems.
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HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Belt Replacement Hydrostatic Drive Belt Removal 1. Safely raise and support unit so rear wheels are off the ground. 11. Inspect the idler arm / tensioner pivot and pulley bearings for excessive wear and replace if necessary (Fig. 072). F 2. Remove PTO belt tensioner spring (A) from the deck to relieve PTO belt tension as shown in chapter 6 (Fig. 071). B 5 A Fig. 071 E PICT-2041 3. Remove PTO belt from PTO clutch. 4.
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HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Belt Installation 3. Install the drive belt around the drive pulley. 1. Properly route the belt around the (2) hydro input pulleys, and (2) tensioner / idler pulleys (Fig. 073). 4. Install the drive belt tensioner spring as oriented below (Fig. 075). Fig. 073 PICT-2043 2. Install the drive pulley onto the crankshaft and hold in position. Note: The drive pulley is marked “CLUTCH SIDE” for proper installation (Fig. 074). Fig. 075 PICT-2041 5.
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HYDROSTATIC DRIVE SYSTEM 7. Torque the clutch bolt to specification - 55 ft-lbs. (75 Nm). 8. Install the PTO belt around the PTO clutch pulley. 9. Verify proper PTO belt routing and then install the PTO belt tensioner spring to the deck. See PTO Belt Replacement and Belt Routing on page 6-5. 10. Safely lower unit and verify proper drive system function. Transaxle Replacement Transaxle Removal – RH Side Shown 1. Disconnect the battery terminals. 2.
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HYDROSTATIC DRIVE SYSTEM 8. Remove the drive belt tensioner spring (Fig. 078). Fig. 078 11. Remove the (2) bolts that secure hydro center support. Remove support from the unit (Fig. 080). PICT-2041 Fig. 080 9. Slip the drive belt off the idler / tensioner pulleys, then off the appropriate hydro input pulley. 10. Disconnect and plug the hydro reservoir hoses at the hydro fitting. Be sure to capture and dispose of fluid and shop towels properly (Fig. 079). 12.
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HYDROSTATIC DRIVE SYSTEM 13. Remove the (1) front hydro mount fastener (Fig. 082). Transaxle Installation 1. Position the hydro assembly up into the unit frame and align mounting points. 2. Apply Loctite® 242 to the (2) hydro center support bolts. 3. Loosely install ALL hydro mounting spacers, fast eners and center support bolts. Do not fully tighten at this time. 4. Torque hydro mounting fasteners in sequence to specification and shown: Fig.
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HYDROSTATIC DRIVE SYSTEM 2nd - Torque the (1) front hydro mount fastener to specification – 17 ft-lbs. (23 Nm) (Fig. 085). Fig. 085 PICT-2050 3rd – Torque the (1) rear hydro mount fastener to specification – 17 ft-lbs. (23 Nm) (Fig. 086). 4th – Torque the (2) outside hydro mount fasteners to specification – 17 ft-lbs. (23 Nm) (Fig. 087). Fig. 087 PICT-2049 5. Connect the hydro reservoir hoses at the hydro fitting (Fig. 088). 5 Fig. 086 Toro TITAN 2009-2013 Service Manual PICT-2051 Fig.
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HYDROSTATIC DRIVE SYSTEM 6. Install the hydro drive belt and verify proper routing (Fig. 089). 8. Install the parking brake return spring (A). 9. Install the brake rod into the hydro arm and insert the retaining pin (B). 10. Install the hydro bypass rod, washer and retaining clip (C). 11. Install the hydro control rod nut and bolt (D) and torque to specification - 17 ft-lbs. (23 Nm) (Fig. 091). D Fig. 089 PICT-2043 C A 7. Install and orient the drive belt tensioner spring as shown (Fig. 090).
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MOWER DECK Mower Deck Exploded Views 48 Inch Deck (Fig. 092) D D C E 6 INTL. ONLY B A Fig. 092 A. Blade bolt - 105 ft-lbs. (143 Nm) B. Washer - concave side towards blade C. Pulley Nut - 105 ft-lbs. (143 Nm) Toro TITAN 2009-2013 Service Manual PICT-2028 48 D. 30 ft-lbs. (40 Nm) E. Spindle housing-to-deck bolts - 14 ft-lbs.
