Service Manual

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2014

TITAN® ZX/MX

Service Manual

Residential Products

Summary of content (108 pages)

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Residential Products 2014 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 Torque 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 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, and Steel Fasteners (Inch Series) Thread Size 2 # 6-32 UNC Grade 1, 5, & 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs, & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) In-lb N-cm In-lb N-cm In-lb N-cm 10 ± 2 13 ± 2 147 ± 23 15 ± 2 169 ± 23 23 ± 2 260 ± 34 17 ± 2 190 ± 20 25 ± 2 280 ± 20 13 ± 2 25 ± 5 282 ± 30 29 ± 3 330 ± 30 41 ± 4 460 ± 45 31 ± 3 350 ± 30 43 ± 4 31 ± 3 42 ± 4 475 ± 45 60 ±
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SPECIFICATIONS 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 1.25 19 ± 2 ft-lb 26 ± 3 N-m 28 ± 3 ft-lb 38 ± 4 N-m M10 X 1.
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SPECIFICATIONS Other Torque Specifications 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 1.25 Class 8.
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SPECIFICATIONS Equivalents & Conversions Decimal & Millimeter Equivalents Fractions Decimals mm Fractions Decimals mm 1/64 0.015625 0.397 33/64 0.515625 13.097 1/32 0.03125 0.794 16/32 0.53125 13.484 3/64 0.046875 1.191 35/64 0.546875 13.891 1/16 0.0625 1.588 9/16 0.5625 14.288 5/64 0.078125 1.984 37/64 0.578125 14.684 3/32 0.9375 2.381 19/32 0.59375 15.081 1/8 0.1250 3.175 5/8 0.6250 15.875 9/64 0.140625 3.572 41/64 0.640625 16.272 5/32 0.15625 3.
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SPECIFICATIONS U.S. to Metric Conversions 2 2-6 To Convert Into Multiply By Linear Measurement Miles Yards Feet Feet Inches Inches Inches Kilometers Meters Meters Centimeters Meters Centimeters Millimeters 1.609 0.9144 0.3048 30.48 0.0254 2.54 25.4 Area Square Miles Square Feet Square Inches Acre Square Kilometers Square Meters Square Centimeters Hectare 2.59 0.0929 6.452 0.4047 Volume Cubic Yards Cubic Feet Cubic Inches Cubic Meters Cubic Meters Cubic Centimeters 0.7646 0.02832 16.
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SPECIFICATIONS TITAN ZX Specifications Configurations ZX4800 21.
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SPECIFICATIONS TITAN MX Specifications Configurations 23 HP Kawasaki V-Twin MX5400 MX6000 54” SD, 3-Blades 24 HP Kawasaki V-Twin 2 60” SD, 3-Blades Power Systems Clutch Electric Electric Transaxles Twin Hydro-Gear ZT-3100 with Charge Pump, Shock Valves and Heavy Duty Gears Twin Hydro-Gear ZT-3100 with Charge Pump, Shock Valves and Heavy Duty Gears Drive Belt Drive self-tensioning system Belt Drive self-tensioning system Maximum Ground Speed 8.5 mph/4.0 mph 8.5 mph/4.
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SPECIFICATIONS Engine RPM Information Model # Model 74846 ZX 4800 (INTL) Kawasaki, 21.5hp, High Idle: 3000 ± 100 RPM 74848 ZX 5400 (INTL) Kawasaki, 23hp, High Idle: 3000 ± 100 RPM 74851 ZX 4800 Kawasaki, 21.5hp, High Idle: 3600 ± 100 RPM 74852 ZX5400 Kawasaki, 23hp, High Idle: 3600 ± 100 RPM 74853 ZX 6000 Kawasaki, 24hp, High Idle: 3600 ± 100 RPM 74855 ZX 4800 Kawasaki, 21.
