Toro Titan Z4800 Service Manual Download Page 1

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Residential Products

2007 - 2008

Titan™ Z4800 & Z5200

Service Manual

Summary of Contents for Titan Z4800

Page 1: ...Residential Products 2007 2008 Titan Z4800 Z5200 Service Manual...

Page 2: ...7RUR 7LWDQ DQG PRGHO HDUV DQG DUH FRYHUHG LQ WKLV PDQXDO 7KH PDQXDO PD DOVR EH VSHFL HG IRU XVH RQ ODWHU PRGHO SURGXFWV The hydrostatic transaxle is a sophisticated piece of machinery Maintain strict...

Page 3: ...7LWDQ 6HUYLFH 0DQXDO ABOUT THIS MANUAL THIS PAGE INTENTIONALLY LEFT BLANK...

Page 4: ...ssembly Replacement Caster Wheel Assembly Removal DVWHU KHHO VVHPEO QVWDOODWLRQ HIW DQG HQGHU XHO 7DQN 5HSODFHPHQW HIW DQG HQGHU XHO 7DQN 5HPRYDO HIW DQG HQGHU XHO 7DQN QVWDOODWLRQ 5LJKW DQG HQGHU 5HS...

Page 5: ...Measuring Clutch Current Draw 3DUN UDNH 6ZLWFK Purpose RFDWLRQ RZ W RUNV Testing 6HDW 6ZLWFK Purpose RFDWLRQ RZ W RUNV Testing 1HXWUDO 6ZLWFK Purpose RFDWLRQ RZ W RUNV Testing RXU 0HWHU Purpose RFDWL...

Page 6: ...FWLRQ Mower Belt Replacement Mower Belt Removal 0RZHU HOW QVWDOODWLRQ ENGINE Engine Replacement Engine Removal QJLQH QVWDOODWLRQ 0XI HU 5HSODFHPHQW 0XI HU 5HPRYDO 0XI HU QVWDOODWLRQ HYDROSTATIC DRIVE...

Page 7: ...DO TABLE OF CONTENTS HYDROSTATIC DRIVE SYSTEM cont 1HXWUDO GMXVWPHQW Tracking Adjustment 3XUJLQJ 3URFHGXUHV 7UDQVD OHV GUDXOLF 6 VWHP 0DLQWHQDQFH KHFNLQJ WKH GUDXOLF 2LO HYHO KDQJH WKH GUDXOLF 6 VWHP...

Page 8: ...HQWV which may increase in temperature during operation while the unit is running or shortly after it has been running YRLG UHV DQG H SORVLRQV Avoid spilling fuel and never smoke while working with an...

Page 9: ...1 2 2007 2008 Titan Z Service Manual 1 SAFETY INFORMATION THIS PAGE INTENTIONALLY LEFT BLANK...

Page 10: ...RPM Model Briggs Stratton Kohler Full Speed 3650 100 No Load 3600 75 No Load Idle Speed 1650 min 1750 min Electrical System Charging System Flywheel Alternator Flywheel Alternator Charging Capacity 1...

Page 11: ...e Mobil 1 15W 50 synthetic motor oil Speeds 0 7 0 mph 11 3 km hr Forward 0 5 0 mph 8 0 km hr Reverse Cutting Deck 48 Deck 52 Deck Cutting Width 48 122cm 52 132cm Discharge Side Blade Size 3 ea 16 25 4...

Page 12: ...ng Bolt 45 55 ft lbs 61 75 Nm 45 55 ft lbs 61 75 Nm Engine Mounting Bolt 27 33 ft lbs 37 45 Nm 27 33 ft lbs 37 45 Nm Anti Scalp Roller Nut 27 33 ft lbs 37 45 Nm Nyloc nut 27 33 ft lbs 37 45 Nm Wheel L...

Page 13: ...SPECIFICATIONS 2 4 2007 2008 Titan Z Service Manual 2 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 14: ...el D Refer to Operator s Manual for grease instructions E Check hydraulic oil level and refer to Operator s manual for further instructions F Check tire pressure Fig 001 IMG 0162 The unit should be gr...

Page 15: ...g brake stop the engine remove the key and wait for all moving parts to stop before leaving the operating position OHDQ WKH JUHDVH WWLQJV ZLWK D UDJ 0DNH VXUH WR VFUDSH DQ SDLQW RII RI WKH HQG RI WKH...

Page 16: ...followed when replacing the right hand caster fork assembly and bearings 3 Remove the hex head bolt and washer securing the caster fork assembly to the front axle Fig 007 1 Park the machine on a level...

Page 17: ...009 6 With a drift punch and hammer tap the upper ball bearing out of the front axle frame Fig 010 1 Install the upper and lower ball bearings into the front axle frame Fig 011 Fig 009 IMG 0166 Fig 0...