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MOWER DECK 50 Inch Deck (Fig. 093) D D D C E INTL. ONLY 6 B A Fig. 093 A. Blade bolt - 55 ft-lbs. (76 Nm) B. Washer - concave side towards blade C. Pulley Nut - 55 ft-lbs. (76 Nm) 6-2 PICT-2028 50 D. 30 ft-lbs. (40 Nm) E. Spindle housing-to-deck bolts - 17 ft-lbs.
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MOWER DECK 54 Inch Deck (Fig. 094) D D C E INTL. ONLY 6 B A Fig. 094 A. Blade bolt - 105 ft-lbs. (143 Nm) B. Washer - concave side towards blade C. Pulley Nut - 105 ft-lbs. (143 Nm) Toro TITAN 2009-2013 Service Manual PICT-2028 54 D. 30 ft-lbs. (40 Nm) E. Spindle housing-to-deck bolts - 14 ft-lbs.
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MOWER DECK 60 Inch Deck (Fig. 095) D D C E 6 B A Fig. 095 A. Blade bolt - 105 ft-lbs. (143 Nm) B. Washer - concave side towards blade C. Pulley Nut - 105 ft-lbs. (143 Nm) 6-4 PICT-2028 60 D. 30 ft-lbs. (40 Nm) E. Spindle housing-to-deck bolts - 14 ft-lbs.
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MOWER DECK PTO Belt Replacement and Belt Routing 50 Inch Deck Idler / Tensioner Pulley (Fig. 097) 48, 54, 60 Inch Deck Idler / Tensioner Pulley E B B B E C E B (Fig. 096) E C B B A A D D Fig. 097 Fig. 096 A. PTO Belt B. Spindle Pulley C. PTO Belt Tensioner PICT-2030 A. PTO Belt B. Spindle Pulley C. PTO Belt Tensioner PICT-2031 D. PTO Clutch Pulley E. Idler 6 D. PTO Clutch Pulley E.
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MOWER DECK Inspecting the Belts Service Interval: Every 25 hours – Check the belts for wear. Check the belts for cracks, frayed edges, burn marks or any other damage. Replace damaged belts. PTO Belt Replacement - 48, 54 and 60 Inch Deck 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.
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MOWER DECK 5. Using a spring tool, (Toro part no. 92-5771), remove the idler spring from the deck post to remove tension on the idler pulley (Fig. 099). B 9. Using a spring tool, (Toro part no. 92-5771), install the idler spring over the deck post and placing ten sion on the idler pulley and mower belt (Fig. 099). 10. Ensure that the belt is properly seated in all pulleys. 11. Install the belt covers (Fig. 100). A C A B D C E Fig. 099 A. Spring tool B. Idler/Tensioner spring C.
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MOWER DECK PTO Belt Replacement - 50 Inch Deck 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. Lower the mower to the 3 inch (76 mm) height-ofcut.
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MOWER DECK Mower Deck Replacement 8. Remove the hardware from the front deck hangers on both sides of the deck (Fig. 103). Mower Deck Removal - 48 and 54 Inch Deck 1. Park the machine on a level surface and disengage PTO switch. A 2. Move the motion control levers outward to the neutral position and engage parking brake. 3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. D 4. Lower the mower to the 3 inch (76mm) height-of-cut position.
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MOWER DECK Mower Deck Installation - 48 and 54 Inch Deck 1. Slide the deck under the machine. 2. Lower the height-of-cut lever to the lowest position. Place the height-of-cut pin in the lock position for lowest height-of-cut. 3. Lift the rear of the mower deck and guide the hanger brackets over the rear hanger bolts. 4. Attach the front support on the mower deck to the front deck hangers and secure them with a washer and hairpin (Fig. 104). A D B C E F G Mower Deck Removal - 60 Inch Deck 1.
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MOWER DECK 7. Remove the hardware from the front and rear deck hangers on both sides of the deck (Fig. 106). A A D B C D Mower Deck Installation - 60 Inch Deck 1. Slide the mower under the machine. B C 2. Lower the height-of-cut lever to the lowest position. Place the height-of-cut pin in the lock position for lowest height-of-cut. 3. Lift the rear of the mower deck and attach the rear support on the mower deck to the rear deck hangers. Secure them with a washer and hairpin. 4.
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MOWER DECK Mower Deck Removal - 50 Inch Deck 7. Remove the hardware from the front deck hangers on both sides of the deck (Fig. 109). 1. Park the machine on a level surface and disengage the blade control switch. A 2. 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. 3. Lower the mower to the 3 inch (76mm) height-of-cut position. D 4.
