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HYDROSTATIC DRIVE SYSTEM

5-3

Toro TITAN 2014 Service Manual

Hydro-Gear ZT-3100 Hydrostatic Transaxles

(Fig. 058)

Fig. 058

PICT-1002

Fig. 059

fig. 51 G020323

A. Expansion reservoir

C. Engine

B. Full cold line

A
B

Lubrication

Toro HYPR-OIL

500 or 20w50 Engine Oil

Oil Capacity ZT-3100

77.23 fl. oz. (2284ml) each (not including reservoir or hose volume)

Oil Level Check

Check expansion reservoir and if necessary add the specified oil to the

FULL COLD

line. See illustration below. Also see the Hydro-Gear ZT-2800 / ZT-3100 service manual

(BLN-52441).

Fluid Change Interval

After the First 50 hours - change the oil and filters for the hydraulic system and bleed

the system.

Every 400 Hours - change the oil and filters for the hydraulic system and bleed the

system.

Checking the Hydraulic Oil Level

Summary of Contents for titan mx

Page 1: ...2014 TITAN ZX MX Service Manual Residential Products ...

Page 2: ......

Page 3: ... and repair instructions TITAN model year 2014 is covered in this manual The manual may also be specified for use on later model products The hydrostatic transaxle is a sophisticated component Maintain strict cleanliness control during all stages of service and repair Cover or cap all hose ends and fittings whenever they are exposed Even a small amount of dirt or other contamination can severely d...

Page 4: ...ABOUT THIS MANUAL THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 5: ... MX 3 4 Front Axle Caster Fork Bearing Disassembly 3 4 Front Axle Caster Fork Bearing Assembly 3 4 Front Axle Caster Fork Bearing Service ZX 3 5 Front Axle Caster Fork Bearing Disassembly 3 5 Front Axle Caster Fork Bearing Assembly 3 5 Caster Wheel Bushing and Bearing Service MX 3 6 Caster Wheel Bushing and Bearing Disassembly 3 6 Caster Wheel Bushing and Bearing Assembly 3 6 Caster Wheel and Bush...

Page 6: ...nt 4 1 PTO Clutch Clutch Stop Mounting All Models 4 1 Engine Mounting Exploded View 4 2 Engine Mounting Kawasaki Engine 4 2 Engine Removal 4 3 Engine Installation 4 4 5 Hydrostatic Drive System Hydrostatic Drive Exploded View 5 1 Hydrostatic Drive Belt Routing 5 2 Hydro Gear ZT 3100 Hydrostatic Transaxles 5 3 Checking the Hydraulic Oil Level 5 3 Neutral Adjustment 5 4 Forward Tracking Adjustment 5...

Page 7: ...rm Inspection 6 13 Idler Arm Removal 6 13 Idler Arm Installation 6 13 Checking for Bent Blades 6 14 Mower Deck Leveling 6 15 Checking Side to Side Level 6 16 Checking the Front to Rear Blade Slope 6 16 Leveling the Mower Deck 6 17 7 Electrical Chassis Switches 7 1 Key Ignition Switch 7 1 Purpose 7 1 Location 7 1 How It Works 7 1 Testing 7 1 PTO Switch 7 2 Purpose 7 2 Location 7 2 How It Works 7 2 ...

Page 8: ...ement 7 11 PTO Clutch Electrical Specifications 7 11 PTO Clutch Continuity to Ground Check 7 12 Measuring Clutch Current Draw 7 12 PTO Clutch Electrical Specifications 7 12 PTO Circuit Operation 7 12 PTO Circuit Schematic 7 13 PTO Clutch Replacement 7 14 PTO Clutch Removal 7 14 PTO Clutch Installation 7 14 Hour Meter 7 15 Purpose 7 15 Location 7 15 How It Works 7 15 Testing 7 15 Fuses 7 16 Locatio...

Page 9: ...ver remove the fuel cap or add fuel when the engine is running Always use approved labeled containers for storing or transporting fuel and lubricants Avoid asphyxiation Never operate an engine in a confined area without proper ventilation Avoid injury from batteries Battery acid is poisonous and can cause burns Avoid contact with skin eyes and clothing Battery gases can explode Keep cigarettes spa...

Page 10: ...SAFETY INFORMATION 1 2 Toro TITAN 2014 Service Manual 1 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 11: ...g Loctite degree of lubrication on the fastener presence of a prevailing torque feature hardness of the surface underneath of the fastener s head or similar condition which affects the installation As noted in the following tables torque values should be reduced by 25 for lubricated fasteners to achieve the similar stress as a dry fastener Torque values may also have to be reduced when the fastene...

Page 12: ... 8 24 UNF 17 2 18 2 24 3 35 3 47 4 50 4 68 5 7 16 14 UNC 27 3 27 3 37 4 50 5 68 7 70 7 68 9 7 16 20 UNF 29 3 29 3 39 4 55 5 75 7 77 7 104 9 1 2 13 UNC 30 3 48 7 65 9 75 8 102 11 105 10 142 14 1 2 20 UNF 32 3 53 7 72 9 85 8 115 11 120 10 163 14 5 8 11 UNC 65 10 88 12 119 16 150 15 203 20 210 20 285 27 5 8 18 UNF 75 10 95 15 129 20 170 15 230 20 240 20 325 27 3 4 10 UNC 93 12 140 20 190 27 265 25 35...

