Form No. 3438-774 Rev A ® TITAN Service Manual Published: September 2020 © 2020—The Toro® Company 8111 Lyndale Avenue South Bloomington, MN 55420 Original Instructions (EN) Contact us at www.Toro.com.
Revision History Revision History Page 2 Titan Service Manual 3438-774 Rev A
Preface This service manual was written expressly for Toro 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. We are hopeful that you will find this manual a valuable addition to your service shop.
Service Procedure Icons The following icons appear throughout this Service Manual to bring attention to specific important details of a service procedure. Critical Process This icon is used to highlight: • Installing safety equipment (shields, guards, seat belts, brakes, and R.O.P.S.
Table of Contents Preface ................................................................................................................ 3 Chapter 1: Safety ............................................................................................ 1–1 Safety Instructions ....................................................................................... 1–2 Chapter 2: Specifications and Maintenance .................................................... 2–1 Specifications ..............................
Preface Page 6 Titan Service Manual 3438-774 Rev A
Chapter 1 Safety Table of Contents Safety Instructions ................................................................................................................................ 1–2 Think Safety First ...............................................................................................................................
Safety Instructions DANGER This safety symbol means danger. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions could cause serious permanent injury, disability, or death. WARNING This safety symbol means warning. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions can result in serious injury. CAUTION This safety symbol means caution.
Think Safety First (continued) Battery acid is poisonous and can cause burns. Avoid contact with skin, eyes and clothing. Battery gases can explode. Keep cigarettes, sparks and flames away from the battery. Avoid injury due to inferior parts… Use only original equipment parts to ensure that important safety criteria are met. Avoid injury to bystanders… Always clear the area of bystanders before starting or testing powered equipment.
Think Safety First (continued) The proper class of fire extinguisher should be used in case of fire. Class A extinguishers are for ordinary combustible materials such as paper, wood, cardboard, and most plastics. The numerical rating on these types of extinguishers indicates the amount of water it holds and the amount of fire it can extinguish. Geometric symbol (green triangle). Class B fires involve flammable or combustible liquids such as gasoline, kerosene, grease and oil.
Chapter 2 Specifications and Maintenance Table of Contents Specifications ....................................................................................................................................... 2–2 Torque Specifications ........................................................................................................................... 2–4 Equivalents and Conversions............................................................................................................. 2–9 U.S.
Specifications Model 75301 75302 75303 75310 Engine Make Toro Kawasaki Engine Model Toro V-Twin 24.5 HP 708cc Twin 21.5 HP 726cc Engine Model LC2P77F FR651–S12–R (CARB) Crankcase Capacity 1.8 L (61 fl oz); without filter; 2.
Model Crankcase Capacity 75311 75312 75313 1.8 L (61 fl oz); without filter; 2.4 L (81 fl oz) with filter 50 deg - 100+ deg SAE 30 32 deg -100+ deg SAE 20W–50 20 deg - 85 deg SAE 10W–30 20 deg -100+deg SAE 10W–40 -20 deg - 40 deg SAE 5W–20 High Idle 3600 ± 100 rpm Low Idle 1750 ± 150 rpm Spark Plug Champion: RN9YC NGK: BPR6ES Engine Oil 40 deg-100+deg SAE 30 0 deg -80 deg SAE 5W–30,10W–30 -20 deg - 100+ deg synthetic 5wW–20, 5W–30, 10W–30 Oil Capacity 2.
Torque Specifications The 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 for all fasteners which do not have a specific requirement identified in the service manual.
Metric Bolts and Screws g272209 Figure 2 1. Titan Service Manual 3438-774 Rev A Class 8.8 2. Page 2–5 Class 10.
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, 5, & 8 Fasteners with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studes & Sems with Regular Height Nuts (SAE Grade 2 or Better Nut) in-lb in-lb N • cm 10 ± 2 13 ± 2 147 ± 23 13 ± 2 25 ± 5 282 ± 30 18 ± 2 30 ± 5 339 ± 56 1/4-20 UNC 48 ± 7 53 ± 7 1/4-28 UNF 53 ± 7 5/16-18 UNC 5/16-24 UNF SAE Grade 5 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE Grade 5 or Better Nut) SAE Grade 8 Bolt
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Series) Thread Size Class 8.8 Bolts, Screws, Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws, Studs with Regular Height Nuts (Class 10 or stronger Nuts) in-lb N • cm in-lb N • cm M5 X 0.8 57 ± 6 644 ± 68 78 ± 8 881 ± 90 M6 X 1.0 96 ± 10 1085 ± 113 133 ± 14 1503 ± 158 ft-lb N • m ft-lb N • m M8 X 1.25 19 ± 2 26 ± 3 28 ± 3 38 ± 4 M10 X 1.5 38 ± 4 52 ± 5 54 ± 6 73 ± 8 M12 X 1.