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SPECIFICATIONS Hydro-Gear ZT-3100 Hydrostatic Transaxles 2 Fig. 001 PICT-1002 Lubrication Toro HYPR-OIL® 500 or 20w50 Engine Oil Oil Capacity ZT-3100 77.23 fl. oz. (2284ml) each (not including reservoir or hose volume) 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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CHASSIS Model and Serial Number Identification Grease and 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 Frame and Chassis Exploded View (Fig. 005) B D 3 B B B B D B A C Fig. 005 A. 35 ft-lbs. (47 Nm) B. 17 ft-lbs. (23 Nm) 3-2 PICT-3027 C. 5 ft-lbs. (7 Nm) D. 50 in-lbs.
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CHASSIS ROPS Exploded View (Fig. 006) 3 E B B C Fig. 006 A A D D PICT-3005 ROPS Mounting Torque Sequence: 1. 2. 3. 4. 5. Install, but do not tighten all ROPS mounting fasteners. Torque the (4) fasteners (A) to specification – 35 ft-lbs. (47 Nm) Torque the (4) fasteners (B) to specification – 25 ft-lbs. (34 Nm) Torque the (2) fasteners (C) to specification – 75 ft-lbs. (101 Nm) Torque the (4) fasteners (D) to specification – 35 ft-lbs. (47 Nm) Other Torque Values: E.
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CHASSIS Front Axle / Caster Fork / Bearing Service (MX) Front Axle / Caster Fork / Bearing Assembly 1. Use a proper bearing installation tool to install and fully seat new upper and lower bearings into the frame hub. Front Axle / Caster Fork / Bearing Disassembly 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. Remove dust cap (A). 3 4.
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CHASSIS Front Axle / Caster Fork / Bearing Service (ZX) Front Axle / Caster Fork / Bearing Assembly 1. Use a proper bearing installation tool to install and fully seat new upper and lower bearings into the frame hub. Front Axle / Caster Fork / Bearing Disassembly 2. Install spacer (E) and 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 and Bearing Service (MX) Caster Wheel, Bushing and Bearing Assembly Caster Wheel, Bushing and Bearing Disassembly 1. Lightly lubricate bearings (D), 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. Support under caster wheel and remove the nut / bolt fastener (A). 3 3. Remove and inspect wheel spanner (B).
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CHASSIS Caster Wheel and Bushing Service (ZX) 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 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. 3 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. 012). 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 Fuel Tank Installation (MX Shown) Fuel Tank Removal (MX Shown) 1. Position the fuel tank assembly into the unit frame. 1. Raise seat and disconnect battery terminals 2. Install the (2) bolts and nuts (C) that secure the seat support to the frame brackets and torque to specification – 17 ft-lbs. (23 Nm). 2. Remove the RH and LH pod / fender as shown in this chapter. 3. Remove the (2) bolts that secure the hydro expansion tank (A) to the seat support.
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CHASSIS Fuel & Vent Line Routing Fuel & Vent Line Routing - ZX Models A A B 3 B Fig. 016 PICT-3048 Fuel & Vent Line Routing - MX Models A A B B Fig. 017 PICT-3046 A. Fuel supply line to fuel filter and pump B.
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CHASSIS Fuel & Vent Line Routing - CARB Models A B A 3 B A A B Fig. 018 PICT-3047 A. Fuel supply line B.
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CHASSIS Motion Control Damper Service Motion Control Damper Installation Motion Control Damper Removal (LH side shown) 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. 3. Remove the (1) shoulder bolt (A) and washer that secures the upper motion control damper eyelet to the actuator arm. 2.
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CHASSIS Motion Control Box / Seat Pivot Service (MX shown) 5. Remove the RH and LH fenders as shown in this chapter. 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 6. Safely remove the fuel tank as shown in this chapter. 7. Remove the (2) control covers (D) (Fig. 022). D 1.