Page 13: ...6 X 2 0 166 15 ft lb 225 23 N m 229 23 ft lb 310 31 N m M20 X 2 5 325 33 ft lb 440 45 N m 450 36 ft lb 610 62 N m Note Reduce torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a lubricant such as oil graphite or thread sealant such as Loctite Note Torque values may have to be reduced when installing fasteners into threade...

Page 14: ... 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 8 80 10 ft lb 108 14 N m For steel wheels and non lubricated fasteners Thread Cutting Screws Zinc Plated Steel Thread Size Threads per Inch Baseline Torque Type A Type B No 6 18 20 20 5 in lb No 8 15 18 ...

Page 15: ...703125 17 859 7 32 0 21875 5 556 23 32 0 71875 18 256 15 64 0 234375 5 953 47 64 0 734375 18 653 1 4 0 2500 6 350 3 4 0 7500 19 050 17 64 0 265625 6 747 49 64 0 765625 19 447 9 32 0 28125 7 144 25 32 0 78125 19 844 19 64 0 296875 7 541 51 64 0 796875 20 241 5 16 0 3125 7 541 13 16 0 8125 20 638 21 64 0 328125 8 334 53 64 0 828125 21 034 11 32 0 34375 8 731 27 32 0 84375 21 431 23 64 0 359375 9 128...

Page 16: ...Square Centimeters Hectare 2 59 0 0929 6 452 0 4047 Volume Cubic Yards Cubic Feet Cubic Inches Cubic Meters Cubic Meters Cubic Centimeters 0 7646 0 02832 16 39 Weight Tons Short Pounds Ounces Metric Tons Kilograms Grams 0 9078 0 4536 28 3495 Pressure Pounds Sq In Kilopascal 6 895 Work Foot pounds Foot pounds Inch pounds Newton Meters Kilogram Meters Kilogram Centimeters 1 356 0 1383 1 152144 Liqui...

Page 17: ...d steel Spindle Housings Die cast aluminum Die cast aluminum Die cast aluminum Spindle Shaft Bearings Three 25mm diameter spindles in permanently lubed ball bearings Three 25mm diameter spindles in permanently lubed ball bearings Three 25mm diameter spindles in permanently lubed ball bearings Blade Tip Speed 18 800 ft min 3700 RPM 18 644 ft min 3700 RPM 18 908 ft min 3700 RPM Cutting Height 1 5 to...

Page 18: ...rge Deck Construction Material 10 gauge fabricated steel 10 gauge fabricated steel Spindle Housing Die cast aluminum Die cast aluminum Spindle Shaft Bearings Three 25mm diameter spindles in permanently lubed ball bearings Three 25mm diameter spindles in permanently lubed ball bearings Blade Tip Speed 18 644 ft min 3700 RPM 18 908 ft min 3700 RPM Cutting Height 1 5 to 4 5 13 Positions 1 5 to 4 5 13...

Page 19: ... 74848 ZX 5400 INTL Kawasaki 23hp High Idle 3000 100 RPM 74851 ZX 4800 Kawasaki 21 5hp High Idle 3600 100 RPM 74852 ZX5400 Kawasaki 23hp High Idle 3600 100 RPM 74853 ZX 6000 Kawasaki 24hp High Idle 3600 100 RPM 74855 ZX 4800 Kawasaki 21 5hp High Idle 3600 100 RPM 74882 MX 5400 Kawasaki 23hp High Idle 3600 100 RPM 74883 MX 6000 Kawasaki 24hp High Idle 3600 100 RPM ...

Page 20: ...n reservoir and if necessary add the specified oil to the FULL COLD line See illustration below Also see the Hydro Gear ZT 2800 ZT 3100 service manual BLN 52441 Fluid Change Interval After the First 50 hours change the oil and filters for the hydraulic system and bleed the system Every 400 Hours change the oil and filters for the hydraulic system and bleed the system Checking the Hydraulic Oil Lev...

Page 21: ...tion plate is located on the frame near the engine on the RH side of the unit Fig 003 Grease and Lubrication Point Grease Type No 2 general purpose lithium base grease A grease fitting is located on each of the front wheel hubs The front wheel hubs should be greased every 25 hrs Fig 004 Fig 004 PICT 3006 Fig 003 PICT 2057 ...

Page 22: ...CHASSIS 3 2 Toro TITAN 2014 Service Manual 3 Fig 005 PICT 3027 Frame and Chassis Exploded View Fig 005 A 35 ft lbs 47 Nm C 5 ft lbs 7 Nm B 17 ft lbs 23 Nm D 50 in lbs 4 Nm B B A C B B B B D D ...

Page 23: ...ll ROPS mounting fasteners 2 Torque the 4 fasteners A to specification 35 ft lbs 47 Nm 3 Torque the 4 fasteners B to specification 25 ft lbs 34 Nm 4 Torque the 2 fasteners C to specification 75 ft lbs 101 Nm 5 Torque the 4 fasteners D to specification 35 ft lbs 47 Nm Other Torque Values E Seat Belt Mounting Fasteners 75 ft lbs 101 Nm A A B E D D B C ...