Page 18: ...y Fig 015 1 Park the machine on a level surface disengage the blade control PTO and turn the ignition key to OFF to stop the engine Remove the ignition key 2 Raise the front of the machine high enough...

Page 19: ...he wheel assembly Fig 018 3 Position the wheel assembly into the caster fork VR WKH YDOYH VWHP DQG JUHDVH WWLQJ DUH IDFLQJ WKH inside Fig 019 Fig 017 IMG 0175a Fig 018 IMG 0172 Fig 019 IMG 0176 4 Posi...

Page 20: ...wheel assembly to the caster fork Fig 021 1 Park the machine on a level surface disengage the blade control PTO and turn the ignition key to OFF to stop the engine Remove the ignition key 2 Raise the...

Page 21: ...to the front of the seat box Fig 025 A Bolt and nut B Screw 6 Remove the bolt and nut securing the left hand engine guard to the rear engine guard and the screw securing the left hand engine guard to...

Page 22: ...three screws that secure the left hand fender to the top of the seat box Fig 028 10 Turn the fuel shut off valve to the OFF position Slide the hose clamp off the engine side of the fuel shut off valv...

Page 23: ...of the seat box assembly Open the clamp to release the fuel line Fig 032 13 Remove the fuel tank from the machine Fig 033 1 Position the fuel tank to the left hand side of the machine Route the fuel l...

Page 24: ...rear fuel tank mounting hole Loosely install a washer spring and nut onto the carriage bolt Fig 038 Fig 036 IMG 0196 3 Install a carriage bolt through the left hand tank mount bracket and the top fron...

Page 25: ...fuel shut off valve Slide the hose clamp in place to secure the fuel line to the shut off valve Fig 041 9 Install three screws to secure the left hand fender to the seat box assembly Fig 043 8 Positi...

Page 26: ...nd rear tank mounting bracket Fig 044 12 Install the two screws to secure the left side fender to the front of the seat box Fig 046 A Bolt and nut B Screw Fig 044 IMG 0186 Fig 046 IMG 0183 Fig 047 IMG...

Page 27: ...position 16 Connect the negative battery cable to the negative battery terminal 1 Park the machine on a level surface disengage the blade control PTO and turn the ignition key to OFF to stop the engin...

Page 28: ...the panel from the slots in the seat box assembly Fig 050 6 Remove the bolt and nut securing the right hand engine guard to the rear engine guard and the screw securing the right hand engine guard to...

Page 29: ...ure the right hand fender to the top of the seat box assembly Fig 055 A Ignition switch C Hour meter B PTO Switch 10 Remove the wire harness plugs from the back of the ignition switch the PTO switch a...

Page 30: ...machine Fig 059 2 Feed the control panel up through the opening in the right hand fender Fig 061 12 Feed the control panel through the right hand fender Fig 058 1 Position the right hand fender onto t...

Page 31: ...he seat box assembly Fig 062 4 Plug the wire harness plug onto the terminals on the hour meter Fig 063 6 Connect the two red wire terminal to the outside terminal on the ignition switch Fig 065 5 Plug...

Page 32: ...onto the ignition switch Fig 066 9 Install a bolt washer and nut securing the right hand rear console bracket and right hand fender Fig 068 Fig 066 IMG 0219 Fig 067 IMG 0208 Fig 068 IMG 0206 QVWDOO D...

Page 33: ...e seat box assembly Fig 070 12 Install the front panel into the slots in the seat box assembly Fig 071 14 Connect the negative battery cable to the negative battery terminal 13 Install two screws to s...

Page 34: ...TO and turn the ignition key to OFF to stop the engine Remove the ignition key 2 Raise the seat and disconnect the negative and positive battery cables from the battery 3 Remove the two wing nuts secu...

Page 35: ...d remove the seat from the machine Fig 077 11 Repeat the previous step to remove the left hand lever grip 8 Remove the left hand fender and fuel tank Refer to Left Hand Fender and Fuel Tank Removal on...

Page 36: ...ydro vent tank to the side away from the seat box Fig 082 12 Remove the two screws retaining the hydro fan cover to the seat box assembly Fig 079 14 Remove the two bolts washers and nuts securing the...

Page 37: ...n the right side of the seat box assembly Fig 084 18 Push the two wire clamps through the right side of the seat box to free the harness from the seat box Fig 085 Fig 083 IMG 0236 Fig 084 IMG 0237 Fig...

Page 38: ...that the throttle and choke cables are routed through on the right side of the seat box Remove the clamp from the seat box Fig 087 22 Remove the wire harness plug from the left side neutral switch Fi...

Page 39: ...enoid Fig 091 25 Remove the nut securing the two ground wires to the engine base Remove the ground wires Fig 092 27 Remove the alternator violet wire from the red wire Fig 094 26 Unplug the fuel solen...