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MOWER DECK Mower Deck Installation - 50 Inch Deck 1. Slide the mower under the machine. 2. Lower the height-of-cut lever to the lowest position. Place the height-of-cut pin in the lock position for lowest height-of-cut. 3. Lift the rear of the mower deck and guide the hanger brackets over the rear hanger bolts (Fig. 110). 4. Attach the front support on the mower deck to the front deck hangers and secure them with a clevis pin and hairpin (Fig. 110). A D B E F G C 6 Fig. 110 A. B. C. D.
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MOWER DECK Spindle Service Spindle Installation Spindle Removal 1. Install blade and washer onto spindle shaft. Install and torque blade bolt to specification: 1. If necessary, remove deck from chassis as outlined in this chapter. Note: Install blade washer so concave surface is towards blade. 2. Remove belt cover(s) from deck. - 48, 54 and 60 inch decks – 105 ft-lbs. (143 Nm) - 50 inch decks - 55 ft-lbs (76 Nm) 3.
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MOWER DECK Spindle Exploded Views Spindle Assembly - 48, 54 and 60 Inch Deck (Fig. 112) A A C B B C A A Fig. 112 Spindle Assembly - 50 Inch Deck PICT-2033 (Fig. 113) A A C 6 B B A A Fig. 113 A. Bearing B. Bearing spacer Toro TITAN 2009-2013 Service Manual C PICT-2032a C.
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MOWER DECK Spindle Disassembly Spindle Assembly 1. If necessary, remove deck from the frame as shown in this chapter. 1. Fully seat a new UPPER bearing (pulley side) into spindle housing until it contacts the bearing bore shoulder. Be sure to press equally on inner and outer race while installing bearing. 2. Remove spindle assembly from deck as outlined in this chapter. 3. Remove spindle shaft (D) from spindle assembly. Inspect for excessive wear and replace if necessary (Fig. 114). 4.
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MOWER DECK Idler Arm / Deck Belt Tensioner Service Idler Arm / Tensioner Exploded Views Idler Arm / Tensioner - 48, 54, 60 Inch Deck (Fig. 116) D A C A B B 6 A D Fig. 116 A. Washer B. Friction washer (composite) Toro TITAN 2009-2013 Service Manual PICT-2037 C. Spacer D. 30 ft-lbs.
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MOWER DECK Idler Arm / Tensioner - 50 Inch Deck (Fig. 117) D D A B B A C 6 Fig. 117 A. Washer B. Friction washer (composite) 6-18 PICT-2036 C. Spacer D. 30 ft-lbs.
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MOWER DECK Idler Arm Inspection Idler Arm Installation 1. Remove deck belt as shown in this chapter. 1. Install idler pulley to the idler arm and torque mounting bolt to specification - 30 ft-lbs. (40 Nm). 2. Remove deck if necessary, as outlined in this chapter. 3. Rotate idler arm by hand. The idler arm should not pivot freely, it should take some force to rotate the idler arm.
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MOWER DECK Checking for Bent Blades 3. Measure from the tip of the blade to the level surface (Fig. 119). Note: The machine must be on a level surface for the following procedure. 1. Raise deck to the highest height-of-cut position. A 2. While wearing thickly padded gloves or other adequate hand protection slowly rotate blade to be measured into a position that allows effective measurement of the distance between the cutting edge and the level surface the unit is on (Fig. 118). C B C Fig. 119 fig.
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MOWER DECK 5. Measure from the tip of the blade to the level surface. The variance should be no more than 1/8” (3mm) (Fig. 121). Leveling Mower Deck - 48, 54, 60 Inch Deck Check to ensure the mower deck is level any time you install the mower or when you see an uneven cut. 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.
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MOWER DECK 4. Measure between the outside cutting edges and the flat surface (Fig. 122). If both measurements are not within 3/16 inch (5mm), an adjustment is required; continue to the Leveling procedure. Checking the Front-to-Rear Blade Slope Check the front-to-rear blade level any time you install the mower. If the front of the mower is more than 5/16 inch (7.9mm) lower than the rear of the mower, adjust the blade level using the following instructions: 1.
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MOWER DECK Leveling the Mower Deck tighten the four leveling adjust locking nuts (C) (Fig. 125 and Fig. 126). 1. Set anti-scalp rollers to top holes or remove completely for this procedure. 2. Set the height-of-cut lever to the 3 inch (76mm) position. 3. Place two 2-5/8 inch (6.66cm) blocks under each side of the front edge of the deck, but not under the anti-scalp roller brackets. Place two 2-7/8 inch (7.