Page 24: ...fely lower unit and verify proper function Fig 007 Fig 007 PICT 3002 Front Axle Caster Fork Bearing Service MX Front Axle Caster Fork Bearing Disassembly 1 Safely raise and support unit so front wheels are off the ground 2 Remove dust cap A 3 Support under caster wheel and remove the fastener B 4 Remove caster fork C from frame hub Inspect the caster fork shaft and thrust washer D for excessive we...

Page 25: ...bearings from the frame hub 6 Using an appropriate punch tap out and remove the UPPER bearings from the frame hub 7 Properly clean and inspect the front axle bearing area Front Axle Caster Fork Bearing Assembly 1 Use a proper bearing installation tool to install and fully seat new upper and lower bearings into the frame hub 2 Install spacer E and thrust washer D onto the caster fork shaft 3 Instal...

Page 26: ... 6 Lubricate bushings bearings through grease fitting with No 2 general purpose lithium base grease 7 Safely lower unit and verify proper function Fig 009 Fig 009 PICT 3003 Caster Wheel Bushing and Bearing Service MX Caster Wheel Bushing and Bearing Disassembly 1 Safely raise and support unit so front wheels are off the ground 2 Support under caster wheel and remove the nut bolt fastener A 3 Remov...

Page 27: ...and inspect the front wheel hub area Caster Wheel Bushing Assembly 1 Lightly lubricate bushings C and wheel spanner B with No 2 general purpose lithium base grease Fill center of wheel hub with grease 2 Install the 2 bushings C into front wheel hub making sure they are fully seated 3 Install wheel spanner B into the front wheel assembly 4 Install front wheel assembly into the front caster 5 Instal...

Page 28: ... screws that secure the control panel to the RH fender 4 Verify choke cable throttle cable and wiring are properly routed 5 Connect battery terminals and lower seat Fig 011 Fig 011 PICT 2061 Pod Fender Service Pod Fender Removal RH 1 Raise seat and disconnect battery terminals 2 Remove the 4 screws securing control panel A to RH fender Move control panel inward towards the center of the unit 3 Rem...

Page 29: ... from fuel tank 3 Install LH fender assembly onto unit frame Use care while installing LH fender as the fuel tank neck slips through the grommet 4 Install fuel cap 5 Install the 3 screws A that secure the fender to the unit frame and torque to specification 7 ft lbs 9 Nm 6 Connect battery terminals and lower seat Fig 013 Fig 012 PICT 2065 4 Remove fuel cap from fuel tank 5 Lift LH fender assembly ...

Page 30: ...ank retaining rod B and remove it from the chassis 5 Remove the 2 bolts and nuts C that secure the seat support to the frame brackets 6 Note the location of and remove any cable ties loom clamps securing wiring cables to the seat support bar 7 Disconnect and properly secure the fuel vent line s from the top of the fuel tank assembly 8 Remove the seat support bar from the frame 9 The fuel tank is n...

Page 31: ...TAN 2014 Service Manual 3 Fuel Vent Line Routing Fuel Vent Line Routing ZX Models Fig 016 PICT 3048 Fuel Vent Line Routing MX Models Fig 017 PICT 3046 A Fuel supply line to fuel filter and pump B Vent line A B A B A B A B ...

Page 32: ...CHASSIS 3 12 Toro TITAN 2014 Service Manual 3 Fig 018 PICT 3047 Fuel Vent Line Routing CARB Models A Fuel supply line B Vent line A B A A B A B ...

Page 33: ... bolt B that secure the lower motion control damper eyelet to the control box Fig 019 Motion Control Damper Installation 1 Install the washer and upper damper eyelet to the actuator arm and torque the shoulder bolt A to specification 7 5 ft lbs 10 Nm 2 Install the lower damper eyelet to the Control Box and torque the nut B to specification 7 5 ft lbs 10 Nm 3 Install the fender pod as shown in this...

Page 34: ...or clarity and ease of service Motion Control Box Seat Pivot Removal 1 Raise seat disconnect battery terminals and remove the battery from the unit 2 Remove the 2 control handles 3 Disconnect the seat switch harness connection and remove seat switch harness from the routing clip on the Motion Control Box 4 Disengage the seat stop A from the seat support Remove the cotter pins B and seat pivot rod ...

Page 35: ... 024 PICT 3011 F G Fig 025 PICT 3012 11 Remove the 4 fasteners H that secure the Control Box to the frame 12 Remove the 2 nuts and 2 carriage bolts I that secure the Control Box to the frame Fig 025 H I 13 Remove the 2 bolts nuts J that secure the front control box and floor pan to the frame Remove the floor pan from the unit Fig 026 Fig 026 PICT 3013 14 The Motion Control Box is now loose and can...

Page 36: ...pecification H Bolts 7 ft lbs 10 Nm I Carriage Bolt Fasteners 14 ft lbs 18 Nm Fig 027 Fig 027 PICT 3010 Fig 029 PICT 3010 5 Install the parking brake linkage washer and pin and G Fig 030 Fig 030 PICT 3011 Fig 028 PICT 3013 J J H I 4 Install the motion control rod and clips and pins F Fig 029 3 Install the 2 bolts nuts J that secure the floor pan and front motion control bolt to the frame and torqu...