Page 40: ...ORFDWHG QH W WR WKH RLO OWHU LJ 30 Open the clamp that secures the PTO clutch wire Fig 097 Pull the wire harness up through the frame Fig 095 IMG 0264a Fig 096 IMG 0268a Fig 097 IMG 0271a 31 Push the...

Page 41: ...3 Remove the relay from the wire harness relay plug Fig 100 35 Remove the two screws and nuts that secure the fuse block to the rear of the seat box assembly Fig 102 34 Remove the screw and nut that s...

Page 42: ...the seat box assembly Fig 104 39 Remove the brake assembly carriage bolt Fig 106 36 Remove the clamp for the fuel hose located on the left rear side of the seat box assembly Fig 103 38 Remove the nut...

Page 43: ...assembly Fig 107 41 Remove the brake assembly spacer Fig 108 43 Remove the washer located on the inside end of the brake pivot tube Fig 110 42 Pull the brake pivot tube assembly slightly outward Fig 1...

Page 44: ...5HPRYH WKH DQJH EXVKLQJ ORFDWHG RQ WKH LQVLGH RI the seat box Fig 114 42 Remove the spacer from the inside end of the brake pivot tube Fig 111 5HPRYH WKH DQJHG EXVKLQJ ORFDWHG RQ WKH RXWVLGH of the se...

Page 45: ...ft side of the seat box to the frame Fig 118 48 Repeat steps 46 and 47 to remove the cotter pin and control pivot pin on the right hand side 49 Remove the two screws securing the right side of the sea...

Page 46: ...x and remove the tank mount bracket Fig 120 54 Remove the two screws and washers that secure the left side motion control stop Fig 122 51 Remove the seat box assembly from the frame Fig 119 53 Remove...

Page 47: ...rol stop Fig 123 56 Repeat steps 54 and 55 to remove the right side motion control stop 2 Install two screws and washers to secure the control stop to the seat box Fig 125 1 Position the left side mot...

Page 48: ...e of the seat box assembly to the frame Fig 129 3 Follow the previous 2 steps to install the right side motion control stop 4 Position a compression spring to the seat box Install D VFUHZ DQG D DQJH Q...

Page 49: ...o secure Fig 132 Fig 130 IMG 0300 9 Tighten all 4 screws to secure 10 Install a control pivot pin through the left side of the seat box assembly and left hand motion control pivot assembly Fig 131 Fig...

Page 50: ...135 17 Install a washer on the inside end of the brake shaft Fig 137 QVWDOO WKH EUDNH VKDIW DQJH EXVKLQJ WR WKH RXWVLGH of the seat box Fig 134 16 Install a spacer on the inside end of the brake shaft...

Page 51: ...on the bell crank Fig 138 19 Install a spacer on the outside end of the brake shaft Fig 139 21 Slide a carriage bolt through the brake shaft Fig 141 20 Install the brake lever assembly onto the outsi...

Page 52: ...Fig 143 25 Install the harness plug onto the right side neutral switch Fig 145 22 Install a nut onto the carriage bolt Fig 142 24 Install a clamp around the harness and install the clamp barb through...

Page 53: ...lamp barb through the left rear side of the seat box Fig 147 29 Position the relay harness plug to the inside rear of the seat box next to the fuse block and install a screw and nut to secure it Fig 1...

Page 54: ...Fig 150 32 Pull the wire harness from inside the rear of the seat box assembly toward the outside through the thru hole Install the rubber grommet into the thru hole to protect the wire harness Fig 15...

Page 55: ...Install a clamp securing the PTO clutch wire harness to the clutch anchor bracket Fig 155 37 Install the violet wire connector to the alternator red wire Fig 157 36 Install the blue harness wire to th...

Page 56: ...and engine magneto Fig 158 40 Position the solenoid to the back side of the seat box assembly Install two bolts washers and nuts to secure it to the seat box assembly Fig 160 Fig 158 IMG 0258 Fig 159...

Page 57: ...the inside of the seat box to the rear right side Install two bolts washers and nuts to secure Fig 163 45 Pull the control panel wire harness through the hole on the right side of the seat box assembl...

Page 58: ...corner of the seat box assembly Fig 167 49 Install the hydro fan cover Fig 169 46 Install the rubber grommet in the wire harness hole Fig 166 48 Install two bolts washers and nuts to secure the hydro...

Page 59: ...revious step to install the left hand grip assembly 53 Install the right fender Refer to Right Hand Fender Installation on page 3 17 54 Install the left hand fender and fuel tank Refer to Left Hand Fe...

Page 60: ...the seat pivot rod to secure Fig 173 57 Route the seat switch harness wire through the wire clamp located on the bottom of the seat plate Fig 175 Fig 173 IMG 0227 56 Support the seat and position the...

