LCE/ Resi dent i alPr oduct s TI TAN®HD Ser vi ceManual I ssued:Januar y2018
ABOUT THIS MANUAL 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. An electronic version of this service manual is available on the Toro Dealer Portal.
TABLE OF CONTENTS Safety...................................................................................................................................... 1-1 Specifications........................................................................................................................ 2-1 Maintenance...........................................................................................................................3-1 Troubleshooting........................................................
ICON LEGEND This icon is used to denote Critical Processes or actions that if missed, could greatly impact your safety, lead to mechanical failure, or improper product/ part use. Please pay close attention to these steps as they are distinguished throughout the manual.
Safety SAFETY Table of Contents General Safety Information....................................................................................................1-2 Think Safety First...............................................................................................................
SAFETY This symbol means WARNING or PERSONAL 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 Toro Titan HD Riding Mower. The Titan HD operator’s manual contains safety information and tips for safe operating practices.
SPECIFICATIONS General Specifications....................................................................................................... 2-2 Unit Dimensions.................................................................................................................. 2-6 Torque Specifications......................................................................................................... 2-7 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (U.S.)..................................
SPECIFICATIONS General Specifications Configuration Titan HD 1500 Titan HD 1500 (CA) Titan HD 1500 Model 74450 78450 74451 Engine Toro Kohler Toro Engine Model Toro V-Twin 708CC Kohler 725CC Toro V-Twin 708CC Engine Model LC2P77F ZT720 LC2P77F High Idle 3600 ± 100 RPM 3750 ± 75 RPM 3600 ± 100 RPM Low Idle 1800 ± 150 RPM (Governor Set) 1650 ± 75 RPM (Governor Set) 1800 ± 150 RPM (Governor Set) Spark Plug Champion: RN9YC NGK: BPR6ES Champion: XC12YC Champion: RN9YC NGK: BPR6ES
SPECIFICATIONS Configuration Model Titan HD 1500 Titan HD 1500 CE Titan HD 1500 CE 74452 74447TE 74451TE Engine Toro Engine Model Toro V-Twin 708CC Engine Model LCP77F High Idle Specifications General Specifications (Cont.) 3600 ± 100 RPM Low Idle 3000 ± 100 RPM 1800 ± 150 RPM (Governor Set) Spark Plug Champion: RN9YC / NGK: BPR6ES Engine Oil See “Viscosity Table,” chapter 3, page 3-11 Oil Capacity 2.4 L (80 oz.
SPECIFICATIONS General Specifications (Cont.) Configuration Model Titan HD 2000 Titan HD 2000 Titan HD 2000 Titan HD 2000 74460 74461 74462 74463 Engine Kohler Engine Model Kohler 725CC Engine Model ZT720 Kohler 747CC ZT730 ZT740 High Idle 3750 ± 75 RPM Low Idle 1650 ± 75 RPM (Governor Set) Spark Plug Champion: XC12YC Engine Oil See “Viscosity Table,” chapter 3, page 3-21 Oil Capacity 1.9 L (64 oz.
SPECIFICATIONS Configuration Model Titan HD 2500 Titan HD 2500 Titan HD 2500 74470 74471 74472 Engine Kawasaki Engine Model Engine Model Specifications General Specifications (Cont.) Kawasaki FX 726CC FX651V FX691V High Idle 3750 ± 100 RPM Low Idle 1550 RPM (Governor Set) FX730V Spark Plug NGK: BPR4ES Engine Oil See “Viscosity Table,” chapter 3, page 3-31 Oil Capacity 2.1 L (71 oz.
SPECIFICATIONS Unit Dimensions Model Overall Height Tread Width ROPS ROPS Caster UP Down Wheels Overall Width Overall Length Drive Wheels Wheel Base Curb Weight Tires Deck Chute Down Deck Chute Up ROPS UP ROPS Down 74450 69.7 47 33.1 37.7 49.7 881 46.7 63.1 54.1 81.7 80.8 78450 69.7 47 33.1 37.7 49.7 885 46.7 63.1 54.1 81.7 80.8 74451 69.7 47 33.1 39 49.7 892 48 67.2 57.9 81.7 80.8 74452 69.6 46.9 38.2 40.7 50.2 930 51.2 75.2 64.2 82.2 81.
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.
SPECIFICATIONS Standard Torque for Dry, Zinc Plated, and Steel Fasteners (U.S.) Thread Size Grade 1, 5, & 8 Fasteners with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE Grade 2 or Better Nut) SAE Grade 5 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE Grade 5 or Better Nut) SAE Grade 8 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE Grade 8 or Better Nut) In-lb. In-lb. N-cm In-lb. N-cm In-lb.
SPECIFICATIONS 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-lbs. N-m ft-lbs. 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 1.75 66 ± 7 90 ± 10 93 ± 10 126 ± 14 M16 X 2.
SPECIFICATIONS Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric) (Cont.) SAE Grade 8 Steel Set Screws Thread Size Recommended Torque 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. 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.
SPECIFICATIONS Specifications 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.
SPECIFICATIONS U.S. to Metric Conversions Linear Measurement Area Volume Weight Pressure Work 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.
MAINTENANCE Table of Contents Recommended Maintenance Schedule(s).........................................................................3-3 Lubrication........................................................................................................................... 3-5 Engine Maintenance............................................................................................................ 3-8 Servicing the Toro V Twin Engine...................................................................
MAINTENANCE Table of Contents Checking the Wheel Lug Nuts........................................................................................... 3-39 Brake Maintenance............................................................................................................. 3-39 Belt Maintenance................................................................................................................ 3-39 Mower Belt Replacement (Side Discharge Machines)............................................
MAINTENANCE Recommended Maintenance Schedule(s) Maintenance Procedure Before each use or daily • Check the safety interlock system • Check the air cleaner for dirty, loose or damaged parts • Clean the blower housing* • Check the engine oil level • Check the seat belt • Check the rollover protection system (ROPS) knobs to make sure they are locked • Clean the engine screen and the area around the engine • Clean around the engine exhaust system • Check the hydraulic fluid level in the expansion tank • Inspe
MAINTENANCE Recommended Maintenance Schedule(s) (Cont.
MAINTENANCE Lubrication . Service Interval: Every 50 hours NOTE: Grease more frequently when operating conditions are extremely dusty or sandy. 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. Clean the grease fittings with a clean rag. 3. Grease the mower deck idler pulley and pump idler pivot with 1 or 2 pumps of grease (Figure 1). 4.
MAINTENANCE Lubricating the Caster Wheel Hubs (2500 Series Machines Only) Service Interval: Yearly 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. A B Figure 2 A. Seal Guard B. Spacer Nut with Wrench Flats 2. Remove the caster wheel from the caster forks. 3. Remove the seal guards from the wheel hub (Figure 2). 4. Remove the spacer nut from the axle assembly in the caster wheel (Figure 2).
MAINTENANCE Lubricating the Caster Wheel Hubs (2500 Series Machines Only) (Cont.) NOTE: Do not thread the spacer nut all the way onto the end of the axle. Leave approximately 1/8 in. (3 mm) from the outer surface of the spacer nut to the end of the axle inside the nut. 10. Insert the assembled nut and axle into the wheel on the side with the new seal and bearing. Maintenance 11. With the open end of the wheel facing up, fill the area inside the wheel around the axle full of general purpose grease. 12.
MAINTENANCE Engine Maintenance A B C Figure 3 A. Kawasaki Engine B. Kohler Engine C. Toro Engine Important: For Kawasaki and Kohler Engines, refer to the Engine Operator’s Manual for additional maintenance procedures. Engine Safety: Shut off the engine before checking the oil or adding oil to the crankcase.
MAINTENANCE Servicing the Toro V-Twin Engine Servicing the Air Cleaner Service Interval Maintenance Procedure • Check for build-up of dirt and debris around the air cleaner system • Check for loose or damaged components, replace or make appropriate repairs • Replace all bent or damaged air cleaner components Every 25 hours/monthly (whichever comes first) • Clean the air cleaner foam element* Every 100 hours/yearly (whichever comes first) • Service the air cleaner paper element* • Replace the air cleane
MAINTENANCE Servicing the Toro V-Twin Engine (Cont.) Removing the Elements (Cont.) 3. Lift the cover and rotate the air cleaner assembly out of the engine (Figure 4). 4. Remove the foam element from the paper element (Figure 5).
MAINTENANCE Servicing the Toro V-Twin Engine (Cont.) Cleaning the Foam and Paper Elements Foam Element: Wash the foam element with water. NOTE: Replace the foam element if it is torn or worn. 2. Inspect the element for tears, an oily film, and damage to the seal. NOTE: Do not clean the paper element with pressurized air or liquids, such as solvent, gas or kerosene. Replace the paper element if it’s damaged or cannot be cleaned thoroughly.
MAINTENANCE Servicing the Toro V-Twin Engine (Cont.) Servicing the Engine Oil (Cont.) Service interval: Before each use or daily NOTE: Check the engine oil level when engine is cold. NOTE: Do not overfill the crankcase with oil and run the engine, damage may result. 1. Park the machine on a level surface, disengage the PTO, stop the engine, engage the parking brake, and remove the key. 2. Make sure the engine is stopped, level, and cool so the oil has time to drain into the sump. 3.