Page 37: ...ion and verify proper harness routing 12 Install the 2 control handles and torque the 4 fasteners to specification 30 ft lbs 40 Nm 13 Install the battery and battery cables 14 Verify proper function Fig 031 PICT 3014 Motion Control Actuator Arm Service Note The entire Control Box Motion control assembly does not need to be removed from the chassis to service the Actuator Arm assembly A The fenders...

Page 38: ...shers to the activator arm assembly E Be sure the 4 washers are positioned correctly Washer 1 Standard Pivot Washer Washer 2 Standard Pivot Washer Washer 3 Standard Pivot Washer Washer 4 Teflon Washer Fig 034 Fig 034 PICT 2085 3 Remove the actuator arm nut B and 2 washers 4 Remove the shoulder bolt C actuator arm D and the 2 washers from the activator arm E Fig 032 Fig 032 PICT 2082 5 Remove the a...

Page 39: ...t threads C 5 Tighten nut B until the control lever has an acceptable and safe resistance feel when moved from stop to stop Over tightening nut B may damage the Teflon washer and cause excessive resistance Under tightening nut B may cause the actuator arm to feel loose Fig 035 Fig 035 PICT 2082 B ...

Page 40: ...ll the control lever and torque the fasteners to specification 30 ft lbs 40 Nm 9 Perform the Neutral Adjustment and Forward Tracking Adjustment procedures on pages 5 4 and 5 5 Fig 036 Fig 036 PICT 3015 Washer 1 Standard Pivot Washer Washer 2 Standard Pivot Washer Washer 3 Standard Pivot Washer Washer 4 Teflon Washer A Shoulder bolt 7 5 ft lbs 10 Nm B Actuator arm nut C Actuator arm pivot bolt D Ac...

Page 41: ...uts C that secure the seat support to the frame brackets 8 Remove the seat support bar from the frame Fig 037 Seat Support Installation MX Shown 1 Position the Seat Support assembly into the unit frame 2 Install the 2 bolts and nuts C that secure the seat support to the frame brackets and torque to specification 17 ft lbs 23 Nm 3 Install the fuel tank retaining rod B and torque retaining bolt to s...

Page 42: ...m the PTO clutch See PTO Belt Replacement 48 54 60 Inch Deck on page 6 5 2 Remove the deck from the frame See Mower Deck Removal 48 54 60 Inch Deck on page 6 7 3 Remove the deck lift foot pedal center pivot bolt A 4 Remove the rear lift arm pivot bolt B 5 Remove the 2 HOC plate assembly mounting bolts C 6 Remove the HOC plate and foot lift assembly from the chassis Fig 039 G Fig 039 PICT 3029 A B ...

Page 43: ...t foot pedal center pivot bolt A 6 Install the rear lift arm pivot bolt B 7 Torque fasteners A B and C to specification 30 ft lbs 40 Nm 8 Install and level the deck as shown in Mower Deck Installation 48 54 60 Inch Deck on page 6 8 and Mower Deck Leveling on page 6 15 9 Install and properly route the PTO belt then install the PTO belt tensioner spring 10 Verify proper operation Fig 041 Fig 041 PIC...

Page 44: ...ide the brake bell crank H to one side and remove the bell crank from the frame 9 Inspect all linkage rods pivot points and bushings for excessive wear replace if necessary Parking Brake Linkage Service Parking Brake Linkage Removal 1 Tilt seat forward disconnect and remove the battery 2 Remove the LH control cover to access the parking brake handle area 3 Remove the parking brake pin and washer A...

Page 45: ...ction surface with a light coating of engine assembly lube 6 Install the parking brake handle into the motion control box and torque the mounting fastener B to specification 17 ft lbs 23 Nm 7 Install the parking brake linkage rod to the handle stud using the washer and clip A 8 Install the LH control cover and torque the 1 mounting fastener to specification 5 ft lbs 7 Nm 9 Install and connect the ...

Page 46: ...CHASSIS 3 26 Toro TITAN 2014 Service Manual 3 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 47: ... information please see the service information provided by the engine manufacturer PTO Clutch Clutch Stop Mounting All Models Fig 048 Fig 048 PICT 3024 A A C B D A Clutch stop bracket B PTO clutch C PTO clutch bolt apply Loctite 242 55 ft lbs 76 Nm D Drive pulley marked for orientation ...

Page 48: ... Mounting Exploded View Engine Mounting Kawasaki Engine Fig 049 Fig 049 PICT 3025 A PTO clutch bolt apply Loctite 242 55 ft lbs 76 Nm B Engine clutch stop mounting bolts Loctite 242 33 ft lbs 44 Nm C Muffler to engine fastener 13 ft lbs 17 5 Nm A B B C ...

Page 49: ...rankshaft 7 Remove the drive belt tensioner spring B Fig 050 8 Remove the belt from around the crankshaft drive pulley and remove the drive pulley from the engine crankshaft Make note of pulley orientation for assembly 9 If necessary remove rear engine guard 10 Remove the fasteners that secure the heat shield to the muffler and frame and remove the heat shield If necessary remove the muffler from ...