Page 61: ...7 60 Install the positive and then the negative battery cable to the battery Fig 177 IMG 0220 HLJKW RI XW 2 VVHPEO Front Rear Shaft Assembly 5HSODFHPHQW 2 VVHPEO URQW 5HDU 6KDIW Assembly Removal 1 Dis...

Page 62: ...ndle and lower the mower deck so that it is resting on the blocks Fig 179 Fig 179 IMG 0347 Fig 180 IMG 0348 5 Remove the external retaining ring washer and clevis pin securing the front shaft assembly...

Page 63: ...lts and nuts that secure the front VKDIW DVVHPEO WR WKH IUDPH RQ WKH ULJKW DQJH RQ WKH OHIW DQJH LJ Fig 185 IMG 0355a Fig 186 IMG 0357 5HPRYH WKH KHLJKW DGMXVWPHQW DVVHPEO LJ 7 Remove external retaini...

Page 64: ...KH OHIW DQJH LJ Fig 187 IMG 0359a Fig 188 IMG 0360 2 VVHPEO URQW 5HDU 6KDIW Assembly Installation 1 Position the rear shaft assembly to the frame Install IRXU EROWV DQG QXWV WKURXJK WKH DQJH EHDULQJV...

Page 65: ...carriage bolt Position the deck hangers onto each of the strut spacers Install a nut onto each of the deck hanger carriage bolts to secure the four deck hangers to the front and rear shaft assemblies...

Page 66: ...CHASSIS 3 53 2007 2008 Titan Z Service Manual 3 8 Install the negative battery cable QVWDOO WKH KHLJKW DGMXVWHU SLQ LQWR WKH KHLJKW RI FXW DGMXVWPHQW LJ Fig 195 IMG 0345...

Page 67: ...CHASSIS 3 54 2007 2008 Titan Z Service Manual 3 7 6 3 17 17 21 7 1...

Page 68: ...U RI WKH HQJLQH Interlock Relay Kill Relay Purpose The relay used in the Titan Z is used to connect or disconnect the engines electronic ignition and starter VROHQRLG IURP FKDVVLV JURXQG UHOD LV DQ HO...

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Page 83: ...ELECTRICAL 2007 2008 Titan Z Service Manual 4 Electrical Schematics Briggs Stratton Engine Fig 224 6 VFKHPH...

Page 84: ...ELECTRICAL 4 17 2007 2008 Titan Z Service Manual 4 Briggs Stratton Engine cont Fig 225 6 VFKHPH...

Page 85: ...SWITCH ACCESSORIES TERMINAL Y HOUR METER PTO SWITCH CONNECTORS VIEWED FROM WIRE END NOTE BRAKE SWITCH RH MOTION CONTROL LH MOTION CONTROL STARTER LOCKOUT KILL RELAY START SOLENOID GROUND START SOLENO...

Page 86: ...ON SWITCH ORANGE ORANGE ORANGE ORANGE DARK GREEN DARK GREEN BROWN BROWN VIOLET VIOLET VIOLET RED RED RED Y S X A B I ORANGE BLACK PINK LIGHT BLUE LIGHT BLUE PINK PINK PINK PINK RED VIOLET YELLOW WHITE...

Page 87: ...ELECTRICAL 4 20 2007 2008 Titan Z Service Manual 4 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 88: ...eck from the machine Refer to Mower Deck Removal on page 5 18 2 Remove the 2 nuts securing the spindle cover to the deck Fig 228 And remove the spindle cover 4 Using a rag or a thickly padded glove fo...

Page 89: ...spindle shaft Fig 235 9 Using a rag or a thickly padded glove for protection hold the end of the blade and loosen the blade bolt Fig 234 Fig 232 IMG 0616 Fig 233 IMG 0617 Fig 234 IMG 0618a Fig 235 IM...

Page 90: ...bearing shield Fig 237 14 With a punch drive one of the bearings out of the housing Fig 239 11 Remove the spacer on the bottom of the spindle shaft Fig 236 13 Remove the spacer from the spindle housin...

Page 91: ...the spacer from the housing Fig 240 16 Turn the housing over and drive the other bearing out of the other side with a punch Fig 241 A Housing C Bearing 2 B Spacer Housing spacer and bearings Fig 242 F...

Page 92: ...Tap a bearing into the blade end of the housing until it seats Fig 243 3 Tap the second bearing into the pulley side of the spindle housing until it seats Fig 245 Fig 243 IMG 0636a Fig 244 IMG 0637a...

Page 93: ...shaft and spacer Fig 248 7 With two washers on the blade bolt install the blade bolt and two washers into the spindle shaft Fig 249 Fig 247 IMG 0650a Fig 248 IMG 0647a Fig 249 IMG 0648 8 Torque the bl...