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MOWER DECK 5. Recheck that blocks fit just snugly under the deck skirt. Make sure all attachment bolts are tight. 6. Verify the deck is level by checking the side-to-side level and front-to-rear blade slope; repeat deck leveling procedure if necessary. Leveling Mower Deck - 50 Inch Deck Check to ensure the mower deck is level any time you install the mower or when you see an uneven cut. The mower deck must be checked for bent blades prior to leveling; any bent blades must be removed and replaced.
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MOWER DECK 4. Measure between the outside cutting edges and the flat surface (Fig. 127). If both measurements are not within 3/16 inch (5mm), an adjustment is required; continue to the Leveling procedure. B C C A D B D Fig. 127 fig. 61 G005278 A. Blades side-to-side D. Measure from the tip of B. Outside cutting edges the blade to the flat C. Sail area of blade surface here Checking the Front-to-Rear Blade Slope Check the front-to-rear blade level any time you install the mower.
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MOWER DECK Leveling the Mower Deck 1. Set anti-scalp rollers to top holes or remove completely for this procedure. 2. Set the height-of-cut lever to the 3 inch (76mm) position. 3. Place two 2-5/8 inch (6.66 cm) blocks under each side of the front edge of the deck, but not under the anti-scalp roller brackets. Place two 2-7/8 inch (7.30cm) thick blocks under the rear edge of the cutting deck skirt; one on each side of the cutting deck (Fig. 129). B 6 4.
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ELECTRICAL Chassis Switches How It Works Key/Ignition Switch Detents inside the switch give it 3 positions: OFF, RUN, and START. The START position is spring loaded so the key automatically returns to RUN when released (Fig. 132). Purpose The ignition switch makes the proper connections for the starter, accessories, and safety circuits. S Location I B The ignition switch is located on the control panel, on the right fender (Fig. 131). R A Fig.
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ELECTRICAL PTO Switch How It Works • PTO Switch ON (Switch Pulled Up) Purpose The PTO (Power Take Off) switch is used to turn on the Electric PTO Clutch and to function as part of the safety interlock system. Location The PTO switch is located on the control panel, on the right fender (Fig. 133). The PTO Switch provides battery voltage from the key switch to the PTO clutch. The PTO Switch provides battery voltage from the key switch to the hour meter.
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ELECTRICAL Continuity Testing Terminals viewed from the back of the switch. With the Switch “ON” (Button pulled OUT): - Pin 2 and 5 should have continuity (closed - circled below) - Pin 1 and 4 should have continuity (closed - circled below) - Pin 1 and 7 should not have continuity (open) - Pin 2 and 8 should not have continutiy (open) (Fig. 135 and Fig. 136) 3 2 1 5 4 9 8 7 Fig. 135 PICT-1005 Fig.
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ELECTRICAL Seat Switch How It Works Purpose With the ignition switch ON, and the seat switch closed, it supplies battery voltage to the neutral switches. The seat switch is a part of the safety interlock system. If the engine is running and the operator vacates the seat with the PTO engaged and/or the handles pulled IN, the engine will shut off. Location The seat switch is attached to the seat base, accessible by flipping the seat up into the service position.
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ELECTRICAL RH and LH Neutral Switch How it Works Purpose This single pole plunger (normally open) type switch has two terminals. When the motion control handles are in the neutral position (handles in the OUT position), it pushes on the plunger, closing the contact and connecting the terminals (Fig. 143). Used to ensure the motion control handles are in neutral to start the unit. It is activated by moving the motion control handles to the neutral position (handles outward).
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ELECTRICAL Parking Brake Switch Purpose The Parking Brake Switch is part of the safety interlock system. The parking brake switch circuit can: • Prevent the engine from cranking if parking brake is not engaged. • Prevent the engine from cranking if a control handle is not in the neutral position. • Turn the engine OFF if a control handle is moved out of neutral with the brake engaged. Location The Parking Brake Switch is located in the control box assembly, near the parking brake lever.
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ELECTRICAL Testing Parking Brake Circuit (Fig. 148) 1. Remove the LH control cover (A). 2. Press inward on the locking taps and push the switch out of the mounting slot. 3. Pull the switch and harness downward, in-between the frame and deck assembly. 4. Disconnect the harness connection to switch and remove the switch from the unit. 5. Use a ohm meter to test the switch continuity as shown below: View From Back of Switch (Fig. 147) To Fuel Solenoid 2 5 3 4 To Magnito - Spark Kill Fig.