Page 50: ...lso secure the clutch stop bracket and stiffener tube to the frame See the exploded views for application and mounting location 8 In a cross pattern torque the 4 engine mounting bolts to specification 33 ft lbs 44 Nm 9 Install muffler and new muffler gaskets if necessary to the engine and torque muffler fasteners to specification 13 ft lbs 17 5 Nm 10 Install heat shield to the muffler mounting scr...

Page 51: ...he clutch stop bracket 18 Install and torque the PTO clutch bolt to specification 55 ft lbs 76 Nm 19 Install PTO belt onto PTO clutch Verify proper PTO belt routing see PTO Belt Replacement and Belt Routing on page 6 4 Install the PTO belt tensioner spring to the deck 20 Connect battery cables and verify engine oil level 21 Safely start engine and verify proper operation ...

Page 52: ...ENGINE 4 6 Toro TITAN 2014 Service Manual 4 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 53: ...ic Drive Exploded View Fig 056 Fig 056 PICT 2038 D Rear hydro mount 17 ft lbs 23 Nm E Outside hydro mount 17 ft lbs 23 Nm F 30 ft lbs 40 Nm A Lug nuts 80 ft lbs 108 Nm B Center support apply Loctite 242 17 ft lbs 23 Nm C Front hydro mount 17 ft lbs 23 Nm A E E F D D B C F ...

Page 54: ...HYDROSTATIC DRIVE SYSTEM 5 2 Toro TITAN 2014 Service Manual 5 Hydrostatic Drive Belt Routing Fig 057 Bottom View Rear View Fig 057 PICT 2039 ...

Page 55: ... oz 2284ml each not including reservoir or hose volume Oil Level Check Check expansion reservoir and if necessary add the specified oil to the FULL COLD line See illustration below Also see the Hydro Gear ZT 2800 ZT 3100 service manual BLN 52441 Fluid Change Interval After the First 50 hours change the oil and filters for the hydraulic system and bleed the system Every 400 Hours change the oil and...

Page 56: ...nstall a jumper wire across the harness terminals Fig 060 Note Jumping the seat switch is for testing adjustment procedures only 3 Safely start the engine and run at full RPM 4 Verify the motion control handles are in the outward neutral position 5 Release the parking brake and observe rear tire movement If the tire is creeping in either forward or reverse a neutral adjustment is required Fig 061 ...

Page 57: ...the RIGHT 1 Remove the LH side control cover 2 Turn the LH adjustment nut 1 full turn CLOCK WISE tightening the nut 3 Test drive unit and verify tracking 4 If unit still pulls to the right repeat steps 2 and 3 until unit tracks straight 5 Install the LH control cover and torque the fastener to specification 5 ft lbs 7Nm If the unit tracks or pulls to the LEFT 1 Remove the RH side control cover 2 T...

Page 58: ...ations it is critical that it is purged from the system This purge procedure should be implemented any time a hydrostatic system has been opened to facilitate maintenance any additional oil has been added to the system or a replacement transaxle has been installed Air creates inefficiency because its compression and expansion rate is higher than that of the oil in hydrostatic drive systems The res...

Page 59: ...t Installation 1 Properly route the belt around the 2 hydro input pulleys and 2 tensioner idler pulleys Fig 067 2 Install the drive pulley onto the crankshaft and hold in position Note The drive pulley is marked CLUTCH SIDE for proper installation Fig 068 C Washer E Spacer D Friction washer F 30 ft lbs 40 Nm composite G Arm Fig 066 PICT 2042 F F E D G F D E C Fig 067 PICT 2043 Fig 068 PICT 2044 ...

Page 60: ...spring to the deck See PTO Belt Replacement and Belt Routing on page 6 4 10 Safely lower unit and verify proper drive system function Fig 069 PICT 3034 5 Apply Loctite 242 to the PTO clutch bolt threads 6 Install the PTO clutch Be sure the PTO clutch stop bracket is properly engaged into the clutch slot Fig 070 Fig 070 PICT 3036 3 Install the drive belt around the drive pulley 4 Install the drive ...

Page 61: ...he brake linkage then remove the brake rod from the hydro arm 6 Remove the hydro bypass rod C retaining clip and washer then remove the rod from the unit 7 Remove the hydro control rod nut and bolt D Fig 071 8 Remove the drive belt tensioner spring Fig 072 Fig 071 PICT 3030 Fig 072 PICT 3034 D B C A 9 Slip the drive belt off the idler tensioner pulleys then off the appropriate hydro input pulley 1...

Page 62: ... support Remove support from the unit Fig 074 Fig 074 PICT 2048 12 Safely support hydro assembly in current position using a hydraulic floor jack Remove the 2 outer hydro mounting fasteners Fig 075 Fig 075 PICT 2049 Fig 076 PICT 2050 14 Remove the 1 rear hydro mounting fastener Fig 077 Fig 077 PICT 2051 15 Lower the hydro assembly then remove it from the frame ...