MAINTENANCE Servicing the Toro V-Twin Engine (Cont.) Changing the Engine Oil and Oil Filter Service Interval: After the first 5 hours/after the first month (whichever comes first) Every 100 hours/Yearly (whichever comes first): Change the engine oil and oil filter (more often in dirty or dusty conditions) Maintenance 1. Park the machine on a level surface, disengage the PTO, stop the engine, engage the parking brake, and remove the key. 2. Drain the engine oil (Figure 8).
MAINTENANCE Servicing the Toro V-Twin Engine (Cont.) Changing the Engine Oil and Oil Filter (Cont.) 3. Change the oil filter (Figure 9). NOTE: Ensure that the oil filter gasket touches the engine and then turn the filter an additional 3/4 turn. A BB C D E F 3/4 Figure 9 4. Slowly pour approximately 80% of the specified oil into the filler tube. Check the oil level and slowly add the additional oil needed to bring it to the FULL mark (Figure 10).
MAINTENANCE Servicing the Toro V-Twin Engine (Cont.) Servicing the Spark Plug Make sure the air gap between the center and side electrodes is correct before installing the spark plug. Use a spark plug wrench to remove and install the spark plug. Use a gapping tool or feeler gauge to check and adjust the air gap. Install a new spark plug if necessary. Type: Champion RN9YC or equivalent Air Gap: 0.030 in. (0.76 mm) Removing the Spark Plug 1.
MAINTENANCE Servicing the Toro V-Twin Engine (Cont.) Servicing the Spark Plug (Cont.) Installing the Spark Plug 1. Tighten the spark plugs to 22 ± 2 ft-lbs. (25-30 Nm) (Figure 12). Figure 12 Cleaning the Cooling System Service Interval: Before each use 1. Park the machine on a level surface, disengage the PTO, stop the engine, engage the parking brake, and remove the key. 2. Remove the air filter from the engine. 3. Remove the engine shroud. 4.
MAINTENANCE Servicing the Toro V-Twin Engine (Cont.) Checking the Spark Arrestor (if equipped) Service Interval: Every 50 hours WARNING! Maintenance Hot exhaust system components may ignite gasoline vapors even after shutting off the engine. Hot particles exhausted during engine operation may ignite flammable materials. Fire may result in personal injury or property damage. Do NOT refuel or run the engine unless a spark arrester is installed. 1.
MAINTENANCE Servicing the Toro V-Twin Engine (Cont.) Replacing the Emissions - Air Intake Filter Service Interval: Every 500 hours Figure 13 1. Park the machine on a level surface, disengage the PTO, stop the engine, engage the parking brake, and remove the key. 2. Remove the filter from the vent hose (Figure 13). 3. Insert a new filter into the end of the vent hose.
MAINTENANCE Servicing the Kohler Engine Servicing the Air Cleaner Maintenance Procedure Daily or before starting engine • Check the air cleaner for dirty, loose or damaged parts. Every 25 hours/monthly* • Service or replace the air cleaner pre-cleaner Every 50 hours* • Service the air cleaner paper element Every 100 hours/yearly* • Replace the air cleaner paper element *More often in dusty/dirty conditions This engine is equipped with a replaceable, high density paper air cleaner element.
MAINTENANCE Servicing the Kohler Engine (Cont.) Servicing the Air Cleaner (Cont.) 3. Remove the pre-cleaner and paper element. 4. Remove the element, and gently tap the element to dislodge dirt. NOTE: Do NOT wash the paper element or use pressurized air, as this will damage the element. NOTE: Replace a dirty, bent, or damaged element. Handle the new element carefully, do not use if the sealing surfaces are bent or damaged. 5. Wash the foam element in warm water with detergent, rinse, and air dry. 6.
MAINTENANCE Servicing the Kohler Engine (Cont.) Servicing the Engine Oil Maintenance Oil Type: Detergent Oil (API service SJ or higher) Crankcase Capacity: 1.9 L (64 oz.) Viscosity: See Table (Figure 15) SAE 30 50 0 0 Figure 15 Service Interval: Before each use or daily NOTE: Do not overfill the crankcase with oil and run the engine, damage may result. 1. Park the machine on a level surface, disengage the PTO, stop the engine, engage the parking brake, and remove the key. 2.
MAINTENANCE Servicing the Kohler Engine (Cont.) Servicing the Engine Oil (Cont.) 4. Check the engine oil level (Figure 16). A C F B D B E G H Figure 16 5. If the level is low, wipe off the area around the oil fill cap, remove cap/dipstick and add oil to the “F” (FULL) mark on the dipstick. NOTE: To prevent extensive engine wear or damage, always maintain the proper oil level in the crankcase.
MAINTENANCE Servicing the Kohler Engine (Cont.) Changing the Engine Oil and Oil Filter Service Interval: Every 100 hours/Yearly (whichever comes first). Change the engine oil and oil filter more often in dirty or dusty conditions. Maintenance 1. Park the machine on a level surface, disengage the PTO, stop the engine, engage the parking brake, and remove the key. 2. Drain the engine oil (Figure 17). Figure 17 3. Change the oil filter.
MAINTENANCE Servicing the Kohler Engine (Cont.) Changing the Engine Oil and Oil Filter (Cont.) NOTE: Ensure the oil filter gasket touches the engine, then turn the filter an additional extra 3/4 turn (Figure 18). A BB C D E F G H 02:00 Min 2:00 Min 3/4 Figure 18 4. Slowly pour approximately 80% of the specified oil into the filler tube.
MAINTENANCE Servicing the Kohler Engine (Cont.) Servicing the Spark Plugs Service Interval: Every 200 hours - Check the spark plugs Every 500 hours - Replace the spark plugs Make sure the air gap between the center and side electrodes is correct before installing the spark plug. Use a spark plug wrench to remove and install the spark plug. Use a gapping tool or feeler gauge to check and adjust the air gap. Install a new spark plug if necessary. Type: Champion XC12YC Air Gap: 0.030 inch (.
MAINTENANCE Servicing the Kohler Engine (Cont.) Checking the Spark Plug 1. Inspect the spark plug. NOTE: If you see light brown or gray coating on the insulator, the engine is operating properly. A black coating on the insulator usually means the air cleaner is dirty. NOTE: Do not clean the spark plug(s). Always replace the spark plug(s) when it has: A black coating, worn electrodes, an oily film, or cracks. 2. Check the gap between the center and side electrodes (Figure 20). 3. Set the gap to 0.030 in. (0.
MAINTENANCE Servicing the Kohler Engine (Cont.) Cleaning the Blower Housing To ensure proper cooling, ensure that the grass screen, cooling fins, and other external surfaces of the engine are kept clean at all times. Remove the blower housing and any other cooling shrouds. Clean the cooling fins and external surfaces as necessary. Make sure that the cooling shrouds are re-installed.
MAINTENANCE Servicing the Kawasaki Engine Servicing the Air Cleaner Service Interval Maintenance Procedure Every 250 hours/yearly (whichever comes first)* • Replace the primary air filter • Check the safety air filter Every 500 hours/every 2 years (whichever comes first)* • Replace the safety air filter *More often in dusty/dirty conditions NOTE: Service the air cleaner more often under extremely dusty, dirty conditions. 1.
MAINTENANCE Servicing the Kawasaki Engine (Cont.) Servicing the Air Cleaner (Cont.) 3. Clean the inside of the air cleaner cover with compressed air. 4. Gently, slide the primary filter out of the air-cleaner body. 5. Remove the safety filter only if intending to replace it. NOTE: Do NOT attempt to clean the safety filter. If the safety filter is dirty, then the primary filter is damaged. Replace both filters. 6.
MAINTENANCE Servicing the Kawasaki Engine (Cont.) Servicing the Primary Filter • If the primary filter is dirty, bent, or damaged, replace it • Do not clean the primary filter Servicing the Safety Filter Replace the safety filter, never clean it NOTE: Do not attempt to clean the safety filter. If the safety filter is dirty, then the primary filter is damaged. Replace both filters. Installing the Filters NOTE: To prevent engine damage, always operate the engine with both air filters and the cover installed.
MAINTENANCE Servicing the Kawasaki Engine (Cont.) Servicing the Engine Oil Maintenance Oil Type: Detergent Oil (API service SF, SG, SH, SJ or SL) Crankcase Capacity: 2.1 L (71 oz.) Viscosity: See Table (Figure 23) Figure 23 NOTE: Although 10W-40 engine oil is recommended for most conditions, you may need to change oil viscosity to accommodate atmospheric conditions. Using 20W-50 engine oil in higher ambient temperatures can reduce oil consumption.
MAINTENANCE Servicing the Kawasaki Engine (Cont.) Servicing the Engine Oil (Cont.) 4. Check the engine oil level (Figure 24). A BB C D F G H I E J Figure 24 5. If the level is low, wipe off the area around the oil fill cap, remove cap/dipstick and add oil to the “FULL” mark on the dipstick. NOTE: To prevent extensive engine wear or damage, always maintain the proper oil level in the crankcase.
MAINTENANCE Servicing the Kawasaki Engine (Cont.) Changing the Engine Oil and Oil Filter Service Interval: Every 100 hours- Change the Engine Oil (more often in dirty or dusty conditions) Every 200- hours Change the Oil Filter Maintenance 1. Park the machine on a level surface, disengage the PTO, stop the engine, engage the parking brake, and remove the key. 2. Drain the engine oil (Figure 25). Figure 25 3. Change the oil filter.