SAE Grade 8 Steel Set Screws Recommended Torque Thread Size 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 1/2 - 13 UNC 75 ± 15 ft-lb 50 ± 10 ft-lb 3/8 - 16 UNC 35 ± 10 ft-lb 18 ± 3 ft-lb Wheel Bolts and Lug Nuts 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 8.8 80 ± 10 ft-lb 108 ± 14 N •m M12 X 1.5 Class 8.
Equivalents and Conversions Decimal and 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 3.969 21/32 0.
U.S. to Metric Conversions To Convert Into Multiply By Miles Kilometers 1.609 Yards Meters 0.9144 Feet Meters 0.3048 Feet Centimeters 30.48 Inches Meters 0.0254 Inches Centimeters 2.54 Inches Millimeters 25.4 Square Miles Square Kilometers 2.59 Square Feet Square Meters 0.0929 Square Inches Square Centimeters 6.452 Acre Hectare 0.4047 Cubic Yards Cubic Meters 0.7646 Cubic Feet Cubic Meters 0.02832 Cubic Inches Cubic Centimeters 16.39 Tons (Short) Metric Tons 0.
Chapter 3 Troubleshooting Table of Contents General Troubleshooting .......................................................................................................................
GEARS The Systematic approach to defining, diagnosing and solving problems.
General Troubleshooting Problem The starter does not crank The engine does not start, starts hard, or fails to keep running Engine loses power Titan Service Manual 3438-774 Rev A Possible Cause Corrective Action The blade control switch (PTO) is engaged. Move the blade control switch (PTO) to the disengaged position. The parking brake is not engaged. Set the parking brake. The motion control levers are not in the neutral lock position.
General Troubleshooting (continued) Problem The engine overheats The mower pulls to the left or right (with levers fully forward) The machine does not drive The machine vibrates abnormally The machine produces an uneven cutting height The blades do not rotate Troubleshooting: General Troubleshooting Possible Cause Corrective Action The engine load is excessive. Reduce the ground speed. The oil level in the crankcase is low. Add oil to the crankcase.
General Troubleshooting (continued) Problem The clutch does not engage Titan Service Manual 3438-774 Rev A Possible Cause Corrective Action The fuse is blown. Replace the fuse. Check the coil resistance, battery charge, charging system, and wiring connections. Replace components if necessary. There is a low voltage supply at the clutch. Check the coil resistance, battery charge, charging system, and wiring connections. Replace components if necessary. The coil is damaged. Replace the clutch.
Troubleshooting: General Troubleshooting Page 3–6 Titan Service Manual 3438-774 Rev A
Chapter 4 Engine Table of Contents General Information .............................................................................................................................. 4–2 Service and Repairs ............................................................................................................................. 4–3 Toro Twin Cylinder Engine Replacement............................................................................................ 4–4 Kawasaki Engine Replacement .............
General Information The TITAN® series of mowers use 2 different engine combinations; 708cc Toro twin cylinder OHV 4 cycle engine (LC2P77F) and 726cc Kawasaki twin cylinder OHV 4 cycle engine (FR651V).
Service and Repairs Engine Assembly g322220 Figure 3 1. Engine 3. Taptite Screw 2. Flat Washer 4.
Toro Twin Cylinder Engine Replacement Toro Twin Cylinder Engine Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery by removing the negative cable first, then the positive cable from the battery. 3. Remove the engine guard. 4. Remove the muffler. 5. Remove the mower belt. 6. Remove the hydrostatic drive belt. 7.
Toro Twin Cylinder Engine Removal (continued) g321702 Figure 6 10. Disconnect the fuel supply line at the fuel filter. g321705 Figure 7 11. Remove vent line at splice with Toro supplied hose.
Toro Twin Cylinder Engine Removal (continued) g321706 Figure 8 12. Disconnect the throttle cable. 13. Disconnect the choke cable. 14. Remove the clutch mounting bolt and washer. Slide the clutch off of the crankshaft. 15. Remove the engine pulley. 16. Remove the engine mounting bolts. 17. Lift the engine away from the frame. Toro Twin Cylinder Engine Installation 1. Prepare the frame and secure any fuel lines or wire harness components. 2. Lower the engine onto the frame. 3.
Toro Twin Cylinder Engine Installation (continued) g321707 Figure 9 5. Install the 3 remaining engine bolts. 6. Torque the 4 engine mounting bolts to 52 ± 5.8 N • m (450 ± 50 in-lb). 7. Apply anti-seize to the clutch end of the crankshaft. 8. Install the engine pulley onto the crankshaft. 9. Install the clutch on to the crankshaft ensuring that the slot in the clutch aligns with the tab on the clutch anchor. g212682 Figure 10 1. Engine Pulley 5. Clutch Isolator 2. 3. Screw Clutch Stop 6. 7.