Page 63: ... eners and center support bolts Do not fully tighten at this time 4 Torque hydro mounting fasteners in sequence to specification and shown 1st Apply Loctite 242 to the hydro center support bolts Torque bolts to specification 17 ft lbs 23 Nm Fig 078 2nd Torque the 1 front hydro mount fastener to specification 17 ft lbs 23 Nm Fig 079 Fig 078 PICT 2048 Fig 079 PICT 2050 3rd Torque the 1 rear hydro mo...

Page 64: ...r routing Fig 083 7 Install and orient the drive belt tensioner spring as shown Fig 084 Fig 084 PICT 3034 4th Torque the 2 outside hydro mount fasteners to specification 17 ft lbs 23 Nm Fig 081 Fig 081 PICT 2049 5 Connect the hydro reservoir hoses at the hydro fitting Fig 082 Fig 082 PICT 2047 Fig 083 PICT 2043 ...

Page 65: ...olt D and torque to specification 17 ft lbs 23 Nm Fig 085 Fig 085 PICT 3030 D B C A 12 Install the rear wheels and torque lug nuts to specification 80 ft lbs 108 Nm 13 Connect battery terminals 14 Safely lower unit 15 Add 20w50 engine oil or Toro HYPR OIL 500 to the hydro reservoir FULL COLD mark 16 Perform the purging procedure as shown in this chapter 17 Perform the neutral and tracking adjustme...

Page 66: ...HYDROSTATIC DRIVE SYSTEM 5 14 Toro TITAN 2014 Service Manual 5 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 67: ...al 6 Mower Deck Exploded Views 48 Inch Deck Fig 086 Fig 086 PICT 3040 A Blade bolt 105 ft lbs 143 Nm B Washer concave side towards blade C Pulley Nut 105 ft lbs 143 Nm D 30 ft lbs 40 Nm E Spindle housing to deck bolts 14 ft lbs 19 Nm D D C B A E ...

Page 68: ... Service Manual 6 Fig 087 PICT 3041 54 Inch Deck Fig 087 A Blade bolt 105 ft lbs 143 Nm B Washer concave side towards blade C Pulley Nut 105 ft lbs 143 Nm D 30 ft lbs 40 Nm E Spindle housing to deck bolts 14 ft lbs 19 Nm D D C B A E ...

Page 69: ... Service Manual 6 60 Inch Deck Fig 088 Fig 088 PICT 3042 A Blade bolt 105 ft lbs 143 Nm B Washer concave side towards blade C Pulley Nut 105 ft lbs 143 Nm D 30 ft lbs 40 Nm E Spindle housing to deck bolts 14 ft lbs 19 Nm D D C B A E ...

Page 70: ...k the belts for wear Check the belts for cracks frayed edges burn marks or any other damage Replace damaged belts Fig 089 PICT 2030 A PTO belt D PTO clutch pulley B Spindle pulley E Stationary idler pulley C PTO belt tensioner PTO Belt Replacement and Belt Routing 48 54 60 Inch Deck Fig 089 D C B B B E E A ...

Page 71: ...54 60 Inch Deck Squealing when the belt is rotating blades slipping when cutting grass frayed belt edges burn marks and cracks are signs of a worn mower belt Replace the mower belt if any of these conditions are evident 1 Disengage the blade control switch PTO move the motion control levers to the neutral locked position and set the parking brake 2 Stop the engine remove the key and wait for all m...

Page 72: ...idler pulley and mower belt Fig 092 Fig 092 PICT 3035 10 Ensure that the belt is properly seated in all pulleys 11 Install the belt covers 12 Verify proper PTO operation 8 Properly route new belt around the deck pulleys and PTO pulley Fig 091 Fig 091 PICT 2030 A PTO belt D PTO clutch pulley B Spindle pulley E Stationary idler pulley C PTO belt tensioner D C B B B E E A ...

Page 73: ...hown in this chapter 6 Lower the mower to the lowest height of cut 7 Remove the 2 cotter pins and 2 washer securing the front pivot pin to the deck Remove the pivot pin from the deck Fig 093 8 Safely lift upward on the mower deck to relieve tension from the chain links 9 Carefully maneuver the top chain link up and off the lift rod hooks Repeat for the three remaining chain lift points Fig 094 Fig...

Page 74: ...moving parts to stop before leaving the operating position 3 Slide deck assembly under the machine 4 Lower the height of cut lever to the lowest position 5 Safely lift the mower deck and attach the top chain link to the lift arm hooks on all four lift points 6 Install the front pivot pin 2 washers and 2 cotter pins 7 Properly route and install the PTO belt and tensioner spring and shown in this ch...

Page 75: ...le Installation 1 Install blade and washer onto spindle shaft Install and torque blade bolt D to specification 105 ft lbs 143 Nm Note Install blade washer so concave surface is towards blade 2 Install spindle assembly onto the deck shell and torque fasteners C to specification 14 ft lbs 19 Nm 3 Safely hold blade in position 4 Install the bearing shield B and spindle pulley onto the spindle shaft a...

Page 76: ...r excessive wear and replace if necessary 4 Use an appropriate punch or bearing extractor to remove the 2 bearings A from the spindle housing 5 Inspect bearing spacer B for wear and replace if necessary 6 Clean and inspect spindle housing C bearing bores for excessive wear and replace if necessary Fig 097 Fig 096 PICT 2033 Fig 097 PICT 2035 Spindle Exploded Views Spindle Assembly 48 54 60 Inch Dec...