MAINTENANCE Servicing the Kawasaki Engine (Cont.) Changing the Engine Oil and Oil Filter (Cont.) NOTE: Ensure that the oil filter gasket touches the engine and then turn the filter an additional ¾ turn (Figure 26). A B B C D E F 3/4 Figure 26 4. Slowly pour approximately 80% of the specified oil into the filler tube. Check the oil level and slowly add the additional oil needed to bring it to the FULL mark (Figure 27).
MAINTENANCE Servicing the Kawasaki Engine (Cont.) Servicing the Spark Plug Service Interval: Every 100 hours - Replace the spark plugs. Type: NGK BPR4ES or equivalent Air Gap: 0.030 in. (0.76 mm) Removing the Spark Plug 1. Park the machine on a level surface, disengage the PTO, stop the engine, engage parking brake, and remove the key. 2. Disconnect the wire from the spark plug.
MAINTENANCE Servicing the Kawasaki Engine (Cont.) Checking the Spark Plug (Cont.) 2. Check the gap between the center and side electrodes (Figure 28). 3. Set the gap to 0.030 in. (0.76 mm). A BB Figure 28 Installing the Spark Plug 1. Tighten the spark plugs to 16 ft-lbs. (22 Nm).
MAINTENANCE Fuel System Maintenance Replacing the Fuel Filter Service Interval: Every 500 hours/yearly (whichever comes first) - Replace the fuel filter more often in dirty or dusty conditions. Maintenance NOTE: If any cable ties or clamps are removed, note the position of the tie and replace after servicing the fuel filter. If these ties or clamps are removed, damage to the fuel filter may occur. 1.
MAINTENANCE Electrical System Maintenance Electrical System Safety • Disconnect the battery before repairing the machine. Disconnect the negative terminal first and the positive last. Connect the positive terminal first and the negative last. • Charge the battery in an open, well-ventilated area, away from sparks and flames. Unplug the charger before connecting or disconnecting the battery. Wear protective clothing and use insulated tools.
MAINTENANCE Servicing the Battery Service Interval: Monthly NOTE: The battery should be maintained at 12.6 volts or greater. A battery that has reached a voltage of 12.4 volts or less is considered discharged, and should be recharged. 1. Charge the battery for 30 minutes at 10 A. Maintenance 2. Test the battery voltage. Servicing the Fuses The electrical system is protected by fuses. The fuses require no maintenance. For more information on troubleshooting the electrical system, refer to chapter 9.
MAINTENANCE Hydraulic System Maintenance Hydraulic System Safety • Ensure that all hydraulic-fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system. • Keep your body and hands away from pinhole leaks or nozzles that eject high-pressure hydraulic fluid. • Use cardboard or paper to find hydraulic leaks • Relieve all pressure in the hydraulic system before performing any work on the hydraulic system.
MAINTENANCE Hydraulic System Maintenance (Cont.) Changing the Hydraulic System Filters and Fluid Change the oil and the filters at the same time. Do not reuse the oil. Purge any air from the system after installing the new filters and add oil see “Purging Procedure,” chapter 7, page 7-8. Repeat the purging procedure until the oil remains at the FULL COLD line in the reservoir after purging. NOTE: Failure to properly perform this procedure can result in irreparable damage to the hydrostatic drive system.
MAINTENANCE Hydraulic System Maintenance (Cont.) Removing the Hydraulic System Filters (Cont.) 5. Carefully, clean the area around the filters. NOTE: Do not allow dirt to enter the hydraulic system - contamination may occur. 6. Place a drain pan below the filter to catch the oil that drains when the filter and vent plugs are removed. 7. Locate and remove the vent plug on each transmission. 8. Unscrew the filter to remove it and allow the oil to drain from the drive system. 9.
MAINTENANCE Hydraulic System Maintenance (Cont.) Installing the Hydraulic System Filters and Adding Oil (Cont.) 6. Verify that the vent plugs are removed before adding the oil. 7. Slowly pour the specified oil through the expansion reservoir until oil comes out of one of the vent plug holes. 9. Torque the plug to 15 ft-lbs. (20 Nm). 10. Continue to add oil through the expansion reservoir until oil comes out of the remaining vent plug hole on the other transmission. 11. Install the vent plug. 12.
MAINTENANCE Servicing the Cutting Blades Blade Safety A worn or damaged blade can break and a piece of the blade could be thrown at you or bystanders, resulting in serious injury or death. Trying to repair a damaged blade may result in discontinued safety certification of the product. 1. Inspect blades periodically for wear. 2. Use care when checking the blades. Wrap the blades or wear gloves, and use caution when servicing the blades. Only replace the blades, never straighten or weld them. 3.
MAINTENANCE Servicing the Cutting Blades (Cont.) Checking for Bent Blades 1. Park the machine on a level surface, disengage the PTO, stop the engine, engage parking brake, and remove the key. 2. Disconnect the spark plug wires from the spark plugs. Maintenance 3. Rotate the blades so they are perpendicular to the rear of the deck (Figure 34) A Figure 34 A. Measure here from Blade to Hard Surface 4. Measure from a level surface to the cutting edge, position A (Figure 34). 5.
MAINTENANCE Changing the Blades (Side Discharge Mower Deck) Removal Replace the blade if it hits an object, if the blade is out of balance, or if the blade is bent. To ensure optimum performance and continued safety conformance of the machine, use genuine Toro replacement blades. Replacement blades made by other manufacturers may result in non-conformance with safety standards. 1. Hold the spindle shaft with a wrench. 2. Remove the blade bolt, curved washer, and blade from the spindle shaft (Figure 35).
MAINTENANCE Changing the Blades (Rear Discharge Mower Deck) Removal Replace the blade if it hits an object, if the blade is out of balance, or if the blade is bent. To ensure optimum performance and continued safety conformance of the machine, use genuine Toro replacement blades. Replacement blades made by other manufacturers may result in non-conformance with safety standards. 1. Hold the spindle shaft with a wrench. Maintenance 2.
MAINTENANCE Changing the Blades (Rear Discharge Mower Deck) (Cont.) Removal (Cont.) NOTE: Note the type blade and where each blade is installed. See Figure 37 for the correct position. A B E D C Figure 37 A. Front of Mower Deck B. Right - Hand Threaded Blade Bolts C. Standard Blades D. Counter - Rotating Blade E. Left - Hand Threaded Blade Bolt Installation NOTE: The right blade on this mower deck is counter-rotating and uses a left hand threaded blade bolt.
MAINTENANCE Changing the Blades (Rear Discharge Mower Deck) (Cont.) Installation (Cont.) 2. Install the right blade, curved washer, and blade bolt (left hand threaded bolt) to the spindle shaft (Figure 38) Maintenance 3. Torque the blade bolts to 95 ± 5 ft-lbs. (122-136 Nm). E AB C D Figure 38 A. Sail Area of the Blade B. Blade C. Curved Washer D. Blade Bolt E. Spindle Shaft A B E D C Figure 39 A. Front of Mower Deck B. Right - Hand Threaded Blade Bolts C. Standard Blades D.
MAINTENANCE Sharpening the Blades 1. Use a file to sharpen the cutting edge at both ends of the blade (Figure 40). NOTE: Maintain the original angle. NOTE: The blade retains balance if you remove the same amount of material from both cutting edges. A Figure 40 A. Sharpen at the Original Angle 2. Check balance of the blade by putting it on a blade balancer (Figure 41). NOTE: If the blade stays in a horizontal position, the blade is balanced and ready to use. A B Figure 41 A. Blade B. Balancer 3.
TROUBLESHOOTING Table of Contents Troubleshooting Troubleshooting Table...........................................................................................................
TROUBLESHOOTING Troubleshooting Problem The starter does not crank The engine does not start, starts hard, or fails to keep running 4-2 Table of Contents Possible Cause Next Step... 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. Ensure that the motion-control levers are in the Neutral-Lock position.
TROUBLESHOOTING Troubleshooting (Cont.) Possible Cause Engine loses power Next Step... The engine load is excessive. Reduce the ground speed. The air cleaner is dirty. Clean the air cleaner element. The oil level in the crankcase is low. Add oil to the crankcase. The cooling fins and air passages above the engine are plugged. Remove the obstruction and thoroughly clean cooling fins and the air passages. The vent hole in the fuel cap is plugged. Clean or replace the fuel cap.
TROUBLESHOOTING Troubleshooting (Cont.) Problem The machine produces an uneven cutting height The blades do not rotate The clutch does not engage 4-4 Table of Contents Possible Cause Next Step... The blade(s) is/are not sharp. Sharpen the blade(s). The cutting blade(s) is/are bent. Install new cutting blade(s). The mower deck is not level. Level the mower deck from side-toside and front-to-rear. The underside of mower is dirty. Clean the underside of the mower.
CHASSIS Table of Contents MyRide Exploded View....................................................................................................... 5-3 Caster Assembly and Bearing........................................................................................... 5-4 Exploded View............................................................................................................... 5-4 Removal...................................................................................................
CHASSIS Table of Contents Park Brake Handle Assembly............................................................................................ 5-27 Removal..........................................................................................................................5-27 Installation.......................................................................................................................5-28 Adjusting the Park Brake....................................................................