Toro Twin Cylinder Engine Installation (continued) 11. Torque the clutch bolt to 69-83 N • m (50-60 ft-lb). 12. Connect the choke cable. 13. Connect the throttle cable. 14. Connect the black engine ground wire. Note: Apply Loctite to ground bolt. g321702 Figure 11 15. Connect the red wire to the starter. g321704 Figure 12 16. Connect the chassis wire harness to the main engine wire harness.
Toro Twin Cylinder Engine Installation (continued) g321703 Figure 13 17. Connect the fuel supply line to the fuel pump. 18. Connect the vent line to barb/splice. g321706 Figure 14 19. Install the hydrostatic drive belt. 20. Install the mower belt. 21. Install the muffler and new exhaust. Note: Torque muffler mounting bolts or nuts to 17-20 N • m (150-170 in-lb). 22. Install the engine guard. 23. Fill crankcase with approved oil and verify proper oil level. 24.
Toro Twin Cylinder Engine Installation (continued) Note: Verify Engine speed is set to proper RPM specification for the applicable model. Kawasaki Engine Replacement Kawasaki Engine Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery by removing the negative cable first, then the positive cable from the battery. 3. Remove the engine guard. 4. Remove the muffler. 5.
Kawasaki Engine Installation (continued) 3. Align the four holes of the engine base to the frame and attach the two rear mounting bolts and two flat washers loosely. Note: Apply Loctite 243 to engine mounting bolts. 4. Attach the front bolt through the clutch anchor and into the engine base. 5. Install the 3 remaining engine bolts. 6. Torque the 4 engine mounting bolts to 52 ± 5.8 N • m (450 ± 50 in-lb). 7. Apply anti-seize to the clutch end of the crankshaft. 8.
Kawasaki Engine Installation (continued) 22. Install the engine guard. 23. Fill crankcase with approved oil and verify proper oil level. 24. Connect the battery by installing the positive cable first, then the negative cable to the battery. 25. Lower the unit and verify proper function. Note: Verify engine speed is set to proper RPM specification for the applicable model.
Chapter 5 Chassis Table of Contents General Information .............................................................................................................................. 5–2 Service and Repairs ............................................................................................................................. 5–3 Caster Assembly and Bearing Replacement...................................................................................... 5–5 Caster Wheel Bearing Replacement ...........
General Information The TITAN® series uses a common frame with 2 different configurations, a MYRIDE® suspension platform and a conventional solid platform. The frame is constructed from 10 gauge steel.
Service and Repairs Caster Tires Assembly g322218 Figure 17 1. 2. Screw Caster Fork Titan Service Manual 3438-774 Rev A 3.
Seat Assembly g330049 Figure 18 1. 2. 3. Seat Asm Seat Pan Shock Mounting Bracket 10. 11. 12. Rear Subframe Lower Mount Bracket Pivot Rod 4. Seat Stop Bracket 13. Upper Shock Mount Bracket 5. Seat Latch Bracket 14. Shock/Spring Asm 6. Cam Lock Asm 15. Upper Shock Mount Bracket 7. Shock/Spring Asm 16. Trailing Arm Tube 8. Trailing Arm 17. Floormat 9. Backer Plate 18.
Caster Assembly and Bearing Replacement Caster Assembly and Bearing Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery by removing the negative cable first, then the positive cable from the battery. 3. Raise and support the unit so that the front wheels are off the ground, block rear wheels. 4. Remove the caster cap. 5.
Caster Wheel Bearing Installation 1. Install new bearings (bearings may have a slight press fit). Note: The bearings are sealed and do not require grease/lubrication. They may also have a slight press fit. 2. Install the spanner into the caster wheel, then install felt washers and dust caps over the caster bearings. 3. Place the caster wheel inside of the caster fork, aligning the spanner with the holes in the caster fork. 4. Install the bolt and nut and torque to 44 ± 7 N• m (32 ± 5 ft-lb). 5.
Left Console Removal (continued) g321206 Figure 20 5. Remove the left side control lever. 6. Lift the console upward off of the machine. 7. Replace the fuel cap. Left Console Installation 1. Remove the fuel cap from the gas tank. 2. Lower the console into place, ensuring that it seats properly on the supports. g321204 Figure 21 3. Install the left side control lever. 4. Install the keeper line into the fuel cap, and reinstall the fuel cap.
Left Console Installation (continued) 5. Install the 3 (T30) shoulder screws securing the left console to the machine. Torque screws to 11 N• m (100 in-lb). g321205 Figure 22 6. Install the battery onto the battery tray and secure with the bungee strap 7. Connect the battery by installing the positive cable first, then the negative cable to the battery. Right Console Replacement Right Console Removal 1. Park the machine on a level surface and disengage the PTO.