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CHASSIS 9. Remove the motion control rod clips and pins (F) (Fig. 023). 11. Remove the (4) fasteners (H) that secure the Control Box to the frame. 12. Remove the (2) nuts and (2) carriage bolts (I) that secure the Control Box to the frame (Fig. 025). F H 3 Fig. 023 I PICT-3010 10. Remove the parking brake pin and washer (G). Remove the parking brake links from the handle stud (Fig. 024). Fig. 025 PICT-3012 13.
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CHASSIS Motion Control Box / Seat Pivot Installation 4. Install the motion control rod and clips and pins (F) (Fig. 029). 1. Install the control box / motion control assembly onto the frame. 2. Install the (6) fasteners securing the control box assembly (G) to the frame and torque to specification: • (H) Bolts - 7 ft-lbs. (10 Nm) • (I) Carriage Bolt Fasteners - 14 ft-lbs. (18 Nm) (Fig. 027) 3 H F Fig. 029 PICT-3010 5. Install the parking brake linkage, washer and pin, and (G) (Fig. 030). I Fig.
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CHASSIS 6. Properly route the wire harness and connect the RH and LH neutral switches, and parking brake switches. Motion Control / Actuator Arm Service 7. Install the control covers and torque the fasteners to specification – 5 ft-lbs. (7 Nm). Note: The entire Control Box / Motion control assembly does not need to be removed from the chassis to service the Actuator Arm assembly (A). The fenders and control box are shown removed from the chassis for clarity and ease of service. 8.
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CHASSIS 3. Remove the actuator arm nut (B) and (2) washers. Motion Control Assembly 4. Remove the shoulder bolt (C), actuator arm (D) and the (2) washers from the activator arm (E) (Fig. 032). 1. Install the activator arm assembly (E) into the control box and torque the pivot bolt (F) to specification – 30 ft-lbs. (40 Nm). Do not apply lubrication to the activator arm pivot bolt (F). B D 3 3. Install the actuator arm (D) and (4) washers to the activator arm assembly (E). C Fig. 032 2.
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CHASSIS 4. Apply Loctite® 242 to the actuator arm pivot bolt threads (C). 5. Tighten nut (B) until the control lever has an acceptable and safe resistance feel when moved from stop to stop. - Over tightening nut (B) may damage the Teflon washer and cause excessive resistance. - Under tightening nut (B) may cause the actuator arm to feel loose. (Fig. 035) 3 B Fig.
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CHASSIS 6. Install the upper motion control damper washer and shoulder bolt (A) to the activator arm (E) and torque to specification - 7.5 ft-lbs. (10 Nm). 7. If needed, install the control box back onto the frame as outlined in this chapter. 8. Install the control lever and torque the fasteners to specification - 30 ft-lbs. (40 Nm). 9. Perform the “Neutral Adjustment” and “Forward Tracking Adjustment” procedures on pages 5-4 and 5-5 (Fig. 036). 3 F A D B 2 1 Shoulder bolt - 7.5 ft-lbs.
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CHASSIS Seat Support / Fender Support Service Seat Support Installation (MX Shown) 1. Position the Seat Support assembly into the unit frame. Seat Support Removal (MX Shown) 1. Raise seat and disconnect battery terminals 2. Remove RH and LH pods / fenders as shown in this chapter. 3. Remove the (2) bolts that secure the hydro expansion tank (A) to the seat support. 2. Install the (2) bolts and nuts (C) that secure the seat support to the frame brackets and torque to specification – 17 ft-lbs. (23 Nm). 3.
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CHASSIS Deck Lift Service 10. Inspect the front lift pan, front pivot rod (F), the rear pivot rod (H) and all pivot points for excessive wear, bends and cracks. Replace if necessary. Deck Lift Removal Note: Exploded view shown on next page, 3-23. Deck Lift Installation 1. Remove the PTO belt tensioner spring, then remove the PTO belt from the PTO clutch. See “PTO Belt Replacement - 48, 54 & 60 Inch Deck” on page 6-5. 1.