CHASSIS MyRide Exploded View J A E H I B C D G E Chassis F C Figure 1 A. Trailing Arm Tube B. Shoulder Bolt C. Flange Bushing D. Trailing Arm E. Flange Bearing F. LH Trailing Arm Bracket G. Pivot Rod H. RH Trailing Arm Bracket I. Upper Shock Mount Bolt J.
CHASSIS Caster Assembly and Bearing B G E F A A C D Figure 2 A. Ball Bearing B. Grease Cap C. Frame Assembly D. Front Caster Assembly 5-4 Table of Contents E. Spring Washer F. Bolt G.
CHASSIS Caster Fork Assembly and Bearing Service 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 the key. Engage the parking brake. 2. Raise and support the unit so that the front wheels are off the ground. 3. Remove the caster cap. 4. Support the underside of the caster wheel and remove the fastener screw securing the caster bearing assembly (A) (Figure 2). 5. Remove the caster fork (B) from the front axle.
CHASSIS Caster Wheel Service: Titan HD 1500 and Titan HD 2000 Series C A B Figure 3 A. Wheel B. Valve Stem C. Grease Fitting NOTE: The caster wheel is not serviceable and should be replaced as a complete assembly. Caster Wheel Service: Titan HD 2500 Series B C A C E D Figure 4 A. Caster Fork B. Screw C. Seal Guards D. Lock Nut E. Wheel Assembly Lubrication Service Interval: Yearly see “Caster Wheel Lubrication,” chapter 3, page 3-7.
CHASSIS Caster Wheel Service (2500 Series) Disassembly 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. Raise and support the unit so that the front wheels are off the ground. 3. Remove the caster wheel from the caster fork. 4. Remove the seal guards from the wheel hub. 5. Remove one of the spacer nuts from the axle assembly.
CHASSIS Left Console 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 the key. Engage the parking brake. 2. Disconnect the battery cables and remove the battery from the tray. 3. Remove the shoulder bolt (T30) at location (A) at the front of the console (Figure 5). C A B Figure 5 4. Remove the two bolts (B) on the front of the console (Figure 5). 5.
CHASSIS Left Console Removal (Cont.) 6. Remove the two bolts from the support bracket (Figure 6). Figure 6 Chassis 7. Remove the fuel cap and disconnect the keeper line (Figure 7). Figure 7 8. Carefully lift the console upward off of the machine. 9. Replace the fuel cap.
CHASSIS 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 support (Figure 8). Figure 8 3. Install the keeper line into the fuel cap, and reinstall the fuel cap. 4. Install the two bolts and nuts through the support bracket (Figure 9).
CHASSIS Left Console Installation (Cont.) 5. Install the two screws (T25) through the console bracket (C) (Figure 10). C A B Figure 10 6. Install the two bolts (B) and nuts on the front of the console (Figure 10). 7. Install the shoulder bolt (A) (T30) at the front of the console (Figure 10). Chassis 8. Install the battery onto the battery tray and secure with the battery strap. 9. Connect the battery terminals and verify proper function of the unit.
CHASSIS Right Console 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 the key. Engage the parking brake. 2. Disconnect the battery terminals. 3. Remove the shoulder bolt (A) (T30) at the front of the console (Figure 11). B A C Figure 11 4. Remove the two bolts (B) on the front of the console (Figure 11). 5. Remove the two screws (T25) from the console bracket (C) on the underside of the console (Figure 11).
CHASSIS Right Console Removal (Cont.) 6. Remove the two bolts from the support bracket. 7. Remove the hex screw securing the control panel assembly to the console. Figure 12 NOTE: The control panel assembly should be supported while servicing the machine, to avoid damage to cables or the wire harness. Digital Edition - TITAN® HD Service Manual January 2018 5-13 Table of Contents Chassis 8.
CHASSIS 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 (Figure 13). Figure 13 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.
CHASSIS Right Console Installation (Cont.) 5. Install the two bolts (B) and nuts on the front console (Figure 14). 6. Install the shoulder bolt (A) (T30) at the front of the console (Figure 14). Chassis 7. Connect the battery terminals and verify proper function of the unit.
CHASSIS Seat B A B A Figure 15 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 the key. Engage the parking brake. 2. Disconnect the battery terminals. 3. Unlatch and raise the seat, disconnect the operator presence switch on the underside of the seat assembly. 4. Lower the seat back into the latched position. 5. Remove the bolt (A) and the seat pivot (B) from each side of the seat (Figure 15). 6.
CHASSIS Fuel Tank A B A C Figure 16 A. Vent Hose Assembly B. Fuel Supply Line C. Fuel Shut-Off Valve Chassis Removal NOTE: The fuel pick-up system is designed to pull fuel from any part of the tank in low fuel situations as well as reducing the affect of debris in the tank (Figure 17). Figure 17 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 terminals.
CHASSIS Fuel Tank Removal (Cont.) 3. Close the fuel supply valve (Figure 18). Figure 18 4. Remove the right and left side consoles. See “Console Removal,” chapter 5, page 5-8. 5. Remove the seat assembly. See “Seat Removal,”chapter 5, page 5-16. 6. Remove the two bolts and nuts securing the fuel tank retainer plate. 7. Remove the fuel tank retainer plate by lifting the rear of the plate toward the front of the machine and sliding the tabs up and out of the frame slots. 8.
CHASSIS Fuel Tank Installation 1. Position the fuel tank assembly onto the frame with the vent ports toward the rear of the machine. 2. Connect the two vent lines to the fuel tank (A) (Figure 20). 3. Connect the fuel supply line to the fuel tank and route the fuel line in the detents molded into the tank (B) (Figure 20). A B A C A. Vent Hose Assembly B. Fuel Supply Line Chassis Figure 20 C. Fuel Shut-Off Valve 4. Install the fuel tank retainer plate. 5. Install the seat assembly.
CHASSIS Fuel Tank Installation (Cont.) 7. Open the fuel supply valve (Figure 21). Figure 21 8. Connect the battery terminals and verify proper function of the unit.
CHASSIS Roll Over Protection System (ROPS) Figure 22 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 the key. Engage the parking brake. 2. Fold the ROPS assembly into the upright position and lock in place (Figure 22). Chassis NOTE: For easier access, remove the right and left side consoles. See “Console Removal,” chapter 5, page 5-8. 4. Support the ROPS assembly and remove the four mounting bolts (Figure 22). 5.
CHASSIS Roll Over Protection System (ROPS) Installation 1. Lift the ROPS assembly into position on the rear side of the mounting support. 2. Install the four mounting bolts (Figure 23). Figure 23 NOTE: Orientation of the ROPS hardware is critical. Make sure that the bolts are orientated as shown (Figure 22). 3. Torque the ROPS connecting hardware to 95 ± 5 ft-lbs. (122-135 Nm). 4. Install the right and left consoles. See “Console Installation,” chapter 5, page 5-10.
CHASSIS Throttle Cable 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 the key. Engage the parking brake. 2. Disconnect the battery. 3. Remove the control panel assembly from the right console. Chassis 4. Remove the knob from the throttle lever (Figure 24). Figure 24 5. Remove the two bolts and nuts securing the throttle control assembly to the control panel assembly. 6.
CHASSIS Throttle Cable Assembly Installation 1. Route the throttle cable through the right console between the ROPS and the hydraulic fluid reservoir (Figure 26). Figure 26 2. Attach the throttle cable assembly to the control panel assembly using two bolts and nuts. 3. Install the knob on the throttle lever. 4. Install the control panel assembly into the console. 5. Move the throttle control lever to the slow idle position (Figure 27). Figure 27 6.
CHASSIS 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 the key. Engage the parking brake. 2. Disconnect the battery. 3. Loosen the clamp securing the choke cable to the choke plate on the engine (A) (Figure 28). A B Chassis Figure 28 4. Remove the choke cable from the plate (B), noting the position of the cable in the plate (Figure 28). 5.
CHASSIS Choke Control Assembly Installation 1. Route the choke cable through the control panel assembly. 2. Thread the jam nut over the choke cable up to the control panel assembly (Figure 29). Figure 29 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.
CHASSIS Park Brake Handle Assembly C B A Figure 30 A. Locking Cotter Pin B. Bolt C. Flange Nut 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 the key. Chassis 2. Disconnect the battery terminals. 3. Release the parking brake (park brake handle down). 4. Remove the left side console. See “Console Removal,” chapter 5, page 5-8. 5.
CHASSIS Park Brake Handle Assembly Installation 1. Connect the upper brake linkage to the brake shaft. 2. With the park brake handle hardware orientated as shown, install the bolt and flange nut (Figure 31). C B A Figure 31 A. Locking Cotter Pin B. Bolt C. Flange Nut 3. With the park brake shaft in disengaged position and the park brake lever in the lower position, rotate the upper brake linkage until the end aligns with the hole in the park brake lever (Figure 32). Figure 32 4.
CHASSIS Adjusting the Park Brake A B C Figure 33 A. Cotter Pin B. Park Brake Handle C. Brake Linkage Shaft Service Interval: Every 500 hours 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. Raise and support the unit so that the drive wheels are off the ground. 3. Release the drive wheel bypass valves so that the drive wheels are able to spin freely. 4.