Right Console Removal (continued) g321208 Figure 23 4. Remove the screws securing the control panel assembly to the console. g321207 Figure 24 5. Remove the right side control lever. 6. Lift the console upward off of the machine, while feeding the control panel assembly through the opening in the console. Note: The control panel assembly should be supported while servicing the machine, to avoid damage to the cables or wire harness.
Right Console Removal (continued) g322343 Figure 25 Right Console Installation 1. Lower the console into place, while moving the control panel assembly through the opening in the console and into position. Ensure that the console seats properly on the supports. Note: Before securing the control panel to the console, ensure that all cables and electrical connections are seated firmly in place on the underside of the control panel assembly. 2. Secure the control panel assembly to the console. 3.
Right Console Installation (continued) 4. Connect the battery by installing the positive cable first, then the negative cable to the battery. 5. Install the right side control lever. Seat Replacement (zx Models Only) g321210 Figure 27 Titan Service Manual 3438-774 Rev A 1. Stop Rod 2. Seat Pan 3.
Seat Removal (ZX Models Only) 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery by removing the negative cable first, then the positive cable from the battery. 3. Disconnect the wire harness connector at the operator presence switch. 4. Remove the cotter pins from the stop rod on the left and right sides of the seat. 5.
Seat and MyRIDE™ Platform Replacement (MR Models Only) g334845 Figure 29 Titan Service Manual 3438-774 Rev A 1. 2. Seat Asm Seat Pan 7. 8. Pivot Rod Trailing Arm 3. Shock Mounting Bracket 9. Upper Shock Mount Bracket 4. Shock/Spring Asm 10. Trailing Arm Tube 5. 6. Lower Mount Bracket Rear Subframe 11.
Seat and MyRIDE™ Platform (MR Models Only) Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery by removing the negative cable first, then the positive cable from the battery. 3. Remove the right and left side consoles. Left Console Replacement (page 5–6) Right Console Replacement (page 5–8) 4. Disconnect the wire harness connector at the operator presence switch. 5.
Seat and MyRIDE™ Platform (MR Models Only) Removal (continued) g321445 Figure 32 9. Remove the self-tapping screw on the frame brackets on each side of the machine. Release the vent hose keepers. g321448 Figure 33 10. Remove the 2 bolts and nuts securing the frame brackets to the main frame on each side of the machine.
Seat and MyRIDE™ Platform (MR Models Only) Removal (continued) g321447 Figure 34 11. Tilt the MyRIDE® assembly one way. Unhook the fuel line keeper from under the seat. 12. Lift the entire MyRIDE® assembly up and away from the main frame. Removing the MyRIDE® assembly will take two or more people. Note: Do not remove either of the swing arm rods from the swing arm underneath the machine. This could cause damage or misalignment of the MyRIDE® suspension platform.
Seat and MyRIDE™ Platform (MR Models Only) Installation (continued) 3. Install the 2 bolts and nuts securing the frame brackets to the main frame on each side of the machine. g321447 Figure 36 4. Install the self-tapping screw on the frame bracket on each side of the machine. g321446 Figure 37 5. Install the bolt and nut securing the front shock/spring assembly to the MyRIDE™ Platform.
Seat and MyRIDE™ Platform (MR Models Only) Installation (continued) g321445 Figure 38 6. Connect the fuel tank vent line at to the splice fitting. 7. Connect the fuel supply line to the fuel filter. 8. Connect the vent line keepers to the vent lines. 9. Connect the wire harness terminal to the operator presence switch. 10. Install the relay and fuse holder. 11. Install the right and left side consoles. Left Console Replacement (page 5–6) Right Console Replacement (page 5–8) 12.
Fuel Tank Removal (continued) 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery by removing the negative cable first, then the positive cable from the battery. 3. Remove the right and left consoles. Left Console Replacement (page 5–6) Right Console Replacement (page 5–8) 4. Reinstall the fuel cap. 5.
Throttle Control Assembly Replacement Throttle Control Assembly Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery by removing the negative cable first, then the positive cable from the battery. 3. Remove the control panel assembly from the right console. g322343 Figure 41 4. Pry the keeper tab on the throttle control assembly and unsnap the control from the console.
Throttle Control Assembly Installation 1. Route the throttle cable through the right console. g321452 Figure 43 2. Snap the throttle control assembly into place. 3. Install the control panel assembly into the console. 4. Move the throttle control lever to the full speed position. g322343 Figure 44 5. Place the z bend of the throttle cable in the throttle plate on the engine in the position previously noted. 6. Place the cable under the cable clamp. 7.