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ELECTRICAL Starter Solenoid & Starting System Starter Solenoid Testing (solenoid only) Purpose 1. Disconnect solenoid from the wiring harness. The solenoid’s purpose is a remote switch to connect the battery to the starter motor on the engine when the ignition switch is turned to “START”. The solenoid is used to protect the ignition switch from the high current drawn by the starter motor. 2. With a multimeter (ohms setting), check to ensure that terminals “c” and “d” are open (no continuity). 3.
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ELECTRICAL Starter Solenoid Circuit & Operation The starter solenoid B+ (battery positive) input is controlled by the ignition switch when in the START position. The starter solenoid B- (battery negative) is controlled by the Kill Relay. The Kill Relay will only ground and activate the starter solenoid and allow the engine to start when: - The key is in the start position.
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ELECTRICAL Electric PTO Clutch Testing Purpose If the electric PTO clutch is not engaging or is sus pected as a cause of electrical problems, use the troubleshooting steps. These procedures will help you determine if the clutch has failed or is the cause of the electrical problem. The clutch electrically controls the engagement and disengagement of the PTO pulley. Location Coil Resistance Measurement The electric clutch is located on the PTO end of the engine crankshaft. How It works 1.
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ELECTRICAL PTO Clutch Continuity to Ground Check 1. Disengage PTO switch, turn ignition off and remove key. 2. Disconnect clutch wire connector. 3. Set the multimeter to check resistance (ohms). 4. Connect one meter lead to the engine, chassis or battery ground. Connect the other meter lead to each of the PTO clutch terminals. 5. The two PTO terminals should never have continuity to ground and should be OPEN at all times.
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ELECTRICAL PTO Circuit Schematic 7 Fig.
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ELECTRICAL PTO Clutch Replacement PTO Clutch Installation PTO Clutch Removal 1. Clean engine crankshaft. 1. Remove the PTO belt tensioner spring from the deck, then remove the PTO belt from the PTO clutch. 2. Apply anti-seize to engine crankshaft. 2. If necessary, safely raise and support unit. 3. Disconnect harness connection to PTO clutch. 3. Install PTO clutch onto engine crankshaft. Be sure anti–rotation bracket is properly aligned. 4. Apply Loctite® 242 to PTO clutch bolt. 4.
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ELECTRICAL Hour Meter How It Works Purpose When they key is ON, a closed PTO switch supplies battery voltage to the hour meter. The hour meter records hours of operation when: - The Ignition key is ON - The PTO switch is ON Testing Location The hour meter is located on the RH control panel (Fig. 156). Fig. 156 The electric/LCD style hour meter has an internal battery the keeps the hour meter display illuminated at all times.
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ELECTRICAL Fuse Block & Fuses How It Works Purpose The fuse block houses the fuses that protect the electri cal system from electrical surges. The fuse block houses the electrical system fuses. Location The fuse block is located behind the operator’s seat, near the starter solenoid on the RH side of the unit (Fig. 158). Fig. 158 Testing • With a multimeter set to OHM of continuity setting, check the continuity between the fuse blades. If the fuse is OPEN, replace it and test the circuit.
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ELECTRICAL FlyBack Diode Location Purpose The flyback diode is located just in front of the engine, near the hydro expansion tank. The diode is cable tied to the main wire harness (Fig. 162 and Fig 163). The flyback diode protects the electrical system from current surges caused by PTO engagement and disen gagement (Fig. 161). Fig. 162 Fig. 161 PICT-2021 DSCN-0149a 7 Fig.
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ELECTRICAL Testing 1. Remove the diode from the harness connection. 2. Use a volt / ohm meter set to the ohm or diode setting to test the diode. 3. Measure the diode resistance, record the value. 4. Reverse the ohm meter leads on the diode terminals and measure the diode resistance again, record this value. - If the resistance value is the same in steps 3 and 4, the diode is shorted or open – replace the diode. Fig. 164 PICT-2022 Fig.
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ELECTRICAL Wire Harness 1 of 3 7 Fig.
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ELECTRICAL Wire Harness 2 of 3 7 Fig.
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ELECTRICAL Wire Harness 3 of 3 7 Fig.
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2009 - 2013 TITAN® ZX/MX Service Manual Form Number 492-9336