CHASSIS Adjusting the Park Brake (Cont.) 6. Check both spring lengths, if adjustment is necessary, turn the top nut clockwise to shorten and counterclockwise to lengthen. The spring length should measure 1.75 in. (44 mm) (Figure 35). A B C Figure 35 A. Flange Nut B. Compression Spring C. Lower Brake Linkage 7. Re-check the spring length to ensure both springs are tensioned equally. 8. Disengage the parking brake by pushing the park brake handle all the way forward and down. 9.
CHASSIS Motion Control Damper 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 the key. 2. Remove the two bolts securing the motion control damper to the frame (A) and the motion control assembly (B) (Figure 36). A B Figure 36 Digital Edition - TITAN® HD Service Manual January 2018 Chassis 3. Remove the motion control damper from the machine.
CHASSIS Motion Control Damper Installation 1. Position the motion control damper on the outside of the frame mounting tab (Figure 37). Figure 37 2. Torque the rear mounting bolt to 200 ± 25 in-lbs. (237-305 Nm). 3. Torque the front mounting bolt to 90 ± 10 in-lbs. (108-135 Nm). 4. Verify proper function of the unit.
CHASSIS Motion Control Assembly Figure 38 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 the key. 2. Raise and support the unit so that the drive wheels are off the ground. Chassis NOTE: The console may be removed for easier access. See “Console Removal,” chapter 5, page 5-8. 3. Remove the two bolts securing the motion control handle to the motion control assembly. 4.
CHASSIS Motion Control Assembly Removal (Cont.) 6. Disconnect the motion control assembly from the frame (Figure 40). Figure 40 7. Lower the motion control assembly through the frame toward the center of the machine, remove the assembly.
CHASSIS 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 transmission (Figure 41).
CHASSIS Motion Control Assembly Installation (Cont.) 4. Adjust the nut on the motion control assembly until the motion control nut (A) is centered in the control plate slots (Figure 42). A Figure 42 A. Motion Control Nut 5. Connect the motion control damper to the motion control assembly and torque the bolt to 90 ± 10 in-lbs. (108135 Nm). 6. Connect the motion control handle to the motion control assembly. 7. Adjust the neutral setting see “Neutral Adjustment,” chapter 7, page 7-4. 8.
CHASSIS Adjusting the Motion Control Handle Position NOTE: Ensure proper adjustment of neutral and tracking settings before adjusting the motion control handles see “Neutral Adjustment,” chapter 7, page 7-4 and/or “Tracking Adjustment,” chapter 7, page 7-7. 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. 2. Move the levers into the operating position. 3.
CHASSIS MyRide Replacement 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 the key. 2. Lower the ROPS. 3. Remove the two larger nyloc nuts securing the lower shock mounts to the ROPS. The nyloc nuts can be accessed from the rear of the machine. 4. Open the cable retainer and remove the two cables routed across the seat base (Figure 44). Figure 44 5.
CHASSIS MyRide Replacement (Cont.) Removal (Cont.) 6. Place shoulder bolt back in upper mount and finger tighten with the lock nut (Figure 45). Figure 45 Chassis 7. Attach the seat and sub-frame assembly to the overhead lift using three lift points (Figure 46). Figure 46 8. Remove the two shoulder bolts securing the trailing arm to the lower ROPS tubes. 9. Using an overhead lift, raise the seat up about 12 in. 10. Disconnect the seat switch. 11.
CHASSIS MyRide Replacement (Cont.) Installation 1. With the seat and sub-frame assembly attached to the overhead lift, lower the seat into the machine, leaving room under the seat. 2. Connect the seat switch. 3. Lower the seat and sub-frame assembly to align the trailing arm with the mount holes in the ROPS tube (Figure 47). Figure 47 4. Install the two shoulder bolts securing the trailing arm to the lower ROPS tubes. Torque to 37 ± 3 ft-lbs. (50 Nm). 5.
CHASSIS MyRide Replacement (Cont.) Installation (Cont.) 6. Lower the seat and sub-frame all the way onto the machine. 7. Disconnect the seat and sub-frame from the overhead lift. 8. Secure the front shock with a shoulder bolt. Chassis NOTE: Thread should be on the LH side of the machine (from operator’s position) (Figure 49). Figure 49 9. Disconnect the seat and sub-frame from the overhead lift. 10. Install the two nuts securing the lower shock mounts to the ROPS tubes. Torque to 90 ± 9 ft-lbs (122 Nm).
ENGINE Table of Contents Engine Mounting - Toro Twin Cylinder Engine Exploded View..................................... 6-2 Toro Twin Cylinder Engine................................................................................................ 6-3 Removal.........................................................................................................................6-3 Installation......................................................................................................................
ENGINE Engine Mounting - Toro Twin Cylinder Engine A C B Figure 1 A. Muffler Mounting Bolts/Nuts - Torque to 13 ft-lbs. (16-19 Nm) B. PTO Clutch Assembly - Torque clutch mounting bolt to 55 ± 6 ft-lbs. (66-83 Nm) C. Engine/Clutch Stop Mount Bolts (4) - Torque to 30 ± 3 ft-lbs.
ENGINE 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 the key. Engage the parking brake. 2. Disconnect the battery. 3. Close the fuel supply valve (Figure 2). Figure 2 4. Remove the engine guard. 6. Remove the hydrostatic drive belt from the engine pulley see “Hydrostatic Drive Belt Removal,” chapter 7, page 7-9.
ENGINE Toro Twin Cylinder Engine Removal (Cont.) 7. Disconnect the chassis wire harness from the main engine wire harness (Figure 3). Figure 3 8. Disconnect the red (B+) wire from the starter (Figure 4).
ENGINE Toro Twin Cylinder Engine Removal (Cont.) 9. Disconnect the black engine ground wire (Figure 5). Figure 5 Engine 10. Disconnect the fuel supply line at the fuel filter (Figure 6). Figure 6 11. Disconnect the throttle cable see “Throttle Cable Removal,” chapter 5, page 5-23. 12. Disconnect the choke cable see “Choke Cable Removal,” chapter 5, page 5-25. 13. Disconnect the clutch wire from the clutch. 14. Remove the clutch mounting bolt and washers. Slip the clutch off of the crankshaft.
ENGINE Toro Twin Cylinder Engine Removal (Cont.) 16. Remove the engine mounting bolts. NOTE: Before removing the engine mounting bolts, note the orientation of the clutch anchor. The clutch wire can remain attached to the clutch anchor. 17. Lift the engine away from the frame. Installation 1. Prepare the frame and secure any fuel lines or wire harness components. 2. Install the muffler and new exhaust gaskets. 3. Torque the muffler mounting bolts or nuts to 20 ± 2 ft-lbs. (25-30 Nm). 4.
ENGINE Toro Twin Cylinder Engine Installation (Cont.) 9. Install the clutch onto the crankshaft ensuring that the slot in the clutch aligns with the tab on the clutch anchor (Figure 8). Figure 8 Engine 10. Install the two spring washers and the clutch bolt (Figure 9). Figure 9 11. Torque the clutch bolt to 55 ± 6 ft-lbs. (66-83 Nm). 12. Install the hydrostatic drive belt onto the engine pulley see “Hydrostatic Drive Belt Installation,” chapter 7, page 7-11. 13.
ENGINE Toro Twin Cylinder Engine Installation (Cont.) 17. Connect the black engine ground wire (Figure 10). Figure 10 18. Connect the red (B+) wire from the starter (Figure 11).
ENGINE Toro Twin Cylinder Engine Installation (Cont.) 19. Connect the chassis wire harness to the main engine wire harness (Figure 12). Figure 12 20. Connect the fuel supply line to the fuel filter. 21. Install the engine guard. 22. Open the fuel supply valve. 23. Fill the crankcase with approved oil and verify proper oil level. Engine 24. Connect the battery terminals. 25. Verify proper function of the unit. NOTE: Verify engine speed is set to 3600 ± 50 RPM (or 3000 ± 50 RPM for TE models).
ENGINE Engine Mounting - Kohler Engine D A C B Figure 13 A. Muffler Mounting Nuts/Bolts - Torque to 20 ± 2 ft-lbs. (25-30 Nm) B. Clutch Mounting Bolt - Torque to 55 ± 6 ft-lbs. (66-83 Nm) C. Engine/Clutch Stop Mounting Bolts (4) - Torque to 30 ± 3 ft-lbs. (36-45 Nm) D. Oil Drain Hose Assembly - Apply pipe sealant and torque to 20 ± 3 ft-lbs.
ENGINE Kohler 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 the key. Engage the parking brake. 2. Disconnect the battery. 3. Close the fuel supply valve (Figure 14). Figure 14 4. Remove the engine guard. 6. Remove the hydrostatic drive belt from the engine pulley see “Hydrostatic Drive Belt Removal,” chapter 7, page 7-9. 7. Disconnect the chassis wire harness from the main engine wire harness (Figure 15).
ENGINE Kohler Engine Removal (Cont.) 8. Disconnect the red (B+) wire from the starter (Figure 16). Figure 16 9. Disconnect the black engine ground wire (Figure 17).
ENGINE Kohler Engine Removal (Cont.) 10. Disconnect the fuel supply line at the fuel filter (Figure 18). Figure 18 11. Disconnect the throttle cable see “Throttle Cable Removal,” chapter 5, page 5-23. 12. Disconnect the choke cable see “Choke Cable Removal,” chapter 5, page 5-25. 13. Disconnect the clutch wire from the clutch. 14. Remove the clutch mounting bolt and washers. Slip the clutch off of the crankshaft.