Throttle Control Assembly Installation (continued) 8. Connect the battery by installing the positive cable first, then the negative cable to the battery. Choke Control Assembly Replacement Choke Control Assembly Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery by removing the negative cable first, then the positive cable from the battery. 3.
Choke Control Assembly Installation (continued) g321454 Figure 47 3. Attach the choke cable assembly to the control panel with the jam nut. 4. Install the control panel assembly into the console. 5. Move the choke control lever to the open position (down). 6. Place the z bend of the choke cable in the choke plate on the engine in the position previously noted. 7. Place the cable under the cable clamp. 8. Ensure that the choke control lever is pressed down fully and tighten the cable clamp .
Park Brake Handle Assembly Replacement Park Brake Handle Assembly Removal g321540 Figure 49 1. Cotter Pin 5. Wave Spring 2. Intermediate Brake Rod 6. Brake Flanged Bushing 3. Torx Screw 7. Flange Nut 4. Flange Bushing 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. 2. Disconnect the battery by removing the negative cable first, then the positive cable from the battery. 3. Remove the left side console. 4.
Park Brake Handle Assembly Installation (continued) g321541 Figure 50 1. 2. Screw Wave Washer 3. Flange Nut 4. 5. Washer Flange Pivot 2. With the park brake handle hardware oriented as shown, install the bolt through the brake detent and connect the flange nut. Torque to 23 ± 3 N•m (200 ± 25 in-lb). g321540 Figure 51 1. Cotter Pin 5. Wave Spring 2. Intermediate Brake Rod 6. Brake Flanged Bushing 3. Torx Screw 7. Flange Nut 4. Flange Bushing 3.
Motion Control Assembly Replacement Motion Control Assembly Removal g321537 Figure 52 1. Bolt 2. Motion Control Linkage 3. Motion Control Damper 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. 2. Disconnect the battery by removing the negative cable first, then the positive cable from the battery. 3. Raise and support the unit so that the drive wheels are off the ground. Note: The console must be removed for access. 4.
Motion Control Assembly Removal (continued) g321539 Figure 53 Motion Control Assembly Installation 1. Position the motion control assembly in place with the linkage extending toward the transmission. 2. Secure the motion control assembly to the frame. 3. Connect the motion control linkage to the motion control assembly. 4. Connect the motion control damper to the motion control assembly. 5. Connect the motion control handle to the motion control assembly using the two bolts. 6.
Adjust the Motion Control Handle (continued) g321538 Figure 54 6. Move the levers into the park position. 7. Connect the battery by installing the positive cable first, then the negative cable to the battery. 8. Verify proper function of the unit. Note: Motion control levers may be adjusted up or down as well for operator comfort by utilizing the additional mounting holes on the motion control assembly. The motion control levers should always be mounted on the inside of the motion control assembly.
Chapter 6 Hydrostatic Drive System Table of Contents General Information .............................................................................................................................. 6–2 Service and Repairs ............................................................................................................................. 6–3 Using the Drive Wheel Release Valves (Bypass Valves) .................................................................... 6–4 Neutral Adjustment ............
General Information The TITAN® series of mowers use Hydro-Gear hydrostatic transaxles model ZT-2800. All drives use the same type of fluid. The oil must have a minimum rating of 9.0 cSt (55 SUS) at 230° F (110° C) with an API classification of SL is recommended. A 20W-50 engine oil has been selected for use by the factory and is recommended for normal operating procedures.
Service and Repairs Hydrostatic Drive Assembly g334862 Figure 55 1. Hydrostatic Drive Belt 7. Idler Arm 2. Pulley Idler 8. RH Hydro Asm Hydro Hose 3. Pulley Idler 9. 4. Idler Spring 10. Rear Hydro Support 5. Hydro Hose 11. Hydro Cross Plate 6.
Using the Drive Wheel Release Valves (Bypass Valves) The drive wheel release valves are located on the left and right sides underneath the engine block. 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop and remove the key. Engage the parking brake. 2. Disconnect the battery by removing the negative cable first, then the positive cable from the battery. 3. Locate the bypass levers on the frame on both sides of the engine. 4.
Neutral Adjustment (continued) g321828 Figure 56 9. Stop the engine and lower the unit. 10. Verify proper neutral setting and tracking. Tracking Adjustment If the unit tracks or pulls to the RIGHT Turn the LH adjustment nut 1 full turn clockwise. If more adjustment is needed, turn the adjustment nut 1 full turn at a time. If the unit tracks or pulls to the LEFT Turn the RH adjustment nut 1 full turn clockwise. If more adjustment is needed, turn the adjustment nut 1 full turn at a time.