Page 77: ...stall a new LOWER bearing blade side into spindle housing until it contacts bearing spacer and bore shoulder Be sure to press equally on the inner and outer race while installing bearing Note While installing lower bearing align center bore of the bearing spacer s with center bore of the bearings 5 Install spindle shaft D into spindle housing 6 Install spindle assembly to the deck as outlined in t...

Page 78: ...2014 Service Manual 6 Fig 099 PICT 2037 Idler Arm Deck Belt Tensioner Service Idler Arm Tensioner Exploded View 48 54 60 Inch Deck Fig 099 A Standard washer C Spacer B Friction washer D 30 ft lbs 40 Nm composite A A B C B D A D D ...

Page 79: ...Inspect spring and replace if necessary 4 Remove the 1 fastener that secures idler arm assembly to deck 5 Inspect pivot bolt friction washers standard washers spacers and replace if necessary 6 Remove the fastener that secures idler pulley to the idler bracket Inspect pulley bearing and replace if necessary Idler Arm Installation 1 Install idler pulley to the idler arm and torque mounting bolt to ...

Page 80: ... deck to the highest height of cut position 2 While wearing thickly padded gloves or other adequate hand protection slowly rotate blade to be measured into a position that allows effective measurement of the distance between the cutting edge and the level surface the unit is on Fig 100 Fig 100 fig 39 G009679 A Deck C Blade B Spindle housing A B C Fig 101 fig 40 G009680 A Blade in position for meas...

Page 81: ...e dimension obtained continues to exceed 1 8 3mm the blade spindle shaft could be bent b If the variance is within constraints move to the next blade Repeat this procedure on each blade Mower Deck Leveling Check to ensure the mower deck is level any time you install the mower or when you see an uneven cut on your lawn The mower deck must be checked for bent blades prior to leveling any bent blades...

Page 82: ...ig 104 fig 59 G007199 Checking Side to Side Level The mower blades must be level from side to side Check the side to side level any time you install the mower deck or when you see an uneven cut on your lawn 1 Park the machine on a level surface and disengage the blade control switch 2 Move the motion control levers outward to the neutral lock position stop the engine remove the key set the parking...

Page 83: ...ing deck Fig 105 5 Loosen the adjustment bolts on all four corners so that the deck is sitting securely on all four blocks Fig 106 6 Ensure there is tension on all four chains Fig 106 7 Tighten the four adjustment bolts Fig 106 Fig 105 fig 60 G024426 Fig 106 fig 61 G024313 8 Check that blocks fit just snugly under the deck skirt Make sure all bolts are tight 9 Verify that the deck is level by chec...

Page 84: ...MOWER DECK 6 18 Toro TITAN 2014 Service Manual 6 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 85: ... returns to RUN when released Fig 108 Fig 107 PICT 3019 Testing 1 Disconnect switch from wiring harness 2 Verify that continuity exists between the terminals listed for the switch position 3 Verify there is NO continuity between terminals not listed for the position Key Switch Continuity Table OFF No continuity between any terminals RUN Continuity B R I A only START Continuity B R I S only Ignitio...

Page 86: ...kill relay Note The engine will not crank over to start when the PTO switch is ON PTO Switch OFF Switch Pushed Down The PTO Switch will not supply battery voltage to the PTO clutch The PTO Switch provides battery voltage from the key switch to the parking brake switch and neutral switches as a part of the Safety Interlock System to allow the unit to crank start Fig 110 Fig 109 PICT 2001 PTO Switch...

Page 87: ... have continuity open Pin 2 and 8 should not have continutiy open Fig 111 and Fig 112 Fig 111 PICT 1005 Fig 112 PICT 2004 With the Switch OFF Button pushed IN Pin 1 and 7 should have continuity closed circled below Pin 2 and 8 should have continuity closed circled below Pin 2 and 5 should not have continuity open Pin 1 and 4 should not have continuity open Fig 113 and Fig 114 Fig 113 PICT 1006 Fig...

Page 88: ...hes Seat Switch Purpose The seat switch is a part of the safety interlock system If the engine is running and the operator vacates the seat with the PTO engaged and or the handles pulled IN the engine will shut off Location The seat switch is attached to the seat base accessible by flipping the seat up into the service position ZX Seat Switch Fig 115 Fig 115 PICT 1009 Fig 116 PICT 3031 ...

Page 89: ...to the Ohm or Continuity setting check the continuity between the two switch terminals When the seat is vacated the switch should be OPEN and there should be NO continuity between the two switch terminals When the seat is occupied the switch CLOSES and there should be continuity between the two switch terminals Fig 117 Fig 117 PICT 2005 ...

Page 90: ...ches are serviceable by removing the control cover fastener and the control cover A Fig 118 and Fig 119 When the key is ON the RH and LH Neutral Switches get battery voltage from the Parking Brake Switch and or the Seat Switch When both of the Neutral Switches are CLOSED battery voltage is provided to the Kill Relay and the Fuel Solenoid Fig 121 Testing 1 Disconnect the switch from the wiring harn...