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CHASSIS 3. Install the front lift pan and spring (D) to the frame and torque fasteners to specification - 30 ft-lbs. (40 Nm). 4. Install the (2) HOC plate assembly mounting bolts (C). 5. Install the deck lift foot pedal center pivot bolt (A). 6. Install the rear lift arm pivot bolt (B). 7. Torque fasteners A, B and C to specification - 30 ftlbs. (40 Nm). 8. Install and level the deck as shown in “Mower Deck Installation - 48, 54 & 60 Inch Deck” on page 6-8 and “Mower Deck Leveling” on page 6-15. 9.
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CHASSIS Parking Brake & Linkage Service Parking Brake & Linkage Removal 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. 3 6. Remove all of the clips and washers (E), then remove the (3) linkage rods from the chassis. 7. Remove the (2) cotter pins (F), (2) washers and (2) bushings (G) from the brake bell crank (H) (Fig. 044).
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CHASSIS Parking Brake & Linkage Installation 1. Position the brake bell crank (H) into the frame pivot holes. 2. Install the pivot bushings (G), washers and cotter pins to secure the bell crank into the frame. 3. Install the (3) linkage rods to the bell crank and install retaining washers and clips. C 4. Install the brake return spring (C) (Fig. 045 and 046). Fig. 046 PICT-3037 5. Lubricate the brake handle pivot bolt (B) friction surface with a light coating of engine assembly lube. C 6.
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CHASSIS 3 THIS PAGE INTENTIONALLY LEFT BLANK.
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ENGINE Engine Replacement Note: For engine service information, please see the service information provided by the engine manufacturer. PTO Clutch & Clutch Stop Mounting (All Models) (Fig. 048) A 4 D B A C Fig. 048 PICT-3024 A. Clutch stop bracket B. PTO clutch C. PTO clutch bolt - apply Loctite® 242 - 55 ft-lbs. (76 Nm) D.
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ENGINE Engine Mounting Exploded View Engine Mounting – Kawasaki Engine (Fig. 049) 4 C B A B Fig. 049 PICT-3025 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. 051). 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 (Fig. 050). See PTO Belt Replacement 48, 54 & 60 Inch Deck on page 6-5. B A Fig. 051 PICT-2055 12.
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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. 053). E 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 6-4. 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 View (Fig. 056) D E F 5 F B C D E A Fig. 056 A. Lug nuts - 80 ft-lbs. (108 Nm) B. Center support - apply Loctite® 242 - 17 ft-lbs. (23 Nm) C. Front hydro mount - 17 ft-lbs. (23 Nm) Toro TITAN 2014 Service Manual PICT-2038 D. Rear hydro mount - 17 ft-lbs. (23 Nm) E. Outside hydro mount - 17 ft-lbs. (23 Nm) F. 30 ft-lbs.
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HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Belt Routing (Fig. 057) Bottom View 5 Rear View Fig.
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HYDROSTATIC DRIVE SYSTEM Hydro-Gear ZT-3100 Hydrostatic Transaxles (Fig. 058) Fig. 058 PICT-1002 Lubrication Toro HYPR-OIL® 500 or 20w50 Engine Oil Oil Capacity ZT-3100 77.23 fl. oz. (2284ml) each (not including reservoir or hose volume) 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 3. Safely start the engine and run at full RPM. Note: Do not make neutral adjustments on cold hydrostatic drive systems. Safely warm the drive system before making adjustments. 4. Verify the motion control handles are in the outward neutral position. 1. Safely raise and support unit so rear wheels are off the ground. 5. Release the parking brake and observe rear tire movement.
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HYDROSTATIC DRIVE SYSTEM 8. Turn the adjustment nut (B) clockwise or counter clockwise until the tire has stopped rotating OR has only a slight creep in reverse (RH side shown). Note: If the tire is creeping in forward, turn the adjustment nut clockwise, (tighten the nut). If the tire is creeping in reverse, turn the adjustment nut counterclockwise, (loosen the nut) (Fig. 063) (RH side shown). Forward Tracking Adjustment Note: Always adjust the neutral setting before the tracking adjustment.