Hydro Change Procedure (continued) 2. Disconnect the battery by removing the negative cable first, then the positive cable from the battery. 3. Remove the spin on oil filter. 4. Drain the hydraulic oil. 5. Install a new spin on oil filter. 6. Remove the top port plug from the hydro. g334863 Figure 58 1. Top Port Plug 2. Breather Hole 7. Remove the breather hose and fill vent located on the top of the hydro. 8.
Purging Procedure (continued) 1. With the bypass valve open (push button) and the engine running, slowly move the directional controls (forward/reverse levers) in both forward and reverse directions 5–6 time; as air is purged from the transaxles, the oil level will drop. Note: Seat switch must be bypassed. 2. With the bypass valves in the closed position (run position) and the engine running, slowly move the directional control levers in both forward and reverse directions 5–6 times. 3.
Hydrostatic Drive Belt Removal (continued) g321838 Figure 60 9. Remove the drive belt from the hydrostatic drive pulleys. Note: Inspect the belt for excessive wear, damage, or cracking, replace if necessary. Hydrostatic Drive Belt Installation 1. Route the hydrostatic drive belt around the two transmission pulleys. 2. Route the drive belt around the engine pulley. 3. Install the idler arm and pulleys. Note: Make sure that the belt is properly routed before installation. g321833 Figure 61 4.
Hydrostatic Drive Belt Installation (continued) Note: Ensure proper orientation with hook openings facing away from the idler pivot. g321832 Figure 62 7. Install the mower belt onto the clutch. 8. Lower the unit. 9. Connect the battery by installing the positive cable first, then the negative cable to the battery. Hydrostatic Drive Transmission Replacement Hydrostatic Drive Transmission Removal Note: These steps are shown replacing the right side hydrostatic drive transmission.
Hydrostatic Drive Transmission Removal (continued) g321830 Figure 63 7. Disconnect the bypass arm. g321835 Figure 64 8. Disconnect the lower brake linkage from the transmission.
Hydrostatic Drive Transmission Removal (continued) g321834 Figure 65 9. Disconnect the connectors securing the overflow tube to the chassis. Note: Overflow tubes should stay connected to the top of the transmission. To avoid oil leaking, keep the overflow tubes oriented up. g321831 Figure 66 10. Remove the 4 bolts (2 bolts per side) securing the transmission to the hydro cross plate. 11. Loosen the 4 outer frame mounting bolts (2 bolts per side). 12.
Hydrostatic Drive Transmission Installation Note: These steps are shown replacing the right side hydrostatic drive transmission. All of the same steps apply to the left side hydrostatic drive transmission. 1. Lift and support the transmission, and install the 2 outer frame mounting bolts and nuts as shown. Do not fully tighten at this time. g321836 Figure 67 1. Outer mounting bolts to frame bracket 4. Bottom mounting bolts to cross plate 2. Front mid-mounting bolts to frame bracket 5.
Hydrostatic Drive Transmission Installation (continued) g321831 Figure 68 5. Connect the lower brake linkage to the transmission. g321834 Figure 69 6. Connect the bypass arm.
Hydrostatic Drive Transmission Installation (continued) g321835 Figure 70 7. Connect the motion control linkage. g321830 Figure 71 8. Install the drive belt. 9. Install the drive wheel and torque the lug nuts to 110 ± 14 N•m (80 ± 10 ft-lbs). 10. Add hydraulic oil to the proper level using the vent plugs.
Hydrostatic Drive Transmission Installation (continued) g321839 Figure 72 11. Follow the purging procedure to remove all air from the system. 12. Adjust the neutral setting, if necessary. 13. Lower the unit and verify proper function. 14. Connect the battery by installing the positive cable first, then the negative cable to the battery.
Hydrostatic Drive System: Service and Repairs Page 6–16 Titan Service Manual 3438-774 Rev A
Chapter 7 Mower Deck Table of Contents General Information .............................................................................................................................. 7–2 Service and Repairs ............................................................................................................................. 7–3 Mower Belt Replacement ................................................................................................................... 7–6 Mower Deck Replacement .....
General Information The TITAN® series of mowers uses 3 different deck sizes a 48 inch fabricated, 54 inch fabricated, and a 60 inch fabricated. All the decks use a 4-point lift system. All units have a 1.5-4.5 inch height-of-cut range.
Service and Repairs Mower Deck Assembly 1 g334873 Figure 73 1. RH Belt Cover 11. Discharge Deflector 2. 3. LH Belt Cover Pulley 12. 13. Chute Pin Anti Scalp Roller 4. Idler Belt Guide 14. Washout Fitting 5. 6. V-Belt Bearing Shield 15. 16. Hose Connector Cutoff Baffle 7. Flat Idler Pulley 17. Spindle Asm 8. Idler Bushing 18. Spindle Shaft Idler Arm Asm Washout Fitting 19. Blade 9. 10.