Page 94: ...wer deck Torque the 6 screws to 200 250 in lbs 16 7 20 8 Nm Fig 251 12 Install the spindle pulley nut Torque the spindle pulley nut to 50 ft lbs 67 8 Nm Fig 253 Fig 251 IMG 0651a Fig 253 IMG 0653 Fig...

Page 95: ...lt routing decal Fig 255 16 Install the mower deck to the machine Refer to Mower Deck Installation on page 5 19 1 Remove the mower deck from the machine Refer to Mower Deck Removal on page 5 18 2 With...

Page 96: ...g the idler arm to the mower deck Fig 259 6 Remove the carriage bolt and washer from the deck Fig 261 Fig 259 IMG 0657 5 Remove the idler arm from the mower deck Fig 260 Fig 260 IMG 0658 Fig 261 IMG 0...

Page 97: ...the idler pulley and idler bushing from the idler arm assembly Fig 265 Fig 265 IMG 0666a 9 Remove the nut and carriage bolt securing the idler pulley to the idler arm assembly Fig 264 8 Tap out the tw...

Page 98: ...a nut to secure the pulley Fig 267 1 Install the carriage bolt and idler bushing to the idler arm assembly Fig 266 Fig 266 IMG 0667a Fig 267 IMG 0668a 3 Install a sleeve bearing into the top and bott...

Page 99: ...UP DVVHPEO LJ 273 7 Install a washer and nut onto the carriage bolt to secure Fig 272 Fig 272 IMG 0674a Fig 273 IMG 0675 5 Position the pivot bushing onto the carriage bolt Fig 270 Fig 270 IMG 0672a 6...

Page 100: ...he spring post located at the rear of the mower deck Fig 275 Fig 275 IMG 0655 11 Install the mower deck onto the machine Refer to Mower Deck Installation on page 5 19 Fixed Idler Pulley Replacement Fi...

Page 101: ...and position the idler bushing onto the carriage bolt Fig 280 Fig 280 IMG 0680 2 Position the idler pulley onto the idler bushing Install a nut to secure the pulley Fig 281 Fig 281 IMG 0681 3 Remove t...

Page 102: ...the mower deck belt off the idler pulley Fig 282 Fig 282 IMG 0432a 3 Remove the mower deck belt from around the elec tric PTO clutch pulley Fig 283 Fig 283 IMG 0372 Electric PTO Clutch Replacement El...

Page 103: ...ch onto the engine crank shaft Fig 287 Fig 287 IMG 0424 0DNH VXUH WKH VORW RQ WKH HOHFWULF FOXWFK WV RQ WKH clutch anchor Fig 288 Fig 288 IMG 0430a 7 To test the electric PTO clutch refer to the Elect...

Page 104: ...rankshaft Torque the clutch bolt to 55 ft lbs 74 6 Nm 5 Plug the harness plug into the electric PTO clutch plug Fig 290 Fig 290 IMG 0377a 6 Install the mower deck belt around the electric PTO clutch p...

Page 105: ...locking to lower the mower deck to the ground Fig 294 A Deck lift arm B Deck hanger Fig 294 J 1 Park the machine on a level surface and disengage the blade control switch 2 Move the motion control lev...

Page 106: ...r the machine 4 Lower the height of cut lever to the lowest position 5 Use the existing hardware to attach the rear deck strut of the mower to the deck lift arm Fig 295 Fig 295 J A A B B 6 Attach the...

Page 107: ...C Measure here B Outside cutting edges Fig 299 J Leveling the Mower Deck The mower blades must be level from side to side and slightly sloped from front to back Check the side to side level and the f...

Page 108: ...de slope any time you install the mower If the front blade tip is not 1 16 5 16 1 6 7 9mm lower than the rear blade tip adjust the blade slope using the following instruction 2 Park the machine on a l...

Page 109: ...to the Leveling the Mower Deck on page 5 20 A Blades front to rear C Measure here B Outside cutting edges 8 Carefully rotate the blades front to rear Fig 302 Fig 302 Fig 46 G007199 A Deck lift arm C D...

Page 110: ...sition engage parking brake stop the engine remove the key and wait for all moving parts to stop before leaving the operating position 3 Set the height of cut at 1 1 2 38mm 4 Remove the belt covers ov...

Page 111: ...lley and mower pulleys Fig 304 Fig 304 109 6035 A Outside pulley D Mower belt B Spring E Engine pulley C Idler pulley F Pull idler in this direction Fig 305 J 2 Pull the idler pulley in the direction...

Page 112: ...the positive and negative battery cables from the battery 2 Locate the idler arm assembly on the mower deck and pull the arm toward the rear of the machine Remove the mower deck belt from around the...