ENGINE Kohler Engine Installation 1. Prepare the frame and secure any fuel lines or wire harness components. 2. Install the oil drain hose assembly (A) (Figure 19). NOTE: Apply pipe sealant to the threads at installation. Torque to 20 ± 3 ft-lbs. (23-31 Nm). A D A Figure 19 3. Carefully lower the engine onto the frame. 4. Align the four holes of the engine base to the frame and attach the two rear mounting bolts and two belleville washers loosely (orientation of the washers shown Figure 20). 5.
ENGINE Kohler Engine Installation (Cont.) 6. Torque the four engine mounting bolts to 30 ± 3 ft-lbs. (36-45 Nm). 7. Install the key and engine pulley onto the crankshaft. NOTE: Install the engine pulley with the larger diameter hub toward the engine. 8. Install the clutch onto the crankshaft ensuring that the slot in the clutch aligns with the tab on the clutch anchor. 9. Install the two spring washers and the clutch bolt (Figure 21). Engine Figure 21 10. Torque the clutch bolt to 55 ± 6 ft-lbs.
ENGINE Kohler Engine Installation (Cont.) 13. Connect the black engine ground wire (Figure 22). Figure 22 14. Connect the red (B+) wire from the starter (Figure 23).
ENGINE Kohler Engine Installation (Cont.) 15. Connect the chassis wire harness to the main engine wire harness (Figure 24). Figure 24 16. Connect the fuel supply line to the fuel filter. 17. Install the engine guard. 18. Open the fuel supply valve. Engine 19. Fill crankcase with approved oil and verify proper oil level. 20. Connect the battery terminals. 21. Verify proper function of the unit. NOTE: Verify engine RPM is set to 3600 ± 50.
ENGINE Engine Mounting - Kawasaki Engine D A C B Figure 25 A. Muffler Mounting Bolts/Nuts - Torque to 13 ft-lbs. (16-19 Nm) B. Clutch Mounting Bolt - Torque to 55 ± 6 ft-lbs. (66-83 Nm) C. Engine/Clutch Stop Mounting Bolts (4) - Torque to 30 ± 3 ft-lbs. (36-45 Nm) D. Oil Drain Hose Assembly - Torque to 26 ± 3 ft-lbs.
ENGINE 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 the key. Engage the parking brake. 2. Disconnect the battery. 3. Close the fuel supply valve (Figure 26). Figure 26 4. Remove the engine guard. 6. Remove the hydrostatic drive belt from the engine pulley see “Hydrostatic Drive Belt Removal,” chapter 7, page 7-9. 7. Disconnect the chassis wire harness from the main engine wire harness (Figure 27).
ENGINE Kawasaki Engine Removal (Cont.) 8. Disconnect the red (B+) wire from the starter (Figure 28). Figure 28 9. Disconnect the black engine ground wire (Figure 29).
ENGINE Kawasaki Engine Removal (Cont.) 10. Disconnect the fuel supply line at the fuel filter (Figure 30). Figure 30 11. Disconnect the throttle cable see “Throttle Cable Removal,” chapter 5, page 5-23. 12. Disconnect the choke cable see “Choke Cable Removal,” chapter 5, page 5-25. 13. Disconnect the clutch wire from the clutch. 14. Remove the clutch mounting bolt and washers. Slip the clutch off of the crankshaft.
ENGINE Kawasaki Engine Installation 1. Prepare the frame and secure any fuel lines or wire harness components. 2. Install the muffler and new exhaust gaskets. NOTE: Torque the muffler mounting bolts or nuts to 13 ft-lbs. (16-19 Nm). 3. Install the oil drain hose assembly (A) (Figure 31). NOTE: Torque oil drain hose (at engine block) to 26 ± 3 ft-lbs. (31-40 Nm). A D A Figure 31 4. Carefully lower the engine onto the frame. 5.
ENGINE Kawasaki Engine Installation (Cont.) 7. Torque the four engine mounting bolts to 30 ± 3 ft-lbs. (36-45 Nm). 8. Install the key and engine pulley onto the crankshaft. NOTE: Install the engine pulley with smaller diameter hub toward the engine. 9. Install the clutch onto the crankshaft ensuring that the slot in the clutch aligns with the tab on the clutch anchor. 10. Install the two spring washers and the clutch bolt (Figure 33). Figure 33 Engine 11. Torque the clutch bolt to 55 ± 6 ft-lbs.
ENGINE Kawasaki Engine Installation (Cont.) 17. Connect the black engine wire (Figure 34). Figure 34 18. Connect the red (B+) wire from starter (Figure 35). Figure 35 NOTE: Torque nut on starter relay to 32 ± 3 in-lbs. (3-4 Nm).
ENGINE Kawasaki Engine Installation (Cont.) 19. Connect the chassis wire harness to the main engine wire harness (Figure 36). Figure 36 20. Connect the fuel supply line to the fuel filter. 21. Install the engine guard. 22. Open the fuel supply valve. 23. Fill crankcase with approved oil and verify proper oil level. Engine 24. Connect the battery terminals. 25. Verify proper function of the unit. NOTE: Verify engine RPM is set to 3750 ± 50 RPM.
HYDROSTATIC DRIVE SYSTEM Table of Contents Hydrostatic Drive Exploded View.......................................................................................7-2 Using the Drive Wheel Release Valves (Bypass Valves)................................................. 7-3 Adjusting the Motion Control Linkage (Neutral Setting)..................................................7-4 Tracking Adjustment...........................................................................................................
HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Exploded View (2000 Series Shown) C B A D F E Figure 1 A. Right Hydrostatic Drive Transmission B. Bypass Lever C. Hydraulic Fluid Reservoir D. Bypass Lever E. Left Hydrostatic Drive Transmission F. Cross Shaft NOTE: Torque sequence of transmission mounting bolts is critical, see Chapter 7, page 7-16.
HYDROSTATIC DRIVE SYSTEM 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 park brake. 2. Locate the bypass levers behind the seat near the drive wheels, on the left and right side of the frame (Figure 2). 3.
HYDROSTATIC DRIVE SYSTEM Adjusting the Motion Control Linkage (Neutral Setting) Located on either side of the machine, below the seat are the pump control linkages. Rotating the end nut (A) (Figure 3) with 1/2 in. deep socket wrench allows fine tuning adjustments so that the machine does not move in neutral. Any adjustments should be made for neutral positioning only. WARNING! Engine must be running and drive wheels must be turning so adjustments can be performed.
HYDROSTATIC DRIVE SYSTEM Adjusting the Motion Control Linkage (Neutral Setting) (Cont.) NOTE: Ensure that the parking brake is engaged and that the motion control levers are in neutral (out) to start the engine, the operator does not have to be present in the seat. 6. Run the machine for 5 minutes with the drive levers in the full forward speed to bring hydraulic fluid up to operating temperature. 7. Bring the motion control levers into the NEUTRAL position.
HYDROSTATIC DRIVE SYSTEM Adjusting the Motion Control Linkage (Neutral Setting) (Cont.) 11. Shut off the machine. 12. Remove the jumper wire from the wire harness and plug the connector into the seat switch. 13. Lower the unit. 14. Raise the mower deck and install the height-of-cut pin. 15. Check for proper operation and ensure that the machine does not creep in neutral with the park brake disengaged.
HYDROSTATIC DRIVE SYSTEM Tracking Adjustment 1. Disengage the PTO switch. 2. Drive to an open, flat area and move the motion control levers to the neutral-lock position. 3. Move the throttle midway between the FAST and SLOW positions. 4. Move both motion control levers fully forward until they both hit the stops in the t-slot. 5. Observe which direction the machine tracks. 6. If the machine tracks to the right, insert a 3/16 in.
HYDROSTATIC DRIVE SYSTEM Purging Procedure Due to the effects air has on efficiency in hydrostatic drive applications, it is critical that it be 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.
HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Belt Removal 1. Stop the engine, wait for all moving parts to stop, and remove the key. Engage the parking brake. 2. Raise and support the unit so that the drive wheels are off the ground. 3. Remove the mower belt from the clutch see “Mower Belt Replacement, chapter 8, page 8-5. 4. Using a 9/16 socket on the idler pulley, turn the nut clockwise (from the bottom), starting in the 3 O’clock position to remove tension on the belt (Figure 6).
HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Belt (Cont.) Removal (Cont.) NOTE: If the drive idler spring is removed, ensure proper spring orientation on re-installation (Figure 7) Figure 7 5. Slip the drive belt off of the idler pulleys. 6. Carefully, remove the drive belt from the hydrostatic drive pulleys. NOTE: Inspect the belt for excessive wear, damage, or cracking, replace if necessary.
HYDROSTATIC DRIVE SYSTEM Idler Spring and Hydrostatic Drive Belt B B A Figure 8 A. Engine Pulley B. Hydrostatic Transmission Pulleys Installation 1. Route the hydrostatic drive belt around the engine pulley. 2. Carefully route the drive belt around the two hydrostatic transmission pulleys. Drive 3. Place the drive belt on the inside of the right idler pulley.
HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Belt Installation (Cont.) 4. Place the idler spring through the frame slot and onto the idler pulley stud (if previously removed). NOTE: Ensure proper orientation with the hook openings facing away from the idler pivot. 5. Using a 9/16 socket on the idler pulley, turn the nut clockwise (from the bottom of the machine), starting in the 3 O’clock position to remove tension on the belt (Figure 9). B F E D C A Figure 9 A. Idler Pulley B. Idler Spring Post C.
HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Transmission B A C B C Figure 10 A. Cross Shaft B. Front and Rear Mounting Bolts C. Axle Horn Bolts Removal 1. Stop the engine, wait for all moving parts to stop, and remove the key. Engage the parking brake. 2. Disconnect the battery cables. 3. Remove the left and right consoles, see “Console Removal,” chapter 5, page 5-8. 4. Remove the seat see “Seat Removal,” chapter 5, page 5-16. 5. Remove the fuel tank see “Fuel Tank Removal,” chapter 5, page 5-17.
HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Transmission Removal (Cont.) 8. Disconnect the motion control linkage from the transmission (Figure 11). Figure 11 9. Disconnect the bypass arm (Figure 12).
HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Transmission Removal (Cont.) 10. Disconnect the lower brake linkage from the transmission (Figure 13). Figure 13 11. Disconnect the hydraulic fluid hose from the top of the transmission. 12. Remove the bolt that connects the transmission to the cross shaft (A) (Figure 14). 13. Remove the two front and rear hydro mounting bolts (B) (Figure 14). B Drive A C B C Figure 14 A. Cross Shaft B. Front and Rear Mounting Bolts C. Axle Horn Bolts 14.
HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Transmission B A C B C Figure 15 A. Cross Shaft B. Front and Rear Mounting Bolts C. Axle Horn Bolts Installation 1. Lift and support the transmission, and install the two axle horn bolts, washers, and nuts as shown. Do not fully tighten the nuts at this time (Figure 15). 2. Align the cross shaft and install the bolt through the transmission (Figure 16) into the cross shaft (A) (Figure 15). Do not tighten at this time.
HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Transmission Installation (Cont.) 3. Install the front and rear hydro mounting bolts, washers, and nuts (B) (Figure 15). Do not tighten at this time. NOTE: The proper torque sequence, as outlined below, is critical in avoiding damage to the hydrostatic transmission and the frame. 4. Tighten the cross shaft bolt and torque to 43 ± 5 ft-lbs. (52-65 Nm). 5. Tighten the rear hydro mounting bolt. 6. Tighten the two axle horn bolts. 7.
HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Transmission Installation (Cont.) 10. Connect the bypass arm (Figure 18). Figure 18 11. Connect the motion control linkage (Figure 19). Figure 19 NOTE: Attach the motion control linkage as shown with the offset toward the outside of the machine.
HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Transmission Installation (Cont.) 12. Carefully install the drive belt see “Drive Belt Installation,” chapter 7, page 7-11. 13. Install the mower belt, see “Mower Belt Replacement,” chapter 8, page 8-5. 14. Verify that the hub nut is properly torqued, torque to 250 ± 10 ft-lbs. (325-353 Nm). 15. Install the drive wheel and torque the lug nuts, torque to 95 ± 5 ft-lbs. (122-135 Nm). 16. Add hydraulic oil to the reservoir to the FULL COLD line. 17.
MOWER DECK Table of Contents Mower Deck System Exploded View................................................................................ 8-2 Mower Belt (Side Discharge Mower Decks)..................................................................... 8-5 Mower Belt (Rear Discharge Mower Decks)..................................................................... 8-8 Mower Belt Replacement (Rear Discharge Mower Decks)..............................................8-9 Mower Deck..............................
MOWER DECK 1500 and 2000 Series, Side Discharge (48 in. Deck Shown) F C G E D A B Figure 1 A. Discharge Baffle B. Anti-Scalp Roller C. Belt Cover D. Deflector Assembly 8-2 Table of Contents E. Idler Pulley F. Mower Belt G.
MOWER DECK 2500 Series, Side Discharge (60 in. Deck Shown) N G G J A L E M D K H B C F Deck I Figure 2 A. Idler Arm Assembly B. Spindle Assembly C. Spindle Shaft D. Bearing Shield E. Pulley F. Rotary Blade G. Flat Idler Pulley H. Discharge Baffle I. Anti-Scalp Roller J. RH Belt Cover K. LH Belt Cover L. Rubber Deflector Assembly M. Flanged Idler Pulley N.
MOWER DECK Rear Discharge Mower Deck G J F E E H C K I A B T L D M N M M O Figure 3 A. Idler Assembly (Counter Rotating Belt) B. Double Cord Sheave C. Reverse Drive Sheave (Left Hand Thread) D. Spindle Shaft E. Idler Pulley F. Belt Cover G. Counter Rotating Belt H. Idler Arm Assembly 8-4 Table of Contents I. Idler Pulley J. Mower Belt K. Belt Cover L. Flat Idler Pulley M. Anti-Scalp Roller N. Rotary Blade O.
MOWER DECK Mower Belt (Side Discharge Mower Decks) Replacement 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 terminals. 3. Lower the mower deck to the 3 in. (76 mm) height-of-cut position. 4. Remove the mower belt covers. 5. Remove the spring tension from the idler pulley.
MOWER DECK Mower Belt (Side Discharge Mower Decks) Replacement (Cont.) 1 2 B A C 3 4 D E Figure 5 A. Spring Removal Tool B. Idler Spring C. Mower Deck Post D. Idler Arm E. Mower Belt NOTE: For 2500 series mower decks, use a 3/8 in. breaker bar in the square hole in the idler arm. Turn the breaker bar counter clockwise to remove the tension from the mower belt. A BC D E Figure 6 A. Clutch Pulley B. Mower Belt C. Spring Loaded Idler Pulley 8-6 Table of Contents D. Ratchet E.
MOWER DECK Mower Deck (Side Discharge Mower Decks) Replacement (Cont.) 6. Remove the belt from the deck pulleys and the clutch pulley. 7. Route the new belt around the clutch pulley and deck pulleys (Figures 5 and 6). 8. Install the idler spring (if previously removed). NOTE: Make sure to seat the spring ends in the anchor grooves. 9. Install the belt covers. Deck 10. Connect the battery terminals and verify proper function of the unit.
MOWER DECK Mower Belt (Rear Discharge Mower Decks) Replacing the Counter Rotating Belt 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 terminals. 3. Lower the mower deck to the 3 in. (76 mm) height-of-cut position. 4. Lift up the floor pan to gain access to the center pulley. 5. Remove the mower belt cover. 6.
MOWER DECK Mower Belt Replacement (Rear Discharge Mower Deck) 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 terminals. 3. Lower the mower deck to the 3 in. (76 mm) height-of-cut position. 4. Remove the mower belt covers. . 5. Remove the counter rotating belt, see “Replacing the Counter Rotating Belt,” chapter 8, page 8-8. 6. Using a 3/8 in.
MOWER DECK Mower Belt Replacement (Rear Discharge Mower Deck) (Cont.) Figure 9 9. Install the idler spring if previously removed. 10. Install the counter rotating belt, see “Replacing the Counter Rotating Belt,” chapter 8, page 8-8. 11. Install the belt covers. 12. Connect the battery terminals and verify proper function of the unit.
MOWER DECK 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 the key. Engage the parking brake. 2. Disconnect the battery terminals. 3. Remove the height adjustment pin and lower the deck to the ground. 4. Place the height adjustment pin in the 3 in. (76 mm) height-of-cut position. 5. Remove the mower belt covers. 6. Remove the mower belt, see “Mower Belt Replacement,” chapter 8, page 8-5. 7.
MOWER DECK Mower Deck Removal (Cont.) 8. Remove the two bolts and nuts on each side of the machine (Figure 11). A A B Figure 11 A. Remove the Nuts and Bolts here B. Remove the Nuts and Bolts here 9. Slide the deck out toward the right side of the machine.
MOWER DECK Mower Deck Installation 1. Place the deck on the ground on the right side of the machine. 2. Carefully slide the deck into position under the machine. 3. Connect the two bolts and nuts on each side of the machine (A) (Figure 12). 4. Connect the two bolts and nuts on the front of the plate under the footrest (B) (Figure 12).
MOWER DECK Mower Deck Installation (Cont.) 5. Install the mower belt see “Mower Belt Replacement,” chapter 8, page 8-5. 6. Install the mower belt covers. 7. Raise the deck to the 3 in. (76 mm) height-of-cut position and check for deck level see “Leveling the Mower Deck,” chapter 8, page 8-19. 8. Connect the battery terminals and verify proper function of the unit. 9. For 60 in. Decks Only: -Raise the deck to the transport position (5 in. or 127 mm).
MOWER DECK Mower Spindle 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 the key. Engage the parking brake. 2. Disconnect the battery terminals. 3. Remove the mower belt covers. 4. Remove the mower belt, see “Mower Belt Replacement,” chapter 8, page 8-5. 5. Remove the cutting blade. 6. Remove the six self-tapping bolts that secure the spindle to the deck. Deck 7.
MOWER DECK Mower Spindle Installation NOTE: Ensure that the underside of the deck is clean before proceeding with the spindle installation. 1. Carefully position the spindle against the deck and align the mounting holes. 2. Install six spindle mounting screws. Torque to 12 ± 2 ft-lbs. (14-19 Nm). NOTE: Spindle mounting screws are thread forming. Do not reuse spindle mounting screws. 3. Install the belleville washer with the concave side facing the cutting blade, install the blade bolt.