Mower Deck Assembly 2 g322345 Figure 74 1. Left Belt Cover 13. 2. Right Belt Cover 14. Washout Spacer Chute Pin 3. 4. Idler Belt Guide Pulley 15. 16. Connector Hose Rear Axle Spacer 5. V-Belt 17. Anti-Scalp Roller 6. Bearing Shield 18. Spanner Tube 7. Flat Idler Pulley 19. Deck Asm 8. Idler Bushing 20. Cut-off Baffle 9. 10. Idler Arm Asm Washout Fitting 21. 22. Deck Asm Spindle Asm 11. Discharge Deflector 23. Spindle Shaft 12. Spacer Fender 24.
Mower Deck Assembly 3 g322346 Figure 75 1. Right Belt Cover 12. Chute Pin 2. Left Belt Cover 13. Rear Axle Spacer 3. Idler Belt Guide 14. Anti-Scalp Roller 4. Pulley 15. Spanner Tube 5. V-Belt 16. Washout Fitting 6. Flat Idler Pulley 17. Connector Hose 7. Bearing Shield 18. Deck Asm 8. Idler Bushing 19. Spindle Asm 9. Idler Arm Asm 20. Spindle Shaft 10. Discharge Deflector 21. Mulch Blade 11.
Mower Belt Replacement Mower Belt Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake 2. Disconnect the battery by removing the negative cable first, then the positive cable from the battery. 3. Lower the mower deck to the 76 mm (3 inches) height-of-cut position. 4. Remove the bolts from the covers and lift covers off the deck. g322061 Figure 76 5.
Mower Belt Installation (continued) 4. Install the belt covers. Torque the belt cover bolts to 6–8 N • m (50–75 in-lb). 5. Tighten the bolts to secure the cover to the deck. 6. Connect the battery by installing the positive cable first, then the negative cable to the battery. Mower Deck Replacement Mower Deck Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2.
Mower Deck Installation (continued) 5. Install the link pin through the frame hanger and the deck. Secure with hairpins and washers that were previously removed. 6. Install the mower belt onto the engine pulley first, then onto the mower deck. 7. Install the mower belt covers. Torque the belt cover bolts to 6–8 N • m (50–75 in-lbs). 8. Raise the deck to the 76 mm (3 inches) height-of-cut position and check for deck level. 9.
Mower Spindle Disassembly g322066 Figure 79 1. Spindle Nut 6. Spindle (Apply Anti-Seize) 2. Pulley 7. Blade 3. Bearing Shield 8. Belleville Washer 4. Spindle Mounting Screws 9. Blade Bolt 5. Spindle Assembly 1. Clamp the spindle for service by placing the spindle shaft in a vise. 2. Remove the nut and washer from the top of the pulley. 3. Remove the pulley. 4. Remove spindle housing from the shaft. 5. Remove the bearing shield. 6.
Mower Spindle Assembly (continued) g322065 Figure 80 1. Top Bearing 2. Spacer 3. Lower Bearing 3. Flip the spindle housing over and install the bearing spacer. 4. Press the lower bearing into the spindle housing by pressing equally on the inner and outer race. Note: The inner and outer race on the upper bearing must be supported while installing the lower bearing. 5. Apply anti-seize to the spindle shaft and install the spindle shaft. 6.
Mower Spindle Assembly (continued) 9. Install the washer and nut. Torque the top nut to 138-152 N • m (100-110 ft-lb). Electric PTO Clutch Replacement Electric PTO Clutch Removal g322063 Figure 81 1. Engine Pulley to Shaft (Apply Anti-Seize) 4. Clutch Isolator 2. 3. Bolt Clutch Stop Mount 5. 6. PTO Clutch Clutch Mounting Bolt (Apply Loctite) 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. 2.
Electric PTO Clutch Installation g322063 Figure 82 1. Engine Pulley to Shaft (Apply Anti-Seize) 4. Clutch Isolator 2. 3. Bolt Clutch Stop Mount 5. 6. PTO Clutch Clutch Mounting Bolt (Apply Loctite) 1. Install the clutch on to the crankshaft ensuring that the slot in the clutch aligns with the tab on the clutch anchor and the rubber isolator is in place. Note: Apply anti-seize to the end of the pulley shaft. 2. Apply thread lock to the clutch bolt. 3. Install the washer and clutch mounting bolt.
Electric PTO Clutch Installation (continued) 5. Connect the battery by installing the positive cable first, then the negative cable to the battery. 6. Lower the unit and verify proper function.
Mower Deck: Service and Repairs Page 7–14 Titan Service Manual 3438-774 Rev A
Chapter 8 Electrical Table of Contents General Information .............................................................................................................................. 8–2 Service and Repairs ............................................................................................................................. 8–3 Fuse Block and Fuses........................................................................................................................ 8–4 Key/Ignition Switch.......