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HYDROSTATIC DRIVE SYSTEM Purging Procedure Hydrostatic Drive Belt Replacement Due to the effects air has on efficiency in hydrostatic drive applications, it is critical that it is purged from the system. Hydrostatic Drive Belt Removal 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. 1.
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HYDROSTATIC DRIVE SYSTEM 11. Inspect the idler arm / tensioner pivot and pulley bearings for excessive wear and replace if necessary (Fig. 066). Hydrostatic Drive Belt Installation 1. Properly route the belt around the (2) hydro input pulleys, and (2) tensioner / idler pulleys (Fig. 067). F Fig. 067 PICT-2043 2. Install the drive pulley onto the crankshaft and hold in position. E E D D G C F Fig. 066 C. Washer D.
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HYDROSTATIC DRIVE SYSTEM 3. Install the drive belt around the drive pulley. 5. Apply Loctite® 242 to the PTO clutch bolt threads. 4. Install the drive belt tensioner spring as oriented below (Fig. 069). 6. Install the PTO clutch. Be sure the PTO clutch stop bracket is properly engaged into the clutch slot (Fig. 070). Fig. 069 PICT-3034 5 Fig. 070 PICT-3036 7. Torque the clutch bolt to specification - 55 ft-lbs. (75 Nm). 8. Install the PTO belt around the PTO clutch pulley. 9.
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HYDROSTATIC DRIVE SYSTEM Transaxle Replacement 8. Remove the drive belt tensioner spring (Fig. 072). Transaxle Removal – RH Side Shown 1. Disconnect the battery terminals. 2. Safely raise and support rear of unit so rear wheels are off the ground. 3. Remove the rear wheels. 4. Remove the parking brake return spring (A) from the rod and spring plate. 5. Remove the retaining pin (B) from the brake linkage then remove the brake rod from the hydro arm. 6.
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HYDROSTATIC DRIVE SYSTEM 11. Remove the (2) bolts that secure hydro center support. Remove support from the unit (Fig. 074). Fig. 074 PICT-2048 12. Safely support hydro assembly in current position using a hydraulic floor jack. Remove the (2) outer hydro mounting fasteners (Fig. 075). 13. Remove the (1) front hydro mount fastener (Fig. 076). Fig. 076 PICT-2050 14. Remove the (1) rear hydro mounting fastener (Fig. 077). 5 Fig. 077 Fig. 075 PICT-2051 PICT-2049 15.
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HYDROSTATIC DRIVE SYSTEM Transaxle Installation 2nd - Torque the (1) front hydro mount fastener to specification – 17 ft-lbs. (23 Nm) (Fig. 079). 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.
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HYDROSTATIC DRIVE SYSTEM 4th – Torque the (2) outside hydro mount fasteners to specification – 17 ft-lbs. (23 Nm) (Fig. 081). Fig. 081 PICT-2049 5. Connect the hydro reservoir hoses at the hydro fitting (Fig. 082). 6. Install the hydro drive belt and verify proper routing (Fig. 083). Fig. 083 PICT-2043 7. Install and orient the drive belt tensioner spring as shown (Fig. 084). 5 Fig. 082 5-12 PICT-2047 Fig.
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HYDROSTATIC DRIVE SYSTEM 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. 085). D C A B Fig. 085 5 PICT-3030 12. Install the rear wheels and torque lug nuts to specification – 80 ft-lbs. (108 Nm). 13. Connect battery terminals. 14. Safely lower unit. 15.
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HYDROSTATIC DRIVE SYSTEM THIS PAGE INTENTIONALLY LEFT BLANK.