Page 113: ...71 rotate the transmission drive belt idler arm to release tension from the transmission drive belt Remove the transmission drive belt from the idler pulley Fig 311 Fig 311 IMG 0423a 8 Remove the tran...

Page 114: ...of the engine and remove the throttle cable from the clamp Fig 316 Fig 316 IMG 0388 9 Slide the engine pulley off the crankshaft Fig 313 Fig 313 IMG 0385 11 Turn the fuel shut off valve to the OFF pos...

Page 115: ...remove the choke cable from the clamp Fig 318 Fig 318 IMG 0393a 15 Remove the choke cable from the engine choke linkage Fig 319 Fig 319 IMG 0392a 16 Remove the violet wire from the red alternator wir...

Page 116: ...IMG 0258 19 Remove the nut securing the heavy red wire to the starter and remove the heavy read wire from the starter Fig 323 Fig 323 IMG 0394a 17 Remove the blue wire from the oil sending sensor ORFD...

Page 117: ...IMG 0405a Fig 328 IMG 0406 22 Raise the engine off the frame Fig 326 Note For photo purposes the rear engine guards and rear casting was removed Fig 326 IMG 0403a 23 For engine service refer to applic...

Page 118: ...ground base Install a nut to secure the 2 ground wires Fig 329 6 Plug the yellow white wire plug to the grey black fuel solenoid and the engine magneto wire plug Fig 331 Fig 329 IMG 0395a 5 Position...

Page 119: ...e engine Fig 334 11 Install the throttle cable into the throttle linkage located on the rear of the engine Fig 336 10 Move the choke control lever in the full open position the choke linkage is moved...

Page 120: ...control panel to the low throttle position Position the throttle cable into the top of the throttle cable clamp push the throttle cable until the throttle linkage on the engine stops Tighten the throt...

Page 121: ...er 92 5771 rotate the transmission drive belt spring idler arm to release tension on idler arm Route the transmission drive belt around the idler arm pulley Fig 343 Fig 341 IMG 0417a 17 Route the tran...

Page 122: ...the threads of the electric clutch bolt Fig 347 0DNH VXUH WKH VORW RQ WKH HOHFWULF 372 FOXWFK WV RQ the clutch anchor Fig 346 Fig 346 IMG 0430a Fig 347 IMG 0429a 22 Torque the clutch bolt to 50 to 55...

Page 123: ...dler pulley Fig 351 24 Route the mower deck belt around the electric PTO clutch Fig 350 Fig 350 IMG 0372 Fig 351 IMG 0432a 27 Install the positive and then the negative battery cable to the battery 23...

Page 124: ...hers and QXWV UHWDLQLQJ WKH PXI HU JXDUG WR WKH IUDPH DQG WKH engine Fig 355 Fig 355 IMG 0709a Fig 356 IMG 0707 Note This procedure was performed with Briggs 6WUDWWRQ HQJLQH RKOHU HQJLQH PXI HU replac...

Page 125: ...7 2008 Titan Z Service Manual 6 6 Remove the 4 screws washers and 2 gaskets UHWDLQLQJ WKH PXI HU WR WKH HQJLQH LJ DQG LJ 5 Fig 358 IMG 0714 Fig 359 IMG 0715 5HPRYH WKH PXI HU JXDUG IURP WKH XQLW LJ Fi...

Page 126: ...ervice Manual 6 0XI HU QVWDOODWLRQ 5HLQVWDOO WKH PXI HU LQ WKH UHYHUVH RUGHU 1RWH 7RUTXH WKH PXI HU PRXQWLQJ EROWV WR LQ OEV 1P Torque the engine mounting bolts to 200 LQ OEV 1P 5HPRYH WKH PXI HU IURP...

Page 127: ...ENGINE 6 16 2007 2008 Titan Z Service Manual 6 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 128: ...bly on the mower deck Pull the arm toward the rear of the machine and remove the mower deck belt from the idler pulley Fig 361 4 Remove the mower deck belt from around the electric PTO clutch Push the...

Page 129: ...H HG idler pulley Fig 364 7 Remove the hydro drive belt from around the engine pulley Fig 365 9 Remove the hydro fan cover Fig 367 8 Lift the seat assembly Loosen the two screws that secure the hydro...

Page 130: ...Drive Belt Installation 1 Route the hydro drive belt around the left and right hydro pulleys Fig 370 10 Remove the hydro drive belt from around the right and left hydro pulleys and out the bottom of t...

Page 131: ...rive belt around the engine sheave Fig 372 4 Using a spring tool Toro part number 92 5771 release tension from the hyrdo drive idler arm and route the hydro drive belt around the idler pulley Fig 373...

Page 132: ...rear of the machine and route the mower deck belt around the idler pulley and the electric PTO clutch pulley Fig 375 and Fig 376 Fig 375 IMG 0432a Fig 376 IMG 0372 9 Position the hydro fan cover Fig 3...