General Information 1. Always use a digital multi-meter for electrical testing procedures and record voltage reading results. 2. Before performing any electrical troubleshooting, always: • Verify proper battery voltage (above 12.4 volts) : Batteries reading 12.4 volts or less are considered discharged • Check that all engine and chassis ground wires are securely connected and not damaged. 3. Use of test lights and continuity testers may result in false readings and lead to an incorrect diagnosis. 4.
Service and Repairs Electrical System Assembly g322300 Figure 84 1. Ignition Key 2. Ignition Switch 10. Solenoid 3. Battery 11. Negative Cable 4. PTO Switch 12. Engine Ground 5. 6. 7. Hourmeter 15A Fuse Magneto Stop Relay 13. 14. 15. Clutch Diode Neutral Switch Wire Harness 8. 25A Fuse 16. Park Brake Switch Titan Service Manual 3438-774 Rev A 9.
Fuse Block and Fuses The fuse block houses the fuses that protect the electrical system from electrical surges. Note: Always use Toro fuses when replacing a damaged or blown fuse. g322165 Figure 85 Fuse Block and Fuses Testing 1. Visual Inspection: The fuses used in this application may be visually inspected. A failed fuse can be identified by a broken or melted element inside the fuse cover or a damaged spade. 2.
Key/Ignition Switch Testing (continued) g331211 Figure 86 5. Using a digital multi-meter set to the OHM or Continuity setting, verify that NO continuity exists between the terminals not listed for each switch position. Position Circuit “Make” 1. OFF None Run B + R + I + A 3. Start B + R + I + S Hourmeter The hourmeter records hours of operation when the ignition key is ON and the PTO switch is ON. g322162 Figure 87 Hourmeter Testing 1.
Operator Presence Switch (Seat Switch) With the ignition switch in the RUN position, and the operator presence switch closed (operator is in the seat), battery voltage is supplied to the left hand neutral switch. Note: The operator presence switch is part of the seat assembly. Operator Presence Switch (Seat Switch) Testing 1. Disconnect the wire harness from the operator presence switch, located on the bottom of the seat assembly. 2.
Parking Brake Switch (continued) g322166 Figure 89 g322160 Figure 90 Starter Solenoid The solenoid is a remote switch that connects the battery to the starter motor when the ignition switch is turned to START. The solenoid protects the ignition switch from the high current drawn by the starter motor.
g322159 Figure 91 Starter Solenoid Testing 1. Disconnect the battery cables from the solenoid. 2. With a multi-meter set to the OHM or Continuity setting, check to ensure that terminals C and D are open (no continuity). • Green wire is terminal B • Blue wire is terminal A • Large red wire with red cap and extra red wire is terminal C • Large red wire with no cap is terminal D g331279 Figure 92 3. Apply 12 volts (DC) to terminal A and ground terminal B.
Note: NOTE: The engine will not crank over when the PTO switch is in the ON position. The PTO switch provides battery voltage from the ignition switch to the parking brake switch and the neutral switches as part of the safety interlock system. PTO Switch Testing 1. Remove the control panel from the right console. 2. Disconnect the PTO switch from the wire harness. 3. With the switch in the ON position (button pulled OUT). 4.
pressed against the brake material opposite the clutch plate. When power is applied, the friction plate is pulled toward the clutch plate and the two rotate as one. When the clutch plate and the friction plate rotate as different speeds it is known as clutch slipping. Electric PTO Clutch Testing If the PTO clutch is not engaging or is suspect as a cause of electrical problems, use the following electrical troubleshooting steps.
Measuring Clutch Current Draw Note: Do not measure current draw if the clutch has shorted to ground or if the resistance measurement is out of specification. 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove the key. Engage the parking brake. 2. Disconnect the clutch wire connector. 3. Set the multi-meter to measure amps (10 amp scale). 4. Connect the positive meter lead to the chassis harness terminal A. 5.
Magneto Stop Relay (continued) grounded through the stop relay and the magneto is no longer grounded. The magneto stop relay prevents starting in an unsafe position.
Appendix A Foldout Drawings Table of Contents Electrical Drawing Abbreviations........................................................................................................A–2 Electrical Schematic...........................................................................................................................
Electrical Drawing Abbreviations The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter. Abbreviation Color BK Black BR or BN Brown BU Blue GN Green GY Gray OR or OG Orange PK Pink R or RD Red T or TN Tan VIO or VT Violet W or WH White Y or YE Yellow Numerous harness wires include a line with an alternate color. These wires are identified with the wire color followed by a / or _ and then the line color (e.
Electrical Schematic g322167 , Drawing Rev A, Sheet 1 3438-774 Rev A Page A–3