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MOWER DECK Mower Deck Exploded Views 48 Inch Deck (Fig. 086) D D C E 6 B A Fig. 086 A. Blade bolt - 105 ft-lbs. (143 Nm) B. Washer - concave side towards blade C. Pulley Nut - 105 ft-lbs. (143 Nm) Toro TITAN 2014 Service Manual PICT-3040 D. 30 ft-lbs. (40 Nm) E. Spindle housing-to-deck bolts - 14 ft-lbs.
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MOWER DECK 54 Inch Deck (Fig. 087) D D C E 6 B A Fig. 087 A. Blade bolt - 105 ft-lbs. (143 Nm) B. Washer - concave side towards blade C. Pulley Nut - 105 ft-lbs. (143 Nm) 6-2 PICT-3041 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. 088) D D C E 6 B A Fig. 088 A. Blade bolt - 105 ft-lbs. (143 Nm) B. Washer - concave side towards blade C. Pulley Nut - 105 ft-lbs. (143 Nm) Toro TITAN 2014 Service Manual PICT-3042 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 Inspecting the Belts Service Interval: Every 25 hours – Check the belts for wear. 48, 54 & 60 Inch Deck (Fig. 089) E B B E C Check the belts for cracks, frayed edges, burn marks or any other damage. Replace damaged belts. B A D 6 Fig. 089 A. PTO belt B. Spindle pulley C. PTO belt tensioner 6-4 PICT-2030 D. PTO clutch pulley E.
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MOWER DECK PTO Belt Replacement - 48, 54 & 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. 5. Lift the floor pan upward into service position to gain access to the belt tensioner / idler pulley. Using a spring tool, (Toro part no.
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MOWER DECK 8. Properly route new belt around the deck pulleys and PTO pulley (Fig. 091). E B B E C 9. Using a spring tool, (Toro part no. 92-5771), install the tensioner / idler spring over the deck post to place tension on the idler pulley and mower belt (Fig. 092). B A Fig. 092 PICT-3035 10. Ensure that the belt is properly seated in all pulleys. D 11. Install the belt covers. 12. Verify proper PTO operation. Fig. 091 6 A. PTO belt B. Spindle pulley C. PTO belt tensioner 6-6 PICT-2030 D.
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MOWER DECK Mower Deck Replacement 8. Safely lift upward on the mower deck to relieve tension from the chain links. Mower Deck Removal - 48, 54 & 60 Inch Deck 1. Park the machine on a level surface and disengage PTO switch. 2. Move the motion control levers outward to the neutral position and engage parking brake. 9. Carefully maneuver the top chain link up and off the lift rod hooks. Repeat for the three remaining chain lift points (Fig. 094). AB C D ABC D 3.
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MOWER DECK Mower Deck Installation - 48, 54 & 60 Inch Deck 1. Park the machine on a level surface and disengage the PTO 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. Slide deck assembly under the machine. 4. Lower the height-of-cut lever to the lowest position. 5.
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MOWER DECK Spindle Service 8. Safely verify proper function. (Fig. 095) Spindle Removal A 1. If necessary, remove deck from chassis as outlined in this chapter. B C 2. Remove belt cover(s) from deck. 3. Remove the PTO belt tensioner spring and disengage the PTO belt from the spindle pulley(s). 4. Safely hold the blade in position and remove the spindle pulley nut (A). Inspect the pulley, bearing shield (B) and spindle shaft for excessive wear and replace if necessary. 5.
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MOWER DECK Spindle Exploded Views Spindle Disassembly Spindle Assembly - 48, 54 & 60 Inch Deck 1. If necessary, remove deck from the frame as shown in this chapter. (Fig. 096) A A B A B C 3. Remove spindle shaft (D) from spindle assembly. Inspect for excessive wear and replace if necessary. 4. Use an appropriate punch or bearing extractor to remove the (2) bearings (A) from the spindle housing. 5. Inspect bearing spacer (B) for wear and replace if necessary. A Fig. 096 A. Bearing B.