Page 133: ...Titan Z Service Manual 7 10 Install the two screws securing the hydro fan cover to the seat box Fig 379 Fig 379 IMG 0440a 11 Lower the seat RZHU WKH UHDU HQG RI WKH PDFKLQH WR WKH RRU 13 Connect the...

Page 134: ...then the positive battery cable from the battery 3 Loosen the two wing nuts on the battery hold down bolts Remove the battery from the machine Fig 380 5 Remove the motion control damper from the mach...

Page 135: ...of the damper to secure Fig 385 Fig 383 IMG 0468a QVWDOO WKH HG HQG RI WKH GDPSHU WR WKH IUDPH Install the rod end of the damper to the motion control pivot Fig 384 Fig 384 IMG 0476 Fig 385 IMG 0477...

Page 136: ...two screws and washers retaining the left hand lever grip assembly from the lever mount post Fig 388 Motion Control Pivot Removal 1 Raise the seat 2 Remove the negative and then the positive battery c...

Page 137: ...embly Fig 391 10 Remove the control pivot pin from the motion control pivot assembly Fig 393 7 Remove the nut from the top of the left hand motion control damper and move the damper out of the motion...

Page 138: ...HYDROSTATIC DRIVE SYSTEM 7 11 2007 2008 Titan Z Service Manual 7 11 Remove the motion control pivot assembly from the seat box assembly Fig 394 Fig 394 IMG 0485...

Page 139: ...mmer remove the two bearings in the motion control pivot Fig 397 Fig 397 IMG 0494a 2 Remove the two bolts metal washers 2 plastic washers and nuts retaining the lever mount post to the motion control...

Page 140: ...w bearings into the motion control pivot assembly Fig 398 Fig 398 IMG 0502a Fig 399 IMG 0506a A Nuts D Motion Control Pivot B Lever Mount Post E Metal Washers C Plastic Washers 4 F Bolts A B C C D E F...

Page 141: ...all a cotter pin on the end of the control pivot pin Fig 404 Fig 404 IMG 0521 Fig 405 IMG 0482a 1 Install the left hand motion control pivot assembly between the seat box assembly and the motion contr...

Page 142: ...to secure Fig 406 Fig 406 IMG 0480a Fig 407 IMG 0522a 7 Install two screws and washers retaining the left hand lever grip assembly to the lever mount post Fig 408 Fig 408 IMG 0523a 8 Left Hand Motion...

Page 143: ...wing nuts on the battery hold down bolts and remove the battery from the machine Fig 410 Fig 410 IMG 0456 10 Install the positive and then the negative battery cable to the battery 11 Start the machi...

Page 144: ...eft Hand Fender and Fuel Tank Removal on page 3 7 5 Remove the nut securing the brake arm assembly pivot Fig 411 Fig 411 IMG 0287a 6 Remove the brake arm assembly pivot carriage bolt Fig 412 Fig 412 I...

Page 145: ...418 11 Remove the spacer from the inside end of the brake pivot tube Fig 417 Fig 417 IMG 0293a Fig 418 IMG 0294a 10 Remove the washer located on the inside end of the brake pivot tube Fig 416 9 Pull t...

Page 146: ...x assembly Fig 419 Fig 419 IMG 0295a Fig 420 IMG 0296a 15 With a spring tool Toro part number 92 5771 re move the right extension spring located between the spring anchor plate and the brake shaft ass...

Page 147: ...levis pin that secures the right side spring anchor plate to the brake handle on the transmission Fig 425 Fig 425 IMG 0530 Fig 426 IMG 0531 18 Remove the brake arm from the machine Fig 424 17 Rotate t...

Page 148: ...to the transmission and frame Fig 428 21 Repeat steps 19 and 20 to remove the left side spring anchor plate 22 Remove the nut securing the right side of the brake shaft to the transmission and frame F...

Page 149: ...ansmission and frame Fig 432 Fig 432 IMG 0533 4 Install the left side spring anchor plate onto the left brake handle clevis pin Install a cotter pin to secure Fig 433 Fig 433 IMG 0538 1 Position the b...

Page 150: ...434 7 Install an e clip to retain the brake arm to the brake shaft assembly Fig 436 Fig 434 IMG 0539a 6 Install the brake arm from the brake shaft assembly to the seat box assembly Fig 435 Fig 435 IM...

Page 151: ...number 92 5771 install the left extension spring onto the spring anchor plate and the brake shaft assembly Fig 438 QVWDOO WKH DQJH EXVKLQJ WR WKH LQVLGH RI WKH VHDW box assembly for the brake shaft pi...