Page 91: ...ator must be in seat Park Brake OFF engine running Normally closed contacts are closed Battery voltage directly to kill relay coil and fuel solenoid neutral switches NOT in circuit Operator must be in seat Parking Brake Switch Purpose The Parking Brake Switch is part of the safety interlock system The parking brake switch circuit can Prevent the engine from cranking if parking brake is not engaged...

Page 92: ...ch and remove the switch from the unit 5 Use a ohm meter to test the switch continuity as shown below View From Back of Switch Fig 124 Parking Brake Circuit Fig 125 Switch Plunger NOT Depressed Pin 2 and 3 CLOSED continuity between the pins Pin 4 and 5 OPEN NO continuity between the pins Switch Plunger Depressed Pin 2 and 3 OPEN NO continuity between the pins Pin 4 and 5 CLOSED continuity between ...

Page 93: ...e engine When 12 volts is applied to the coil it becomes an elec tromagnet This quickly pulls the contact bar toward the contacts and closes the switch When power is removed from the coil the spring loaded bar returns to its normally open position The solenoid closes and opens the switch very quickly This minimizes the arcing that can damage other types of switches The ignition switch is protected...

Page 94: ... the engine to start when The key is in the start position Proper battery voltage is present at the key switch kill relay and starter solenoid Proper ground is present at the battery chassis and kill relay The PTO switch is OFF supplying battery voltage to the Park Brake Switch Both handles are in the neutral position and both neutral switches are CLOSED supplying battery voltage to the control si...

Page 95: ... Specification Continuity to Ground 3 05 10 3 93 10 OPEN Electric PTO Clutch Purpose The clutch electrically controls the engagement and disengagement of the PTO pulley Location The electric clutch is located on the PTO end of the engine crankshaft How It works The PTO clutch is composed of three major compon ents the field clutch plate and friction plate The clutch plate always turns with the eng...

Page 96: ...ness terminal A brown wire Fig 130 5 Connect the negative meter lead to the correspond ing wire terminal B Fig 130 6 Connect a short jumper lead from terminal C to terminal D Fig 130 7 Turn the ignition key in the switch to RUN position and the PTO switch to the ON position 8 See the PTO Clutch Electrical Specifications chart PTO Clutch Electrical Specifications Ohms Specification Amp Draw Specifi...

Page 97: ...ELECTRICAL 7 13 Toro TITAN 2014 Service Manual 7 PTO Circuit Schematic Fig 131 PICT 2015 ...

Page 98: ...e PTO clutch B from the engine crankshaft PTO Clutch Installation 1 Clean engine crankshaft 2 Apply anti seize to engine crankshaft 3 Install PTO clutch onto engine crankshaft Be sure anti rotation bracket C is properly aligned 4 Apply Loctite 242 to PTO clutch bolt 5 Torque the PTO clutch mounting bolt to 55 ft lbs 75 Nm 6 Connect harness connection to PTO clutch 7 Install PTO belt then tensioner...

Page 99: ...ttery the keeps the hour meter display illuminated at all times Testing With the key ON and PTO switch CLOSED verify battery voltage and ground are present at the hour meter Fig 134 Hour Meter Purpose The hour meter records hours of operation only when The Ignition key is ON The PTO switch is ON Location The hour meter is located on the RH control panel Fig 133 Fig 133 PICT 3019 Fig 134 PICT 2016 ...

Page 100: ...nel Testing With a multimeter set to OHM of continuity setting check the continuity between the fuse blades If the fuse is OPEN replace it and test the circuit The fuses used in this application can also be visually inspected A failed fuse can be identified by the broken melted element inside the fuse cover or a damaged spade Fig 136 and Fig 137 Fig 135 PICT 3044 Fig 136 IMG 1214a Fig 137 PICT 304...

Page 101: ...he engine near the hydro expansion tank The diode is cable tied to the main wire harness Fig 139 and Fig 140 FlyBack Diode Purpose The flyback diode protects the electrical system from current surges caused by PTO engagement and disen gage ment Fig 138 Fig 138 DSCN 0149a Fig 139 PICT 2021 Fig 140 PICT 2024 ...

Page 102: ... diode terminals and measure the diode resistance again record this value If the resistance value is the same in steps 3 and 4 the diode is shorted or open replace the diode Note If the flyback diode tests shorted or open also test the PTO clutch as shown in this chapter A properly functioning diode will be open in one direction and have an ohms resistance value when the meter leads are reversed a...

Page 103: ...ELECTRICAL 7 19 Toro TITAN 2014 Service Manual 7 Fig 143 PICT 3020 Wire Harness View 1 of 3 ...

Page 104: ...ELECTRICAL 7 20 Toro TITAN 2014 Service Manual 7 Wire Harness View 2 of 3 Fig 144 PICT 3021 ...

Page 105: ...ELECTRICAL 7 21 Toro TITAN 2014 Service Manual 7 Fig 145 PICT 3022 Wire Harness View 3 of 3 ...

Page 106: ...ELECTRICAL 7 22 Toro TITAN 2014 Service Manual 7 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 107: ......

Page 108: ...2014 TITAN ZX MX Service Manual Form Number 492 9339 ...

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