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MOWER DECK Spindle Assembly 7. If necessary, install the deck onto the frame. (Fig. 098) 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. A 2. Turn spindle housing over. B 3. Install the bearing spacer (B) into spindle housing (C). 4. Install a new LOWER bearing (blade side) into spindle housing until it contacts bearing spacer and bore shoulder.
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MOWER DECK Idler Arm / Deck Belt Tensioner Service Idler Arm / Tensioner Exploded View - 48, 54 & 60 Inch Deck (Fig. 099) D D A B C B A 6 A D Fig. 099 A. Standard washer B. Friction washer (composite) 6-12 PICT-2037 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 Note: The machine must be on a level surface for the following procedure. 4. Rotate the same blade 180 degrees so that the opposing cutting edge is now in the same position (Fig. 102). 1. Raise deck to the highest height-of-cut position. C 2.
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MOWER DECK ! A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders. • Always replace bent or damaged blades with a new blade • Never file or create sharp notches in the edges or surfaces of blade a. If the difference between A and B is greater than 1/8” (3mm) replace the blade with a new blade as outlined in this chapter. • Recheck, starting at step 1.
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MOWER DECK Checking Side-to-Side Level Checking the Front-to-Rear Blade Slope The mower blades must be level from side to side. Check the side-to-side level any time you install the mower deck or when you see an uneven cut on your lawn. Check the front-to-rear blade level any time you install the mower. 1. Park the machine on a level surface and disengage the blade control switch. 2.
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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” (6.66cm) blocks under each side of the front edge of the deck, but not under the antiscalp roller brackets (Fig. 105). 5. Loosen the adjustment bolts on all four corners so that the deck is sitting securely on all four blocks (Fig. 106). 6. Ensure there is tension on all four chains (Fig.106). 7.
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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. 108). 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. 107). 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. 109). 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. 111 and Fig. 112) 3 2 1 5 4 9 8 7 Fig. 111 PICT-1005 Fig.
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ELECTRICAL Seat Switch MX Seat Switch (Fig. 116) Purpose 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. ZX Seat Switch (Fig. 115) Fig.
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ELECTRICAL Testing 1. Disconnect the harness connection from the seat switch. 2. With a multimeter set to the Ohm or Continuity setting, check the continuity between the two switch terminals: - When the seat is vacated, the switch should be OPEN and there should be NO continuity between the two switch terminals. - When the seat is occupied, the switch CLOSES and there should be continuity between the two switch terminals. (Fig. 117) Fig.
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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. 120). 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. 125) 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. 124) 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 Kill Relay will only ground and activate the starter solenoid and allow the engine to start when: 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 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 The electric clutch is located on the PTO end of the engine crankshaft.
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ELECTRICAL PTO Clutch Continuity to Ground Check 1. Disengage PTO switch, turn ignition off and remove key. A 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. Install PTO clutch onto engine crankshaft. Be sure anti-rotation bracket (C) is properly aligned. 4. Apply Loctite® 242 to PTO clutch bolt. 3. Disconnect harness connection to PTO clutch. 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 only when: - The Ignition key is ON - The PTO switch is ON Testing Location The hour meter is located on the RH control panel (Fig. 133). Fig. 133 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 Fuses Testing Location • 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. • The fuses used in this application can also be visually inspected. A failed fuse can be identified by the broken/melted element inside the fuse cover or a damaged spade (Fig. 136 and Fig. 137). - The main 30 Amp fuse (A) is located near the starter solenoid and kill relay.
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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. 139 and Fig 140). The flyback diode protects the electrical system from current surges caused by PTO engagement and disen gagement (Fig. 138). Fig. 139 Fig. 138 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. 141 PICT-2022 Fig.
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ELECTRICAL Wire Harness View 1 of 3 7 Fig.
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ELECTRICAL Wire Harness View 2 of 3 7 Fig.
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ELECTRICAL Wire Harness View 3 of 3 7 Fig.
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2014 TITAN® ZX/MX Service Manual Form Number 492-9339