Page 152: ...5 Install a washer on the inside end of the brake pivot tube Fig 444 Fig 442 IMG 0314 14 Install a spacer on the inside end of the brake pivot tube Fig 443 Fig 443 IMG 0315a Fig 444 IMG 0316a 6OLGH WK...

Page 153: ...lt to secure Fig 449 Fig 449 IMG 0323a 17 Install a spacer on the outside end of the brake pivot tube Fig 446 19 Slide a carriage bolt through the brake pivot tube Fig 448 Fig 446 IMG 0319 18 Install...

Page 154: ...22 Position the battery in the machine Install the battery hold down to secure Fig 450 Fig 450 IMG 0456 Transaxle Replacement Transaxle Removal Note These instructions show the removal and Installati...

Page 155: ...an cover from the machine Fig 455 Fig 455 IMG 0547 6 Remove the mower deck belt from around the electric PTO clutch and push the excess belt forward toward the mower deck Fig 453 5 Locate the mower de...

Page 156: ...ydro drive belt idler arm and remove the hydro drive belt from the hydro drive idler pulley Fig 456 Fig 456 IMG 0435 Fig 457 IMG 0552a 11 Remove the carriage screw and knob handle secur ing the hydro...

Page 157: ...asher securing the brake pivot and brake shaft assembly to the trans axle and the frame Fig 462 Fig 462 IMG 0558a Fig 463 IMG 0562a 14 Remove the left extension spring located between the spring ancho...

Page 158: ...VLWLRQ D RRU MDFN XQGHU WKH WUDQVD OH IRU VXSSRUW Fig 464 Fig 464 IMG 0563 Fig 465 IMG 0565a 5HPRYH WKH DQJH QXW DQG ZKL QXW VHFXULQJ WKH tension rod and tube between the left and right transaxles Rem...

Page 159: ...ove the spring anchor plate Fig 470 Fig 470 IMG 0575 21 Slowly lower the transaxle away from the frame Fig 468 Fig 468 IMG 0572 22 Remove the hairpin cotter retaining the hydro by pass arm to the tran...

Page 160: ...pass arm onto the bypass arm linkage located on the transaxle Secure with a hair pin cotter Fig 471 Fig 471 IMG 0579 Fig 472 IMG 0572 3 Loosely install two carriage bolts and nuts to secure the transa...

Page 161: ...rriage bolts and nuts securing the transaxle to the frame Fig 477 Fig 477 IMG 0566a Fig 478 IMG 0565a 5 Loosely nstall the carriage bolt spacer and nut to secure the rear of the transaxle to the frame...

Page 162: ...between the right and left transaxles 12 Install the carriage bolt and knob handle securing the hydro bypass arm to the frame Fig 480 Fig 480 IMG 0554a QVWDOO D EROW DQG DQJH QXW VHFXULQJ WKH VWHHULQJ...

Page 163: ...mber 92 5771 install the left extension spring between the spring anchor plate and the brake shaft assembly Fig 485 Fig 485 IMG 0527 Fig 486 IMG 0552a 15 Install the spring anchor plate in the slot lo...

Page 164: ...Route the hydro drive belt around the engine drive pulley Fig 487 20 Using a spring tool Toro part number 92 5771 release the tension on the hydro drive belt idler arm Route the belt around the idler...

Page 165: ...g the oil make sure the system is purged prior to doing any neutral adjustment Refer to Purging Procedures Transaxles on page 7 42 Note After any service where the control linkage was disturbed or aft...

Page 166: ...0589 2 Run the engine and operate the drive system for 10 minutes to warm up the transaxles Shut the engine off 3 Raise the seat Unplug the seat switch and tempor arily connect a jumper wire across t...

Page 167: ...ns the rod for forward tire movement Fig 498 IMG 0600 Fig 500 IMG 0606a 10 Start the engine 11 Operate the left control handle in forward and re verse with the engine running at full throttle Move the...

Page 168: ...just Stop 12 If adjustment is completed tighten the two jam nuts against the adjustment rod nut 13 Install the bolt and nut securing the seat stop cable to the seat plate Fig 502 If the machine turns...

Page 169: ...formed with the vehicle wheels off the ground and repeated under operating conditions 1 With the bypass open push position and the engine running slowly move the directional controls forward reverse l...

Page 170: ...to add oil until it reaches the FULL COLD line on the expansion reservoir Fig 506 Fig 506 J A B C 6 Raise the rear of machine up and support with jack stands or equivalent support just high enough to...

Page 171: ...Noisy Oil level low or contaminated oil Fill to proper level or change oil Excessive loading Reduce vehicle loading Loose parts Repair or replace loose parts Bypass assembly sticking Repair or replac...

Page 172: ...2007 2008 Titan Z4800 Z5200 Service Manual Form No 492 9207...

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Toro Titan Z4800, Service Manual

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