MOWER DECK Mower Spindle J I E C B A D F G H Figure 14 A. Bearing and Spacer Assembly B. Taptite Screw C. Bearing Shield D. Spindle Shaft E. Pulley F. Rotary Blade G. Belleville Washer H. Blade Bolt I. Washer J. Lock Nut Disassembly (Refer to Figure 14) 1. Clamp the spindle for service by placing the spindle shaft in a vise. Deck 2. Remove the nut (J) and washer (I) from the top of the pulley. 3. Remove the pulley (E). 4. Remove the shaft (D) from the spindle housing. 5.
MOWER DECK Mower Spindle Assembly 1. Inspect the inside of the spindle housing for wear or damage. 2. Press the top bearing into the spindle housing by pressing equally on the inner and outer race. NOTE: Ensure that the bearing seats against the shoulder in the spindle housing. 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.
MOWER DECK Leveling the Mower Deck 1. Park the machine on a flat level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove the key. 2. Disconnect the battery terminals. 3. Check to ensure that all tires are properly inflated and adjust as necessary. 4. Position the mower deck in the transport position. 5. Carefully rotate the blades so that they are parallel to the rear of the deck (Figure 15). B A B B C C Figure 15 C.
MOWER DECK Leveling the Mower Deck 6. Measure between the outside cutting edges (blade tips) and the flat surface. If all measurements are not within 3/16 in. (5 mm), an adjustment is required and this procedure should be continued. 7. Carefully rotate the blades so that they are perpendicular to the rear of the deck (Figure 16). Ensure the front blade tip is lower than the rear blade tip as indicated in the Block Height and Rake Table. B A C A B C C B Figure 16 A. Blades Front to Rear B.
MOWER DECK Leveling the Mower Deck (Cont.) 10. Place two blocks (see Block Height and Rake table) under the rear edge of the cutting deck skirt, one on each side of the cutting deck. 11. Set the height-of-cut lever to the 3 in. (76 mm) position. 12. Place two blocks under each side of the front edge of the deck, but not under the anti-scalp roller brackets or welds (Figure 17). A A BA AB Figure 17 A. Block 7.3 cm (2.87 in.) B. Welds Block Height and Rake Table All Mower Decks Block Height Rake 7.
Leveling the Mower Deck (Cont.) MOWER DECK 12. Carefully rotate the blades side-to-side so that they are parallel to the rear of the deck. 13. Loosen the leveling adjustment lock nuts (Figure 18) on all four corners so that the deck is sitting squarely on all four blocks. B C D A Figure 18 A. Leveling Adjustment Lock Nuts B. Deck Lift Arm C. Deck Hanger D. Chain 14. Remove any slack from the deck hangers and make sure the deck lift foot lever is pushed back against the stop. 15.
MOWER DECK Electric PTO Clutch 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 the key. 2. Disconnect the battery terminals. 3. Raise and support the unit so that the drive wheels are off the ground. 4. Remove the mower belt, see “Mower Belt Replacement,” chapter 8, page 8-5. 5. Disconnect the clutch wire connector from the clutch (Figure 19). Figure 19 Deck 6. Remove the clutch mounting bolt and washers.
MOWER DECK Electric PTO Clutch Installation 1. Install the clutch onto the crankshaft ensuring that the slot in the clutch aligns with the tab on the clutch anchor (Figure 20). Figure 20 2. Install the two spring washers and clutch bolt (Figure 21). Figure 21 A. Clutch B. Spacer C. Spring Washers D. Clutch Bolt 3. Torque the clutch bolt to 55 ± 6 ft-lbs. (66-83 Nm). 4. Connect the clutch power wire to the clutch.
MOWER DECK Electric PTO Clutch Installation (Cont.) NOTE: Ensure wire harness is properly routed to avoid contact with the mower belt or drive belt (Figure 22). Figure 22 5. Connect the battery terminals. Deck 6. Lower the unit and verify proper function.
ELECTRICAL Table of Contents Electrical System Exploded View....................................................................................... 9-2 General Information............................................................................................................. 9-3 Fuse Block and Fuses..........................................................................................................9-4 Testing..........................................................................................
ELECTRICAL Electrical System Exploded View D A E C B G I H L J F K H Figure 1 A. Ignition Key B. Ignition Switch C. PTO Switch D. Hourmeter E. 12V Power Port F. Wire Harness 9-2 Table of Contents G. Solenoid H. Neutral Switches I. Park Brake Switch J. Clutch Connector K. Fuse Block L.
ELECTRICAL 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.
ELECTRICAL Fuse Block and Fuses Figure 2 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. 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 (Figure 3). Bad Good Figure 3 2.
ELECTRICAL Key/Ignition Switch Figure 4 The ignition switch makes the proper connections for the starter, safety circuits, and accessories. Detents inside the switch control the three switch positions: OFF, RUN, and START. The START position is spring loaded so that it automatically returns to the RUN position when released.
ELECTRICAL Key/Ignition Switch (Cont.) Testing 1. Remove the control panel from the right console. 2. Disconnect the ignition switch from the wire harness. 3. Using a digital multi-meter set to the OHM or Continuity setting, verify that continuity exists between the terminals listed for each switch position. 4. 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.
ELECTRICAL Hourmeter Figure 6 The hourmeter records hours of operation when the ignition key is ON and the PTO switch is ON. Testing 1. With the ignition switch in the RUN position and the PTO switch closed (ON), verify battery voltage and ground to the hourmeter. 1. Hour 2. PTO 3. Parking Brake Electrical Figure 7 4. Neutral 5. Operator Presence Switch 6.
ELECTRICAL Operator Presence Switch (Seat Switch) NORMALLY OPEN OCCUPANT SWITCH Figure 8 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 neutral switches. NOTE: The operator presence switch is part of the seat assembly. Testing 1. Disconnect the wire harness from the Operator Presence Switch, located on the bottom of the seat assembly. 2.
ELECTRICAL Neutral Switch - Left and Right Figure 9 Figure 10 The neutral switch is a single pole plunger type switch (normally open) with two terminals. When the plunger is depressed, the circuit closes and there is continuity between the terminals. Electrical Motion Control Levers in neutral position (OUT), the switch will have continuity (closed). Motion Control Levers in the operating position (IN), the switch will NOT have continuity (open).
ELECTRICAL Parking Brake Switch Figure 11 Figure 12 The parking brake switch is a single pole plunger type switch (normally open) with two terminals. When the plunger is depressed (parking brake ON), the circuit closes and there is continuity between the terminals. This allows battery voltage to flow to the rest of the safety interlock system. Parking Brake ON, the switch should have continuity (closed). Parking Brake OFF, the switch should NOT have continuity (open).
ELECTRICAL Starter Solenoid Figure 13 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. Testing 1. Disconnect the solenoid from the wiring harness. 2. With a multi-meter set to the OHM or Continuity setting, check to ensure that terminals C and D are open (no continuity) (Figure 14). Electrical 3.
ELECTRICAL PTO Switch Figure 15 The PTO switch provides battery voltage from the ignition switch to the PTO clutch. As part of the safety interlock system, the PTO switch will prevent the engine from cranking/starting when in the ON position by preventing the starter solenoid from grounding through the kill relay. NOTE: The engine will not crank over when the PTO switch is in the ON position.
ELECTRICAL PTO Switch (Cont.) 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). 1 2 3 5 4 9 87 Figure 16 4.
ELECTRICAL Electric PTO Clutch The PTO clutch electronically controls the engagement and disengagement of the PTO pulley (deck belt). The PTO clutch is composed of three major components: -field -clutch plate -friction plate The clutch plate always turns with the engine (crankshaft). The field is a coil of wire on an iron core which becomes an electromagnet when power is applied. The friction plate is the only piece that moves vertically on the crankshaft.
ELECTRICAL Electric PTO Clutch (Cont.) Coil Resistance Measurement Figure 17 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 resistance (OHMs setting). 4. Connect the meter lead wires to the terminals in the clutch connector. 5. See the PTO Clutch Electrical Specifications chart. AMP Draw Continuity to Ground Series 2.
ELECTRICAL Electric PTO Clutch (Cont.) PTO Clutch Continuity to Ground Check 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 resistance (OHM setting). 4. Connect one multi-meter lead to the engine, chassis or battery ground. Connect the other multi-meter lead to each of the clutch connector terminals. 5.
ELECTRICAL Electric PTO Clutch (Cont.) 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. A B C D Figure 19 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.
ELECTRICAL TVS Diode Figure 20 The TVS Diode protects the electrical system from current surges caused by PTO engagement and disengagement. Testing No testing procedure available. If the diode is suspected to be faulty, replace the diode.
ELECTRICAL Electrical Wire Diagram - Toro Engines (1500 Series) Figure 21 Digital Edition - TITAN® HD Service Manual January 2018 9-19 Table of Contents
ELECTRICAL Wire Diagram - Kohler Engines (2000 Series) Figure 22 9-20 Table of Contents Digital Edition - TITAN® HD Service Manual January 2018
ELECTRICAL Electrical Wire Diagram - Kawasaki Engines (2500 Series) Figure 23 Digital Edition - TITAN® HD Service Manual January 2018 9-21 Table of Contents
LCE/ Resi dent i alPr oduct s
